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Manufacturing
System
SECTIONS:
1. What is a Flexible Manufacturing System?
2. FMS Components
3. FMS Applications and Benefits
4. FMS Planning and Implementation Issues
What is
a Flexible Manufacturing System?
it is capable of perform one or more An organized scheme
processing a variety of processing and/or assembly
different part styles operations
simultaneously at the
various workstations,
and the mix of part
styles and quantities
of production can be
adjusted in response
to changing demand
patterns.
Flexible Manufacturing System
https://www.youtube.com/watch?v=BiOzGlaAE_8
https://www.youtube.com/watch?v=iyAWaIYDyZU
The FMS relies on the principles of GT
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
To qualify as being flexible, a manufacturing
system should satisfy the following criteria
Can it Can it
Can it process
Can it accept responds to accommodate
different part
changes in equipment introduction of
styles in a
production malfunctions new part
non-batch
schedule? and designs?
mode?
breakdowns?
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
Automated manufacturing
cell with two machine
tools and robot. Is it a
flexible cell?
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
Types of FMS
Kinds of operations
Processing vs. assembly
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
Single-Machine Manufacturing Cell
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
A single-
machine CNC
machining cell
(photo
courtesy of
Cincinnati
Milacron)
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
Flexible Manufacturing Cell
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
A two-machine
flexible
manufacturing
cell for
machining
(photo courtesy
of Cincinnati
Milacron)
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
A five-machine
flexible
manufacturing
system for
machining (photo
courtesy of
Cincinnati
Milacron)
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
FMS Types - Level of Flexibility
1. Dedicated FMS
Designed to produce a limited variety of part styles
The complete universe of parts to be made on the system is known in
advance
Part family likely based on product commonality rather than geometric
similarity
2. Random-order FMS
Appropriate for large part families
New part designs will be introduced
Production schedule is subject to daily changes
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
Dedicated vs. Random-Order FMSs
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
What is
a Flexible Manufacturing System
Components ?
1. Workstations
2. Material handling and storage system
3. Computer control system
4. Human labor
Workstation
Assembly machines
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
Material Handling and Storage
Random, independent movement of parts between stations
Capability to handle a variety of part styles
Standard pallet fixture base Primary handling
system
Workholding fixture can be adapted
Temporary storage Secondary
handling system
Convenient access for loading and unloading
Compatibility with computer control
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
Material Handling
The layout of the FMS is established by the material
handling system
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
FMS in Line Layout
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
FMS in Line Layout
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
FMS Ladder Layout
Loop with rungs to allow
greater variation in
processing sequence
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
FMS Open Field Layout
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
FMS Computer Functions
1. Workstation control
3. Production control
Product mix, machine scheduling, and other planning
functions
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
FMS Computer Functions
4. Traffic control
Management of the primary handling system to move parts between
workstations
5. Shuttle control
Coordination of secondary handling system with primary handling
system
6. Workpiece monitoring
Monitoring the status of each part in the system
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
FMS Computer Functions
7. Tool control
Tool location
Keeping track of each tool in the system
Tool life monitoring
Monitoring usage of each cutting tool and determining when to
replace worn tools
9. Diagnostics
Diagnose malfunction causes and recommend repairs
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
What is
a Flexible Manufacturing System
Applications?
FMS Application
Machining
Assembly
Inspection
Forging
FMS Application
Machining
Assembly
Inspection
Forging
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
FMS Application
Machining
Assembly
Inspection
Forging
FMS Benefits
Increased machine utilization
Reasons:
24 hour operation likely to justify investment
Automatic tool changing
Automatic pallet changing at stations
Queues of parts at stations to maximize utilization
Dynamic scheduling of production to account for changes in demand
Reduction in
Fewer machines
factory floor
required
space required
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
FMS Benefits
Reduced inventory requirements
Different parts produced continuously rather than in batches
Higher productivity
Production
volume Work-in-process
and storage Tooling
capacity Pallet fixtures
Pallet and
Part fixture
Grouping allocation
Tool
Management
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.