FLEXIBLE MANUFACTURING SYSTEM.pps

Flexible Manufacturing System

FLEXIBLE MANUFACTURING SYSTEM

SUBMITTED BY:

RANJIT PASWAN

RAVI YADAV

AMIT-VII

NIFT, B’LORE

SUBMITTED TO:

Mrs. SHIPRA

(Assit. Professor)

NIFT, B’LORE



IN CONTEX OF ANY INDUSTRY


FMS CONCEPT

Today flexibility means to produce reasonably priced customized products

of high quality that can be quickly delivered to customers.

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.


FMS CONCEPT CONTIUED….

what is flexibility in manufacturing?

(A)BASIC FLEXIBILITIES

•Machine flexibility - the ease with which a machine can process various

operations

•Material handling flexibility - a measure of the ease with which different

part types can be transported and properly positioned at the various machine

tools in a system

•Operation flexibility - a measure of the ease with which alternative

operation sequences can be used for processing a part type


(B) SYSTEM FLEXIBILITIES

•Volume flexibility - a measure of a system’s capability to be operated

profitably at different volumes of the existing part types

Expansion flexibility - the ability to build a system and expand it

incrementally

Routing flexibility - a measure of the alternative paths that a part can

effectively follow through a system for a given process plan

Process flexibility - a measure of the volume of the set of part types that a

system can produce without incurring any setup



(C) AGGREGATE FLEXIBILITIES

Program flexibility - the ability of a system to run for reasonably long periods

without external intervention

Production flexibility - the volume of the set of part types that a system can

produce without major investment in capital equipment

Market flexibility - the ability of a system to efficiently adapt to changing

market conditions

Product flexibility - the volume of the set of part types that can be

manufactured in a system with minor setup



APPROACH FLEXIBILITY MEANING

MANUFACTURING

•The capability of producing different parts without major retooling

•A measure of how fast the company converts its process (es) 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

OPERATIONAL

•The ability to efficiently produce highly customized and unique products

CUSTOMER

•The ability to exploit various dimension of speed of delivery

STRATEGIC

•The ability of a company to offer a wide variety of products to its customers

CAPACITY

•The ability to rapidly increase or decrease production levels or to shift capacity quickly from one product or service to another

DIFFERENT APPROACHES OF FMS


•Flexible Manufacturing Module (FMM). Example : a NC machine, a pallet changer and a part buffer;

•Flexible Manufacturing (Assembly) Cell (F(M/A)C). Example : Four FMMs and an AGV (automated guided vehicle);

•Flexible Manufacturing Group (FMG). Example : Two FMCs, a FMM and two AGVs which will transport parts from a Part Loading area, through machines, to a Part Unloading Area;

•Flexible Production Systems (FPS). Example : A FMG and a FAC, two AGVs, an Automated Tool Storage, and an Automated Part/assembly Storage;

•Flexible Manufacturing Line (FML). Example : multiple stations in a line layout and AGVs.

DIFFERENT LEVEL OF FMS


ADVANTAGE OF IMPLEMENTATION

•Faster, lower- cost changes from one part to another which will improve capital utilization

•Lower direct labor cost, due to the reduction in number of workers

•Reduced inventory, due to the planning and programming precision

•Consistent and better quality, due to the automated control

•Lower cost/unit of output, due to the greater productivity using the same number of workers

•Savings from the indirect labor, from reduced errors, rework, repairs and rejects


DISADVANTAGE OF IMPLEMENTATION

•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 timing

necessary to process a component

•Sophisticated manufacturing systems


CONCLUSION

FMSs complexity and cost are reasons for their slow acceptance

by industry. In most of the cases FMCs are favored.



IN CONTEX OF APPAREL INDUSTRY


Global market (European,US), which is known for its small sized orders and even shorter lead times

Small orders as the start up losses and frequent changes make it difficult

for a factory to run cost effectively with progressive bundle system

The need of the hour is of flexible manufacturing systems that provide

high performance and quick response in a cost effective manner.

Flexible manufacturing System helps a company in :Developing a quick response system.

Developing human capital with decision making power and collaborative capabilities.

Reduction of work in progress.

Utilizing work areas more effectively.

NEED OF FMS IN APPAREL INDUSTRY


It is a contained, manageable work unit that includes an empowered work

team, equipment, and work to be executed. Modules frequently operate as

mini factories with teams responsible for group goals and self-management.

The number of teams in a plant varies with the size and needs of the firm

and product line

Different names used to identify FMS apparel production systems,

Modular manufacturingCellular manufacturing unitsCompact work teamsFlexible work groups, Self-directed work teamsToyota sewing system (tss)

The basic premise is similar among these systems, although the organization and implementation may vary.

INTRODUCTION


Teams may be used to perform all the operations or a certain portion of

the assembly operations depending on the organization of the module and

processes required.

A team-based system operators are given the responsibility for operating

their module to meet goals for throughput and quality.

A FMS System operates as a Pull System, with demand for work coming

from the next operator in line to process the garment.

Teams usually operate as ‘Stand-up’ or ‘Sit-down’ units.

INTRODUCTION contued…..


A module may be divided into several work zones based on the sequence

of operations and the time required for each operation

A general thumb rule to determine the no. of operator required is,

average number of operations required for a style being produced and divide by three

Work flow within a module may one of the following:

Single-piece hand-off,

Kanban

Bump-back system

INTRODUCTION contued…..


SINGLE-PIECE HAND-OFF

Machines are arranged in a very tight configuration

As soon as an operation is completed the part is handed to the next operator

Operations need to be well balanced, usually only one garment component between each operation

If a small bundle is used between operation, an operator will complete the operation on the entire bundle and carry the bundle to the next operation

An operator may follow a component or bundle for as many operations as they have been trained or until the adjacent operator is ready to assume work on the bundle.


KANBAN

Uses a designated work space between operations to balance supply with demand

The designated space will hold a limited number of completed components (two or three) in queue for the next operation

If the designated space is full, there is no need to produce more until it is needed or the space empties.

When the space is full the operator can assist with other operations that may be slow.


BUMP-BACK SYSTEM (TSS)It was developed by the Toyota Sewn Product Management System

Probably the most widely used type of team-based manufacturing

It is a stand-up module with flexible work zones and cross-trained operators

Operators may be cross-trained on up to four different successive operations

Operators shift from operation to operation until the next operator is ready

to begin work on the garment.


The operator who has been relieved of the garment will then move back to

the beginning of the work zone and take over work on another garment

This approach enables continuous work on a garment and allows each

operator to perform several different operations

This arrangement frequently uses a 4-to-l ratio of machines to operators

BUMP-BACK SYSTEM (TSS) contued…..


ADVANTAGES OF FMS

High flexibility

Fast throughput times

Low wastages

Reduced Absenteeism

Low work in process

Increased employee ownership of the production process

Empowered employees

Improved Quality


DISADVANTAGES OF FMS

A high capital investment in equipment.

High investment in initial training.

High cost incurred in continued training


DETERMINATION OF TEAM SIZE

The Key points that should taken care of while deciding upon the number of operators are:

The technical characteristics of the product, that is the S.A.M and

complexity

Expected Production Capacity.

Poly Functionality requirements.

Module continuity and stability in important to adapt with its flexibility

requirements so no changes should be made to the team after setting it up


DETERMINATION OF TEAM SIZE contued..

The team has to be self managed and identification between the team

members is a must to develop the team spirit. So, the team size should not

be exceed a certain limit.

The level of flexibility expected would also be a critical issue since more

number of workers would bring down the flexibility by reducing the poly

functionality requirements.

Module team Size =

Expected Production Capacity * S.A.M of Garment/ Working hours per day


The total machine requirement for the Module will have the total number of

work stations along with all the attachments, work aids and auxiliary

equipment requirements.

Number of SNLS machines required for the Module = Expected Production Capacity*Total SNLS S.A.M / Working Hours per day

Here SNLS is one of the example only, this formula can be used to calculate any type of machine requirement

MACHINE REQUIREMENT


CONCLUSION

•Modular production system is a new concept which has evolved as natural

progression in accordance to the apparel market needs

•Modular Production System brings along with itself benefits like Low

inventory, quick response through reduced throughput time and flexibility to

style changes.

•This brings a feeling of self belief and belongingness to the employee

towards the company.


BIBLIOGRAPHY

1) Flexible manufacturing system

By: DR. Rajesh Bheda

2) Graduation project

BY: Abhinay Shrivastava at Lagoona Clothings

3) www.Apparelsearch.com

4) www.apparelkey.com

5) www.epnet.com


THANK YOU

FLEXIBLE MANUFACTURING SYSTEM.pps

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