1) Flexible Manufacturing System:

2)
A flexible manufacturing system (FMS) is a manufacturing system in which there is some amount of flexibility that allows the
system to react in the case of changes, whether predicted or unpredicted.
Flexibility is generally considered to fall into the following categories:
Machine Flexibility:
This covers the system's ability to be changed to produce new product types, and ability to change the order of
operations executed on a part.
Routing Flexibility:
This which consists of the ability to use multiple machines to perform the same operation on a part, as well as the
system's ability to absorb large-scale changes, such as in volume, capacity, or capability.
Mix Flexibility:
It is defined as the ability to change the product mix while maintaining the same total production quantity that is,
producing the same parts only in different proportions.
Volume Flexibility:
It is the ability of the system to vary the production volumes of different products to accommodate changes in
demand while remaining profitable.
Advantages:
Reduced manufacturing times
Lower cost per unit produced
Greater labor productivity
Greater machine efficiency
Improved quality
Increased system reliability
Reduced parts inventories
Adaptability to CAD/CAM operations
Shorter lead times
Disadvantages:
Cost to implement
Substantial pre-planning
Requirement of skilled labour


TYPES OF FMS:
Flexible manufacturing systems can be divided into various types depending upon their features. They all are discussed below:
1. DEPENDING UPON KINDS OF OPERATION: Flexible manufacturing system can be distinguished depending upon the kinds of operation they
perform:
I. Processing operation. Such operation transforms a work material from one state to another moving towards the final
desired part or product. It adds value by changing the geometry, properties or appearance of the starting materials.
II. Assembly operation. It involves joining of two or more component to create anew entity which is called an
assembly/subassembly. Permanent joining processes include welding, brazing, soldering, adhesive bonding, rivets, press
fitting, and expansion fits.
2. DEPENDING UPON NUMBER OF MACHINES: The following are typical categories of FMS according to the number of machines in the system:
I. Single machine cell (SMC). It consists of a fully automated machine capable of unattended operations for a time period longer
than one machine cycle. It is capableof processing different part styles, responding to changes in production schedule, and
accepting new part introductions. In this case processing is sequential not simultaneous.

II. Flexible manufacturing cell (FMC). It consists of two or three processing workstation and a part handling system. The part
handling system is connected to a load/unload station. It is capable of simultaneous production of different parts.

III. Flexible Manufacturing System (FMS). It has four or more processing work stations (typically CNC machining centers or turning
centers) connected mechanically by a common part handling system and automatically by a distributed computer system. It also
includes non-processing work stations that support production but do not directly participate in it. e.g. part / pallet washing
stations, coordinate measuring machines. These features significantly differentiate it from Flexible manufacturing cell (FMC).
3. DEPENDING UPON LEVEL OF FLEXIBILITY
Another classification of FMS is made according to the level of flexibility associated with the system. Two categories are distinguished here:
I. Dedicated FMS. It is designed to produce a particular variety of part styles. The product design is considered fixed. So,
the system can be designed with a certain amount of process specialization to make the operation more efficient.
II. Random order FMS. It is able to handle thesubstantial variations in part configurations. To accommodate these
variations, a random order FMS must be moreflexible than the dedicated FMS. A random order FMS is capable of
processing parts that have a higher degree of complexity. Thus, to deal with these kinds of complexity, sophisticated
computer control system is used for this FMS type.


3) Value Engineering:

Value engineering (VE) is a systematic method to improve the "value" of goods or products and services by using
an examination of function. Value, as defined, is the ratio of function to cost. Value can therefore be increased by either improving
the function or reducing the cost. It is a primary tenet of value engineering that basic functions be preserved and not be reduced as
a consequence of pursuing value improvements.

The different aspects of value engineering can be encapsulated into a sequence of steps known as a Job Plan.
One modern version has the following eight steps:
Preparation
Information
Analysis
Creation
Evaluation
Development
Presentation
Follow-up
Four basic steps in the job plan are:
Information gathering - This asks what the requirements are for the object. Function analysis, an important technique in value
engineering, is usually done in this initial stage. It tries to determine what functions or performance characteristics are important. It
asks questions like; what does the object do? What must it do? What should it do? What could it do? What must it not do?
Alternative generation (creation) - In this stage value engineers ask; What are the various alternative ways of meeting
requirements? What else will perform the desired function?
Evaluation - In this stage all the alternatives are assessed by evaluating how well they meet the required functions and how great
the cost savings will be.
Presentation - In the final stage, the best alternative will be chosen and presented to the client for final decision.





Value engineering in organizations helps to identify:
The problem or situation that needs to be changed/improved
All that is good about the existing situation
The improvements required in the situation
The functions to be performed
The ways of performing each function
The best ways among the selected functions
The steps to be followed to implement the function
The person who executes the function
Examples:
a. When a product incorporates a computer, it replaces many parts with software that fits into a single light-weight, low-power
memory part or microcontroller. As computers grow faster, digital signal processing software is beginning to replace many
analog electronic circuits for audio and sometimes radio frequency processing.
b. On some printed circuit boards, the conductors are intentionally sized to act as delay lines, resistors and inductors to reduce
the parts count. An important recent innovation was to eliminate the leads of surface mounted components. At one stroke,
this eliminated the need to drill most holes in a printed circuit board, as well as clip off the leads after soldering.

4) Automated Material Handling Systems:

Automated material handling (AMH) systems improve efficiency of transportation, storage and retrieval of
materials. Examples are computerized conveyors, and automated storage and retrieval systems (AS/RS) in which computers direct
automatic loaders to pick and place items. Automated guided vehicle (AGV) systems use embedded floor wires to direct driverless
vehicles to various locations in the plant. Benefits of AMH systems include quicker material movement, lower inventories and
storage space, reduced product damage and higher labour productivity.
a. Computerized Conveyers:
A computerized conveyor system is mechanical handling equipment that moves materials from one location to
another depending on a computer program. Conveyors are especially useful in applications involving the transportation
of heavy or bulky materials. Conveyor systems allow quick and efficient transportation for a wide variety of materials,
which make them very popular in the material handling and packaging industries.
Few types are:
Pneumatically-driven conveyor: utilizes compressed air as well as vacuum cleaner hoses to
make the method run
Shaking conveyor: It is coded in order to carry volatile goods from place to another.
Strip conveyor: The technology performs with the existence of looped metallic belts as well
as plastic hyperlinks. They are well-known inside transmitting airport terminal bags.
Gleam string conveyor:frequently used within the motor vehicle business
b. Automated storage and retrieval systems (AS/RS):
An automated storage and retrieval system AS/RS consists of a variety of computer-controlled systems for
automatically placing and retrieving loads from defined storage locations.
Automated storage and retrieval systems (AS/RS) are typically used in applications where:
There is a very high volume of loads being moved into and out of storage
Storage density is important because of space constraints
No value adding content is present in this process
Accuracy is critical because of potential expensive damages to the load.
c. Automated guided vehicle (AGV):
An automated guided vehicle system is a material handling system that uses
independently operated , self propelled vehicle that are guided along defined pathways
on the floor. The vehicles are powered by means of on board batteries that allow
operation for several hours (8-16 hrs.) between recharging. Guidance is achieved by
using sensors on the vehicles that follow the guide wires. The vehicle is controlled by an
off board controller or a micro- processor. This controller sends commands to the vehicle
such as identification of load, its destination and other special instructions. An AGV
system provides a material handling system i.e. both flexible and readily adaptable to
either production or production changes
An automated guided vehicle or automatic guided vehicle (AGV) is a mobile robot that follows markers or wires in
the floor, or uses vision or lasers. They are most often used in industrial applications to move materials around a
manufacturing facility or a warehouse.
Some common types are:
AGV Towing Vehicles: Towing vehicles can pull a multitude of trailer types and have capacities ranging from 8,000
pounds to 60,000 pounds.
AGVS Unit Load Vehicles:Equipped with decks, which permit unit load transportation and often automatic load
transfer. The decks can either be lift and lower type, powered or non-powered roller, chain or belt decks or
custom decks with multiple compartments.
AGVS Pallet Trucks:Designed to transport palletized loads to and from floor level; eliminating the need for fixed
load stands.
AGVS Fork Truck:Has the ability to service loads both at floor level and on stands. In some cases these vehicles can
also stack loads in rack.
Light Load AGVS:Vehicles which have capacities in the neighborhood of 500 pounds or less and are used to
transport small parts, baskets, or other light loads though a light manufacturing environment.
AGVS Assembly Line Vehicles:An adaptation of the light load AGVS for applications involving serial assembly
processes.
d. Industrial Robots:
An industrial robot is as an automatically controlled, reprogrammable, multipurpose manipulator programmable in three
or more axes. Typical applications of robots include welding, painting, assembly, pick and place (such as packaging,
palletizing and SMT), product inspection, and testing; all accomplished with high endurance, speed, and precision.Work
environment is one of the several characteristics that should be considered when selecting a robot application. The
hazardous characteristics of industrial work tend topromote the substitution of robots for human labour. Hence, robots
are being used in awide field of applications in industry. Currently, robots are mostly used in the field of manufacturing.
The applications can usually be classified into following characteristics:
(i) Material handling
(ii) Processing operations
(iii) Assembly and inspection
Application of the robots in the industry must be technically and economically viable for the industry.
5) Classification elements of time study:

Page 290; Introduction to Work Study by George Kanawaty