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2.0 FLEXIBLE MANUFACTURING SYSTEMS (FMS)

A Flexible Manufacturing System (FMS) is a reprogrammable manufacturing system

capable of producing a variety of products automatically. Conventional manufacturing

systems have been marked by one of two distinct features:

The capability of producing a variety of different product types, but at a high cost (e.g., job

shops).

The capability of producing large volumes of a product at a lower cost, but very inflexible in

terms of the product types which can be produced (e.g., transfer lines).

An FMS is designed to provide both of these features.

Figure 2.1: Flexible Manufacturing System

FMS Components

Numerical Control (NC) machine tools

Automated material handling system (AMHS)

Automated guided vehicles (AGV)

Conveyors

Automated storage and retrieval systems (AS/RS)

Industrial Robots

Control Software

2.1 Equipment of FMS

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Primary equipment

Work centers Universal machining centers (prismatic FMSs) Turning centers (rotational FMSs) Grinding machines Nibbling machines

Process centers Wash machines Coordinate measuring machines Robotic work stations Manual workstations

Secondary equipment

Support stations Pallet/fixture load/unload stations Tool commissioning/setting area

Support equipment Robots Pallet/fixture/stillage stores Pallet buffer stations Tools stores Raw material stores Transport system(AGVs,RGVs,robots) Transport units(pallets/stillages)

2.2 Classification of FMS-related Problems

Strategic analysis and economic justification, which provides long-range, strategic

business plans.

Facility design, in which strategic business plans are integrated into a specific facility

design to accomplish long-term managerial objectives.

Intermediate-range planning, which encompasses decisions related to master

production scheduling and deals with a planning horizon from several days to several

months in duration.

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Dynamic operations planning, which is concerned with the dynamic, minute-to-

minute operations of FMS.

2.3 Types of FMS

Sequential FMS Random FMS Dedicated FMS Engineered FMS Modular FMS

2.4 Application of FMS

Metal-cutting machining Metal forming Assembly Joining-welding (arc , spot), glueing Surface treatment Inspection

Testing

2.5 FMS different approaches

The capability of producing different parts without major retooling A measure of how fast the company converts its processes from making an old line of

products to produce a new product

The ability to change a production schedule, to modify a part, or to handle multiple

parts

2.6 Advantages of using FMS

To reduce set up and queue times Improve efficiency Reduce time for product completion Utilize human workers better

Improve product routing Produce a variety of Items under one roof

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Improve product quality Serve a variety of vendors simultaneously Produce more product more quickly

2.7 Disadvantage of using FMS

Limited ability to adapt to changes in product or product mix (ex:machines are of

limited capacity and the tooling necessary for products, even of the same family,

is not always feasible in a given FMS)

Substantial pre-planning activity Expensive, costing millions of dollars

Technological problems of exact component positioning and precise timingnecessary to process a component

Sophisticated manufacturing systems

Figure 2.2: Illustration example of a FMS cell

2.8 FMS Layouts

Progressive Layout:

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o Best for producing a variety of parts Closed Loop Layout:

o Parts can skip stations for flexibilityo Used for large part sizeso Best for long process times

Ladder Layout:o Parts can be sent to any machine in any sequence

o Parts not limited to particular part families Open Field Layout:

o Most complex FMS layouto Includes several support stations

2.9 FMS Problems

Part type selection - selecting parts that will be produced in the FMS over some

relatively long planning horizon.

Part selection - from the set of parts that have current production requirements and

have been selected for processing in the FMS, select a subset for immediate and

simultaneous processing.

Machine grouping - partition machines into groups where each machine in a group

can perform the same set of operations.

Loading - allocate the operations and required tools of the selected part types among

the machine groups.

Control - provide instructions for, and monitor the equipment in the FMS so that the

production goals identified by the above problems are met.