FLEXIBLE MANUFACTURING SYSTEM

Definition:
 Flexible Manufacturing System consists of group of processing
work stations interconnected by means of an automated
material handling and storage system and also controlled by
intergrated computer control system.
 A flexible manufacturing system is an arrangement of machines
interconnected by a transport system. The transporter carries
work to the machines on pallets or other interface units so that
work machine registration is accurate, rapid and automatic.
 A central computer control both machines and transport
system.
 Flexibiliy in manufacturing means the ability to deal wih slightly
or greatly mixed part, to allow variations in process sequence,
change the production volume and change the design of certain
product being manufacturing


Type of flexibilities
Volume flexibility
Mix flexibility
Manufacturing flexibility
Delivery flexibility
 Component of Flexible Manufacturing System

 Workstations
 Material Handling Systems
 Storage Systems
 Computer Control Systems
 Human resources
 WORK STATION

Load/unload stations

o It act as the physical interface between the FMS and the

rest of the factory
o Raw workparts enter the system at load station, while
finished work parts exit at unload station
o Manual loading/unloading is more prevalent
o A certain level of cleanliness should be maintained at
this workplace and hence air hoses/washing facilities are
often required to flush away chips
o Generally, these stations are raised slightly above the
floor level using an open ground platform for permitting
the chips and cutting fluid to drop through the openings
o It may have a data entry unit and monitor to
communicate between the operator and computer
system which includes which parts are to be loaded,
which pallet is required, etc.
Machining centre
o Most common application of FMS are for machining operation
o Workstations are predominantly CNC machine tools –
especially, horizontal machining centers
o CNC machining centres will have the following features:
 Automatic tool changer
 Tool magazine
 Use of palletized work parts
 CNC machine
 Capability of distributed numerical control
o Machining centres are used for non-rotational parts (or for
milling, drilling, etc.)
o Turning centres are used for rotational parts
o Certain machining centres will have horizontal, vertical and
multiple spindles, while in certain turning centres, single point
cutting tool can be rotated around the work part

OTHER PROCESSING STATIONS

o FMS can also be applied for carrying out other processing
operations such as sheet metal fabrication
o Workstations will perform different processes such as
punching, shearing, bending, etc.
Assembly
 Flexible automated assembly systems are developed to
replaced manual assembly systems
 Industrial robots are used as workstations in the flexible
assembly
 It can be programmed to perform tasks with variation in
sequence and motion pattern to accommodate various product
styles
 MATERIAL HANDLING EQUIPMENT
• The material handling function in a FMS is often shared
between two systems
1. Primary handling system
• Establishes the basis layout of the system
• Responsible for moving parts between
workstations
• Eg. Conveyor, AGVs, etc.

2. Secondary handling system

• Consists of transfer devices, automatic
pallet changers etc.
• Main functions are
 Transfer work from the primary
system to the machine tool
 Position the parts with significant
accuracy and repeatability to
perform processing/assembly
operation
 Reorientation of the part if
necessary to present the surface to
be processed
 Buffer storage of parts to minimize
work change time and maximize
station utilization

• MHS determines the layout configuration of FMS

• Different configurations of layout are:
 In-line layout
 Loop layout
 Ladder layout
 Open field layout
 Robot centered layout
 In-line layout
 Machines and MHS are arranged in straight line
 Parts moves from one machine to another in sequence
and there is no backflow
 Work moves in one direction only, which is similar to
transfer line (FML)
 Has only a primary MHS
 If greater flexibility is required, a linear transfer system
that permits movement in 2 directions can be installed
 In this case, a secondary MHS is provided along with
primary MHS
 Loop layout
 Workstations are organized in a loop, which is served by a
MHS
 Parts usually flow in one direction around the loop, with
the capability to stop and be transferred to any station
 A secondary handling system is used at each workstation
to permit parts to move without obstruction around the
loop
 Load/unload stations are located at one end of the loop
 Alternative term of loop layout is rectangular layout
 This arrangement is used to return pallets to the starting
position in a straight line machine arrangement
 Ladder layout
 Consists of a loop with rings between the straight sections
of the loop on which workstations are located
 Rings increases the possible ways of getting from one
machine to another and removes the need for secondary
MHS
 Reduces average travel distance and congestion in the
handling system, which will lead to reduction in transport
time
Open field layout
 Consists of multiple loops and ladders and may include
sidings
 Is used for processing a large family of parts
 Number of different machine types may be limited and
parts are routed to different workstations depending on

Robot centred cell

 Uses one or more robots as the MHS
 Industrial robots can be equipped with grippers that make
them suited for the handling of rotational parts
 They are often used for processing cylindrical or disc
shaped parts