Unit 2.
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Unit 2
FMS
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Content• Introduction: FMS definition and classification of
manufacturing systems, Automated production cycle, Need of
flexibility, Concept of flexibility, Types of flexibilities and its
measurement.
• FMS Equipment: Why FMS, Factors responsible for the
growth of FMS. FMS types, its components, applications and
its benefits, Economic justification for FMS
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Introduction
• FMS is the most automated and technologically sophisticated
manufacturing system applied in group technology cells.
• An FMS typically possesses multiple stations and is capable of
variable routing among stations. Its flexibility allows it to
operate in mixed model systems.
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What is a flexible manufacturing system
• A flexible manufacturing system is a highly
automated GT 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
computer system.
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FMS
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Types of FMS
• A single Machine Cell• A flexible manufacturing cell• A flexible manufacturing system
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Single Machine Cell
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Flexible Manufacturing cell
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Flexible Manufacturing System
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Comparison
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Flexibility
• A manufacturing system must posses three capabilities to be flexible:
• To identify and distinguish among the different incoming part or product styles processed by the system
• Quick changeover of Operating instructions• Quick changeover of physical setup.
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Flexibility• To qualify as being flexible, a manufacturing system should satisfy
several criteria. The following are four reasonable tests of flexibility in an automated manufacturing system:
1. Part Variety test: Can the system process different part styles in a non-batch mode?
2. Schedule change test: can the system readily accept changes in production schedule, that is changes in part mix and/or production quantity?
3. Error recovery test: can the system recover gracefully from malfunctions and breakdowns, so that production is not completely disrupted?
4. New Part test: Can new part designs can be introduced into the existing product mix?
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Flexibility
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Flexibility Criteria Applied to the three types of manufacturing cell system
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Two categories of Flexibility
A dedicated FMS : Produces a limited variety of part styles, A Random order FMS: It is more appropriate when part family is large,
there are substantial variation in part configurations, new part design will be introduced into the system and engineering changes will occur in p[arts currently produced, and the production schedule is subject to change from day to day.
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FMS Components
• 1. Workstations• 2. Material Handling and storage system• 3. Computer control system• 4. People are required to manage and operate
the system.
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1. Workstations
• Load Unload Stations: This is the physical interference between the FMS and the rest of
the factory. It is where the raw work parts enter the system and finished parts exit the system.
• Machining Stations: The most common applications of flexible manufacturing systems are machining operations. Most common is the CNC machining center.
• Other processing stations: In addition to machining other processes are there in FMS. Ex. Sheet metal fabrication such as punching bending shearing and forming etc.
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1. Workstations
• Assembly: Some flexible manufacturing systems are designed to perform assemble operations. FMS gradually decreasing manual labor in assemble of product typically made in batches.
• Other Station and equipments: Online inspection can be incorporated into a flexible manufacturing system, either by including an operation at a processing work station or by including a station specifically designed for inspection.
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Material Handling and Storage system
• Allows random, independent movements of work parts between stations.
• Enables handling of variety of workpart configuration.
• Provide temporary usage.• Provide convenient access for loading and
unloading workparts.• Creates compatibility with computer control.
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Material Handling Equipments
• A primary handling system: responsible for moving parts in between stations in the system.
• The secondary handling system: it consists of transfer devices like automatic pallet changers, and similar mechanism available at the workstation of FMS.
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FMS layout in According to Material Handling system
• In line layout• Loop layout• Ladder layout• Open field layout• Robot centered cell
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Function performed by FMS computer control system
1. Workstation control2. Distribution of control instruction to workstations3. Production Control4. Traffic control5. Shuttle control6. Work piece monitoring7. Tool control8. Performance Monitoring9. Diagnostics
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