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

What Will Be CoveredWhat Will Be Covered

Flexible Manufacturing is DefinedFlexible Manufacturing is Defined How “you” can use FMSHow “you” can use FMS Nuts and BoltsNuts and Bolts How FMS worksHow FMS works A real world exampleA real world example SummarySummary

What Is A Flexible What Is A Flexible Manufacturing System?Manufacturing System?

Flexible Manufacturing System:Flexible Manufacturing System:

- “A system that consists of numerous - “A system that consists of numerous programmable machine tools connected by an programmable machine tools connected by an automated material handling system”automated material handling system”

Basic Components of FMSBasic Components of FMS

The Basic components of FMS are: The Basic components of FMS are:

1.1. Workstations.Workstations.

2.2. Automated material Handling and Storage Automated material Handling and Storage system.system.

3.3. Computer Control System.Computer Control System.

Stand alone NC machinesStand alone NC machines

Flexible Manufacture Systems

Flexible Manufacture Systems

Transfer LinesTransfer Lines

High

Medium

Low

Low Medium High

Production volume

Product variety

Application Characteristics of FMS

Flexibility in ManufacturingFlexibility in Manufacturing

Basic Flexibility Basic Flexibility Machine flexibilityMachine flexibility Material handling flexibilityMaterial handling flexibility System Flexibility System Flexibility volume flexibilityvolume flexibility Routing flexibilityRouting flexibility Expansion flexibilityExpansion flexibility Aggregate FlexibilityAggregate Flexibility Program flexibility Program flexibility production flexibilityproduction flexibility market flexibilitymarket flexibility

Different Types ofDifferent Types of FMS FMS

Sequential FMSSequential FMS Random FMSRandom FMS Dedicated FMSDedicated FMS Engineered FMSEngineered FMS Modular FMSModular FMS

Progressive Layout:Progressive Layout: Best for producing a variety of partsBest for producing a variety of parts

Closed Loop LayoutClosed Loop Layout:: Parts can skip stations for flexibilityParts can skip stations for flexibility Used for large part sizesUsed for large part sizes Best for long process timesBest for long process times

Types of FMS Layouts

• Robot centered LayoutRobot centered Layout - Robot centered cell with one or more robots are- Robot centered cell with one or more robots are Used as the material handling systemsUsed as the material handling systems.

FMS Layouts ContinuedFMS Layouts Continued

• Ladder Layout:Ladder Layout:― Parts can be sent to any machine in any sequenceParts can be sent to any machine in any sequence― Parts not limited to particular part familiesParts not limited to particular part families

• Open Field Layout:Open Field Layout:― Most complex FMS layoutMost complex FMS layout― Includes several support stationsIncludes several support stations

Types of FMS LayoutsTypes of FMS Layouts

Progressive or Line typeProgressive or Line type Loop TypeLoop Type Ladder TypeLadder Type Open Field TypeOpen Field Type Robot centered typeRobot centered type

Factors Influencing the FMSFactors Influencing the FMS layouts layouts

Available of raw material Available of raw material Proximity to market Proximity to market Transport facilitiesTransport facilities Availability of efficient and cheap laborAvailability of efficient and cheap labor Availability of Power ,Water and FuelAvailability of Power ,Water and Fuel Atmospheric and climatic conditionAtmospheric and climatic condition Social and recreation FacilitiesSocial and recreation Facilities

Objective of FMSObjective of FMS

Decreased Lead Times Decreased Lead Times Increased machine utilizationIncreased machine utilization Improved Due Date ReliabilityImproved Due Date Reliability Decreased Store Inventors levelsDecreased Store Inventors levels Decreased Work in Progress Decreased Work in Progress Increased QualityIncreased Quality

Advantages and disadvantagesAdvantages and disadvantages of FMS Implementationof FMS Implementation

AdvantagesAdvantages

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

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

Reduced inventory.Reduced inventory. Consistent and better quality.Consistent and better quality. Savings from indirect labors, from reduced Savings from indirect labors, from reduced

errors , rework, repairs and rejects.errors , rework, repairs and rejects.

DisadvantagesDisadvantages

Limited ability to adapt to changes in product or Limited ability to adapt to changes in product or product mix .product mix .

Substantial pre-planning activitySubstantial pre-planning activity Expensive , costing millions of Dollars.Expensive , costing millions of Dollars. Technological problems of exact component Technological problems of exact component

positioning.positioning. Sophisticated manufacturing systems. Sophisticated manufacturing systems.

Automated MaterialAutomated Material HandlingHandling

Automated Guided Automated Guided Vehicle (AGV)Vehicle (AGV)

Automated Storage and Automated Storage and Retrieval System Retrieval System (ASRS)(ASRS)

ConveyorsConveyors

Components of Flexible Components of Flexible Manufacturing SystemsManufacturing Systems

NCNC CNCCNC DNCDNC RoboticsRobotics AGVAGV ASRSASRS

Automated Automated InspectionInspection

Cells and CentersCells and Centers

Flexible AutomationFlexible Automation

Ability to adapt to Ability to adapt to engineering changes in engineering changes in partsparts

Increase in number of Increase in number of similar parts produced similar parts produced on the systemon the system

Ability to accommodate Ability to accommodate routing changes routing changes

Ability to rapidly change Ability to rapidly change production set upproduction set up

FMS Nuts and BoltsFMS Nuts and Bolts

RobotsRobots

RobotsRobots

Robots: Programmable ManipulatorsRobots: Programmable Manipulators

― Can tolerate hostile environmentsCan tolerate hostile environments

― Can work much longer hours than humansCan work much longer hours than humans

― Can perform redundant jobs more consistentlyCan perform redundant jobs more consistently

Common Uses of RobotsCommon Uses of Robots

Loading andLoading and unloadingunloading

Spray paintingSpray painting

WeldingWelding

Material handlingMaterial handling

InspectionInspection

Machine AssemblyMachine Assembly

Computer Integrated Computer Integrated ManufacturingManufacturing

CIMCIM: “The Integration of the total manufacturing : “The Integration of the total manufacturing enterprise through the use of integrated systems and enterprise through the use of integrated systems and data communications coupled with new managerial data communications coupled with new managerial philosophies that improve organizational and personnel philosophies that improve organizational and personnel efficiency.”efficiency.”

Components of CIMComponents of CIM

CAD Computer Aided DesignCAD Computer Aided Design

CAM Computer Aided ManufacturingCAM Computer Aided Manufacturing

CAE Computer Aided EngineeringCAE Computer Aided Engineering

Manufacturing Manufacturing TechnologyTechnology

This part of FMS uses:This part of FMS uses:

NC NC Numerically Controlled MachineNumerically Controlled Machine

CNCCNC Computer Controlled Machine Computer Controlled Machine

DNC DNC Direct Numerical ControlledDirect Numerical Controlled

Challenges with FMSChallenges with FMS

Determining if FMS the best production system for your Determining if FMS the best production system for your company (economically and socially)company (economically and socially)

Possible expansion costs associated with implementing Possible expansion costs associated with implementing FMSFMS

Day to day maintenance of FMS operationsDay to day maintenance of FMS operations

Flexible Flexible ManufacturingManufacturing

How Does It Work ?How Does It Work ?

Integration of FMSIntegration of FMS

FMS

Manufacturing Technology CAM Robotics

Making FMS WorkMaking FMS Work

By implementing the components of By implementing the components of robotics, manufacturing technology and robotics, manufacturing technology and computer integrated manufacturing in a computer integrated manufacturing in a correct order one can achieve a successful correct order one can achieve a successful Flexible Manufacturing SystemFlexible Manufacturing System

A Real World ExampleA Real World Example

TheThe

FordFord

Motor CompanyMotor Company

Ford’s ProblemFord’s Problem

At Ford Powertrain they faced the At Ford Powertrain they faced the following challengesfollowing challenges

- outdated cell controller- outdated cell controller

- lack of flexibility because of it- lack of flexibility because of it

- causing loss of efficiency - causing loss of efficiency

SolutionSolution

Implemented a cell control based Implemented a cell control based on an open architecture, on an open architecture, commonly available tools, and commonly available tools, and industry standard hardware, industry standard hardware, software, and protocols. software, and protocols. (3)(3)

BenefitsBenefits

Enabled Ford to mix and match machine Enabled Ford to mix and match machine tools from different vendors tools from different vendors (3)(3)

Reduced the number of man-years Reduced the number of man-years required to implement the application required to implement the application (3)(3)

Benefits ContinuedBenefits Continued

The budget for the fully automatic closed-The budget for the fully automatic closed-loop controller was less than 1/10loop controller was less than 1/10thth the the cost for a system built in language.cost for a system built in language.

No formal training was required for the No formal training was required for the floor shop operatorsfloor shop operators

THANK YOUTHANK YOU