Flexible Manufacturing Flexible Manufacturing SystemsSystems

RAVI SHERASIYARAVI SHERASIYA

MECHANICAL ENGINEERMECHANICAL ENGINEER

G.E.C,BHUJG.E.C,BHUJ

Flexible Manufacturing Flexible Manufacturing Systems (FMS)Systems (FMS)

• An FMS is a “reprogrammable” manufacturing system An FMS is a “reprogrammable” manufacturing system capable of producing a variety of products automatically. capable of producing a variety of products automatically. Conventional manufacturing systems have been Conventional manufacturing systems have been marked by one of two distinct features:marked by one of two distinct features:– The capability of producing a variety of different The capability of producing a variety of different

product types, but at a high cost (e.g., job shops).product types, but at a high cost (e.g., job shops).– The capability of producing large volumes of a The capability of producing large volumes of a

product at a lower cost, but very inflexible in terms of product at a lower cost, but very inflexible in terms of the product types which can be produced (e.g., the product types which can be produced (e.g., transfer lines).transfer lines).

• An FMS is designed to provide both of these features.An FMS is designed to provide both of these features.

FMS ComponentsFMS Components

• Numerical Control (NC) machine toolsNumerical Control (NC) machine tools• Automated material handling system Automated material handling system

(AMHS)(AMHS)– Automated guided vehicles (AGV)Automated guided vehicles (AGV)– ConveyorsConveyors– Automated storage and retrieval systems Automated storage and retrieval systems

(AS/RS)(AS/RS)

• Industrial RobotsIndustrial Robots• Control SoftwareControl Software

Flexible Manufacturing SystemFlexible Manufacturing System

PartsFinishedgoods

Load Unload

Computercontrolroom

Terminal

Machine Machine

Tools

Conveyor

Pallet

Classification of FMS-Classification of FMS-related Problemsrelated Problems

• Strategic analysis and economic justification, which Strategic analysis and economic justification, which provides long-range, strategic business plans.provides long-range, strategic business plans.

• Facility design, in which strategic business plans are Facility design, in which strategic business plans are integrated into a specific facility design to accomplish integrated into a specific facility design to accomplish long-term managerial objectives.long-term managerial objectives.

• Intermediate-range planning, which encompasses Intermediate-range planning, which encompasses decisions related to master production scheduling and decisions related to master production scheduling and deals with a planning horizon from several days to deals with a planning horizon from several days to several months in duration.several months in duration.

• Dynamic operations planning, which is concerned with Dynamic operations planning, which is concerned with the dynamic, minute-to-minute operations of FMS.the dynamic, minute-to-minute operations of FMS.

FMS ProblemsFMS Problems

• Part type selectionPart type selection (Askin) - selecting parts that will be (Askin) - selecting parts that will be produced in the FMS over some relatively long planning produced in the FMS over some relatively long planning horizon.horizon.

• Part selectionPart selection (Stecke) - from the set of parts that have (Stecke) - from the set of parts that have current production requirements and have been selected for current production requirements and have been selected for processing in the FMS, select a subset for immediate and processing in the FMS, select a subset for immediate and simultaneous processing.simultaneous processing.

• Machine groupingMachine grouping (Stecke) - partition machines into groups (Stecke) - partition machines into groups where each machine in a group can perform the same set of where each machine in a group can perform the same set of operations.operations.

• LoadingLoading (Stecke) - allocate the operations and required tools (Stecke) - allocate the operations and required tools of the selected part types among the machine groups.of the selected part types among the machine groups.

• ControlControl - provide instructions for, and monitor the equipment - provide instructions for, and monitor the equipment in the FMS so that the production goals identified by the above in the FMS so that the production goals identified by the above problems are met.problems are met.

Information TechnologyInformation Technology

• Management information system Management information system (MIS)(MIS)

–move large amounts of datamove large amounts of data• Decision support system (DSS)Decision support system (DSS)

–add decision making supportadd decision making support• Expert systemExpert system

–recommend decision based on expert recommend decision based on expert knowledgeknowledge

Decision Support SystemDecision Support System

Information:reportsmodel resultswhat if? analysis

Computersystem:dataprocessing

Data

Quantitativetechniques

Personnel

Accounting

Production

Marketing

Distribution

Other areas

Decisions

Management Information System

What -if? analysis

ManagementDecision Support System

Artificial IntelligenceArtificial Intelligence

• Neural networksNeural networks–emulate interconnections in brainemulate interconnections in brain

• Genetic algorithmsGenetic algorithms–based on adaptive capabilities in based on adaptive capabilities in naturenature

• Fuzzy logicFuzzy logic–simulate human ability to deal with simulate human ability to deal with ambiguityambiguity

Advanced Advanced CommunicationsCommunications

• Electronic data interchange (EDI)Electronic data interchange (EDI)• InternetInternet• Wireless communicationsWireless communications• Teleconferencing Teleconferencing

& telecommuting& telecommuting• Bar codingBar coding• Virtual realityVirtual reality

Manufacturing TechnologyManufacturing Technology

• Numerically controlled (NC) machinesNumerically controlled (NC) machines–controlled by punched tapecontrolled by punched tape

• Computer numerical controlled (CNC)Computer numerical controlled (CNC)–controlled by attached computercontrolled by attached computer

• Direct numerical control (DNC)Direct numerical control (DNC)– several NC machines controlled by several NC machines controlled by single computersingle computer

Automated Material Automated Material HandlingHandling

• ConveyorsConveyors• Automated guided vehicle (AGV)Automated guided vehicle (AGV)• Automated storage & retrieval Automated storage & retrieval

system (ASRS)system (ASRS)

Flexible Manufacturing Flexible Manufacturing Systems (FMS)Systems (FMS)

• Programmable machine toolsProgrammable machine tools• Controlled by common computer Controlled by common computer

networknetwork• Combines flexibility with efficiencyCombines flexibility with efficiency• Reduces setup & queue timesReduces setup & queue times

RoboticsRobotics

• Programmable manipulatorsProgrammable manipulators• Follow specified pathFollow specified path• Better than humans with respect to Better than humans with respect to

–hostile environmentshostile environments–long hourslong hours–consistencyconsistency

Robot PartsRobot Parts

• ControllerController–hardware, software, power sourcehardware, software, power source

• ManipulatorManipulator–robot armrobot arm

• End-effectorEnd-effector–““hand”hand”

Computer Integrated Computer Integrated Manufacturing (CIM) Manufacturing (CIM)

• Integration of design, manufacture & delivery via Integration of design, manufacture & delivery via computer technologycomputer technology

• CAD - uses software to create & modify designsCAD - uses software to create & modify designs• CAM - uses programmable automation in manufacturingCAM - uses programmable automation in manufacturing• CAE - links functional design to CAD form designCAE - links functional design to CAD form design• CAPP - creates processing instructions for CAMCAPP - creates processing instructions for CAM• GT- classifies designs to benefit from prior experienceGT- classifies designs to benefit from prior experience

Components Of CIM Components Of CIM

CIM

Productdesign

Manufacture

Processplanning

Systemsmanagement

RoboticsFMSNC/CNC/

DNCCells

and centersAutomatedinspection

AGV,ASRS

JIT/kanban

DSS/ES/AI

LAN, TOP,satellites

TQM

Bar codes,EDI

MRP

GTCAECADIGES,PDES,DMIS

DFM

Cellularmanufacturing

MAP,STEP

CAD/CAM

CAPP

Adoption Of TechnologyAdoption Of Technology

• Technology ReadinessTechnology Readiness• Need well-designed products & efficient Need well-designed products & efficient

processesprocesses

• Technology DesignTechnology Design• Know what to automate Know what to automate

• Technology SelectionTechnology Selection• Choose the right levelChoose the right level

• Technology IntegrationTechnology Integration• Have a strategy for incremental automationHave a strategy for incremental automation