Report FMS

7/31/2019 Report FMS

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FLEXIBLE MANUFACTURING SYSTEM

GROUP NO 1

ANIS BADSHAH UW-09-ME-BE-001

WAQAS SHAMRAIZ UW-09-ME-BE-001

ABDUL MANAN BASRA UW-09-ME-BE-001ADEEL JAVED UW-09-ME-BE-001

NOMAN BASHIR UW-09-ME-BE-001

SUBMITTEDTO:

Sir AFTAB IQBAL


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FMS (DEFINITION)

A flexible manufacturing system (FMS) is a highly automated OT machine cell, consisting of a

group of processing workstations (usually CNC machine tools), interconnected by an automated

material handling and storage system, and controlled by a distributed computersystem.

HISTORY:

The flexible manufacturing system was first conceptualized for machining, and it required the

prior development of NC The concept is credited to David Williamson. A British engineer

employed by Molins during the mid-l960s.Molins patented the invention (granted in 1965).The

concept was called System24 because It was believed that the group of machine tools

comprising the system could operate 24hr/day, 16 hr of which would be unattended by human

workers, The original concept included computer control of the NC machines, a variety of being

produced and tools for different machining operations.

One of the first FMS to be installed in the United States was a machining system at Ingersoll-

Rand Company in Roanoke, Virginia. in the late 1960s by Sundstrand.In Germany a manufacturing system was developed in 1969 by Heidleberger Druckmaschinen in

cooperation with the University of Stuttgart.

In the Russia an FMS was demonstrated at the 1972 Stanki Exhibition in Moscow.

The first Japanese FMS was installed around the same time by Fuji Xerox By around 1985,the

number of FMS installations throughout the world had increased to about 300.About20-25% of

these were located in the United States. As the importance of flexibility in manufacturing grows

,the number of FMS is expected to increase. In recent years, there has been an emphasis on

smaller, less expensive flexible manufacturing cells.

FLEXIBILITY:

Flexibility is an attribute that allows a mixed model manufacturing system to tackle with

a certain level of variations in part or product style, without having any interruption in

production due to changeovers between models. Flexibility measures the ability to adapt

to a wide range of possibleenvironment.

The reason the FMS is called flexible is that it is capable of processing a variety of different part

styles simultaneously at the various workstations, and the mix of part styles and quantities of

production can be adjusted in response to changing demand patterns

To be flexible, a manufacturing system must posses the following capabilities:

Identification of the different production units to perform the correct operation Quick changeover of operating instructions to the computer controlled production

machines

Quick changeover of physical setups of fixtures, tools and other working units


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TYPES OF FLEXIBILITY IN MANUFACTURING:

1. Machine Flexibility.

It is the capability to adapt a given machine in the system to a wide range of

production operations and part styles. The greater the range of operations and part styles

the greater will be the machine flexibility. The various factors on which machine flexibility

depends are:

Setup or changeover time Ease with which part-programs can be downloaded to machines Tool storage capacity of machines

2. Production Flexibility.

It is the range of part styles that can be produced on the systems. The range of part styles that

can be produced by a manufacturing system at moderate cost and time depends on following

factors:

Machine flexibility of individual stations Range of machine flexibilities of all stations in the system

3. Product Flexibility.

It refers to ability to change over to a new set of products economically and quickly in

response to the changing market requirements. The change over time includes the time for

designing, planning, tooling, and fixturing of new products introduced in the manufacturing line-

up. It depends upon following factors:

Relatedness of new part design with the existing part family Machine flexibility

4. Routing Flexibility.

It can define as capacity to produce parts on alternative workstation in case of equipment

breakdowns, tool failure, and other interruptions at any particular station. It helps in increasing

throughput, in the presence of external changes such as product mix, engineering changes,

or new product introductions. Following are the factors which decides routing

flexibility:

Similarity of parts in the mix Similarity of workstations

Common tooling

5. Expansion Flexibility.

It is defined as the ease with which the system can be expanded to faster total production

volume. Expansion flexibility depends on following factors:

Cost incurred in adding new workstations and trained workers


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Easiness in expansion of layout Type of part handling system used.

TYPES OF FMS:

Flexible manufacturing systems can be divided into various types depending upon their

features. They all are discussed below:

Depending Upon Kinds Of Operation-

Flexible manufacturing system can be distinguished depending upon the kinds of

operation they perform:

I. Processing operation.Such operation transforms a work material from one state to another moving towards

the final desired part or product. It adds value by changing the geometry, properties

or appearance of the starting materials.

II. Assembly operation.It involves joining of two or more component to create a new entity which is called

an assembly/subassembly. Permanent joining processes include welding, brazing,soldering , adhesive bonding, rivets, press fitting.

Depending Upon Number Of Machines

The following are typical categories of FMS according to the number of machines in

the system:

I. Single machine cell (SMC).It consist of a fully automated machine capable of unattended operations for a time

period longer than one machine cycle. It is capable of processing different part styles,

responding to changes in production schedule, and accepting new part

introductions. In this case processing is sequential not simultaneous.

II. Flexible manufacturing cell (FMC).It consists of two or three processing workstation and a part handling system. The

part handling system is connected to a load/unload station. It is capable of simultaneous

production of different parts.

III. A Flexible Manufacturing System (FMS).It has four or more processing work stations (typically CNC machining centers or

turning centers) connected mechanically by a common part handling system and

automatically by a distributed computer system. It also includes non-processing work

stations that support production but do not directly participate in it. e.g. part / pallet

washing stations, co-ordinate measuring machines. These features significantlydifferentiate it from Flexible manufacturing cell (FMC).


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Depending Upon Level Of Flexibility

Another classification of FMS is made according to the level of flexibility associated

with the system. Two categories are distinguished here:

I. Dedicated FMS.It is designed to produce a particular variety of part styles. The product design is

considered fixed. So, the system can be designed with a certain amount of process

specialization to make the operation more efficient.

II. Random order FMS.It is able to handle the substantial variations in part configurations. To

accommodate these variations, a random order FMS must be more flexible than

the dedicated FMS. A random order FMS is capable of processing parts that have a

higher degree of complexity. Thus, to deal with these kinds of complexity, sophisticated

computer control system is used for this FMS type.


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COMPONENTS OF FMS:

There are several basic components of an FMS. A flexible manufacturing system

consists of

1.

Workstations.2. Material Handling and Storage system.3. Computer Control System.4. Human Resources1. Workstations.

It consists of NC machines, machine-tools, inspection equipments, loading and

unloading operation, and machining area.

Load/Unload Stations.

Loading and unloading can be accomplished either manually or by automated handling

systems. The load/unload station should be designed to permit convenient and safemovement of work parts. For parts that are too heavy to lift by the operator, mechanized

cranes and other handling devices are installed to assist the operator

Machining Stations.

Include CNC machining centers and other machining centers for performing different

operations for manufacturing products. The machining centers are able to perform a

wide variety of operations e.g. turning, drilling,boring,etc

CNC machining centers

Turning centers

Other Stations are used in addition of machining like Pressworking, bending, forging.

Assembly.

Some FMSs are designed to perform assembly operations. Flexible automated assembly

systems are being developed to replace manual labor in the assembly of products

typically made in batches. Industrial robots are often used as the automated workstations

in these flexible assembly systems.

Other systems involved are

Inspection stations, CMM, Cleaning/washing of parts, chip removal, AGV maintenance.

2. Material Handling and Storage system.Material handling system includes fixtures, tool changers, tool identification systems,coolant, and chip removal systems.

The material-handling equipments used in flexible manufacturing systems

include robots, conveyers, automated guided vehicle systems(AVGS), and other

rail guided vehicles, and other specially designed vehicles.


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3. Computer Control System.The FMS includes a distributed computer system that is interfaced to the

workstations, material handling system, and other hardware components. A typical

FMS computer system consists of a central computer and microcomputers controlling

the individual machines and other components.

Workstation control.

In a fully automated FMS, the individual processing or assembly stations generally

operate under some form of computer control. For a machining system, CNC is used

to control the individual machine tools

Distribution of control instructions to workstations.

Some form of central intelligence is also required to coordinate the processing at

individual stations.

Production control.

Traffic control.

This refers to the management of the primary material handling sys-tem that movesworkparts between stations. Traffic control is accomplished by switches at branches

and merging points. stopping parts at machine tool transfer locations, and moving

pallets to load/unload stations.

Shuttle control.

This control function is concerned with the operation and control of the secondary

handling system at each workstation.

Tool control.

Diagnostics.

This function is available to a greater or lesser degree on many manufacturing

systems to indicate the probable source of the problem when a malfunctionoccurs.

4. Human ResourcesOne additional component in the FMS is human labor. Humans are needed to manage

the operations of the FMS. Functions typically performed by humans include:

(1) Loading raw work parts into the system,

(2) Unloading finished parts (or assemblies) from the system.

(3) Changing and setting tools.

(4) Equipment maintenance and repair,

(6) Programming and operating the computer system

(7) Overall management of the system

FMS LAYOUT CONFIGURATONS:


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1. In-line layout:

2. Loop layout (secondary part handling systems)

3. Ladder layout


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4. Open field layout

PLANNING THE FMS:Purchase or installation of flexible

manufacturing system requires a major

investment by the company, so a thorough planning is required. Following factors must

considered before designing an FMS

Production volume Variations in process routing Physical characteristics of required workparts Manpower requirements Number of machines required Defining part families according to common characteristics/process for workparts

BENEFITS OF FMS:

A number of benefits can be expected in successful FMS applications. The principal benefits are

the following:

Increased machine utilization.

FMSs achieve a higher average utilization than machines in a conventional batch production

machine shop. Reasons for this include:

24hr/day operation. automatic tool changing of machine tools. line of parts at stations

Fewer machines required

Because of higher machine utilization. fewer machines are required.

Reduction in factory floor space required.

Compared with a job shop of equivalent capacity, an FMS generally requires less floor area.

Reductions in floor space requirements are estimated to he 40-50%


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Greater responsiveness to change.

An FMS improves response capability to part design changes. introduction of new parts, changes

in production schedule and product mix.machine breakdowns. and cutting tool failures.

Adjustments can be made in the production schedule from one day to the next to respond to rush

orders and special customer requests.

Reduced inventory requirements

Because different parts are processed together rather than separately in batches. work-in-process

(WIP) is less than in a batch production mode. The inventory of starting and finished parts can be

reduced as well Inventory reductions of 60-80%

Lower manufacturing lead times.

Closely correlated with reduced WIP is the time spent in process by the parts. This means faster

processing and faster customer deliveries

Reduced direct labor requirements and higher labor productivity.

Higher production rates and lower reliance on direct labor translate to greater productivity per

labor hour with an FMS than with conventional production methods. Labor savings of 30-50%are estimated

Opportunity for unattended production.

The high level of automation in an FMS allows it to operate for extended periods of time without

human attention. In the most optimistic scenario, parts and tools are loaded into the system at the

end of the day shift, and the FMS continues to operate throughout the night so that the finished

parts can be unloaded the next morning

Report FMS

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