Flexible Manufacturing Systemsdrravinderkumar.com/.../Flexible-Manufacturing-Systems.pdfFlexible...

Flexible Manufacturing SystemsFlexible Manufacturing SystemsFlexible Manufacturing SystemsFlexible Manufacturing Systems

Dr.Ravinder Kumar

Core Transformation Process for a

Manufacturing Company

ENVIRONMENT

Organization

Raw Material

Inputs

Product or Service

OutputsCore

Work Processes

Materials

Handling

Milling Inspection

Assembly

Dr.Ravinder Kumar

Classification Based on System of Production� Group I

� Small-batch and unit production

� Group II� Large-batch and mass production

� Group III� Continuous process production

Dr.Ravinder Kumar

Flexible Manufacturing Systems� Computer-aided design

� (CAD)

� Computer-aided manufacturing� (CAM)� (CAM)

� Integrated Information Network

Dr.Ravinder Kumar

NEW CHOICES

Small batchFlexible

ManufacturingMass

Customization

Relationship of Flexible Manufacturing Technology

to Traditional Technologies

Customized

Mass

Production

Continuous

Process

BATCH SIZESmall Unlimited

Standardized

PRODUCT FLEXIBILITY

Source: Based on Jack Meredith, “The Strategic Advantages of New

Manufacturing Technologies For Small Firms.” Strategic Management

Journal 8 (1987): 249-58; Paul Adler, “Managing Flexible Automation,”

California Management Review (Spring 1988): 34-56; and

Otis Port, “Custom-made Direct from the Plant.”

Business Week/21st Century Capitalism, 18 November 1994, 158-59.

Dr.Ravinder Kumar

Comparison of Organizational Characteristics Associated with

Mass Production and

Flexible Manufacturing Systems

CharacteristicCharacteristic Mass ProductionMass Production FMSFMS

Structure:Structure:

Span of ControlSpan of Control WideWide NarrowNarrow

Hierarchical levelsHierarchical levels ManyMany FewFewHierarchical levelsHierarchical levels ManyMany FewFew

TasksTasks Routine, repetitiveRoutine, repetitive Adaptive, Adaptive,

craftcraft--likelike

SpecializationSpecialization HighHigh LowLow

Decision makingDecision making CentralizedCentralized DecentralizedDecentralized

OverallOverall Bureaucratic, Bureaucratic,

mechanisticmechanistic

SelfSelf--regulating, regulating,

organicorganic

Source: Based on Patricia L. Nemetz and Louis W. Fry, “Flexible

Manufacturing Organizations: Implications for Strategy Formulation

and Organization Design.” Academy of Management Review 13

(1988); 627-38; Paul S. Adler, “Managing Flexible Automation,”

California Management Review (Spring 1988); 34-56; Jeremy Main,

“Manufacturing the Right Way,” Fortune, 21 May 1990, 54-64.

Comparison of Organizational Characteristics Associated with

Mass Production and

Flexible Manufacturing Systems (cont.)

CharacteristicCharacteristic Mass ProductionMass Production FMSFMS

Human Human

Resources:Resources:

InteractionsInteractions StandaloneStandalone TeamworkTeamwork

TrainingTraining Narrow, one timeNarrow, one time Broad, frequentBroad, frequent

ExpertiseExpertise Manual, Manual,

technicaltechnical

Cognitive, socialCognitive, social

Solve problemsSolve problems

Source: Based on Patricia L. Nemetz and Louis W. Fry, “Flexible

Manufacturing Organizations: Implications for Strategy Formulation

and Organization Design.” Academy of Management Review 13

(1988); 627-38; Paul S. Adler, “Managing Flexible Automation,”

California Management Review (Spring 1988); 34-56; Jeremy Main,

“Manufacturing the Right Way,” Fortune, 21 May 1990, 54-64.

Flexible Manufacturing Systems (FMS)

� An FMS is a “reprogrammable” manufacturing system capable of producing a variety of products automatically.

� Conventional manufacturing systems have been marked by one of two distinct features:� The capability of producing a variety of different product types, but at a high cost (e.g., job shops).

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

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

Dr.Ravinder Kumar

FMS Components

� Numerical Control (NC) machine tools� Automated material handling system (AMHS)

� Automated guided vehicles (AGV)� Conveyors� Automated storage and retrieval systems (AS/RS)� Automated storage and retrieval systems (AS/RS)

� Industrial Robots� Control Software

Dr.Ravinder Kumar

Flexible Manufacturing System

Computer

control

room

Machine Machine

Tools

Conveyor

Pallet

PartsFinished

goods

Load Unload

Terminal

Pallet

Dr.Ravinder Kumar

Classification of FMS-related Problems

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

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

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

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

Dr.Ravinder Kumar

FMS Problems

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

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

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

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

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

Dr.Ravinder Kumar

Information Technology

� Management information system (MIS)�move large amounts of data

� Decision support system (DSS)�add decision making support

� Expert system� Expert system�recommend decision based on expert knowledge

Dr.Ravinder Kumar

Decision Support System

Information:

Personnel

AccountingManagement Information System

ManagementDecision Support System

Information:reportsmodel resultswhat if?analysis

Computersystem:dataprocessing

Data

Quantitativetechniques

Production

Marketing

Distribution

Other areas

Decisions

What -if? analysis

Dr.Ravinder Kumar

Artificial Intelligence

� Neural networks�emulate interconnections in brain

� Genetic algorithms�based on adaptive capabilities in nature

� Fuzzy logic� Fuzzy logic�simulate human ability to deal with ambiguity

Dr.Ravinder Kumar

Advanced Communications

� Electronic data interchange (EDI)

� Internet

� Wireless communications

� Teleconferencing

& telecommuting

� Bar coding

� Virtual reality

Dr.Ravinder Kumar

Manufacturing Technology

� Numerically controlled (NC) machines�controlled by punched tape

� Computer numerical controlled (CNC)�controlled by attached computer

� Direct numerical control (DNC)� Direct numerical control (DNC)� several NC machines controlled by single computer

Dr.Ravinder Kumar

Automated Material Handling

� Conveyors

� Automated guided vehicle (AGV)

� Automated storage & retrieval system (ASRS)

Dr.Ravinder Kumar

Flexible Manufacturing Systems (FMS)

� Programmable machine tools

� Controlled by common computer network

� Combines flexibility with efficiency

� Reduces setup & queue times

Dr.Ravinder Kumar

Robotics

� Programmable manipulators

� Follow specified path

� Better than humans with respect to �hostile environments

�long hours�long hours

�consistency

Dr.Ravinder Kumar

Robot Parts

� Controller�hardware, software, power source

� Manipulator�robot arm

� End-effector� End-effector�“hand”

Dr.Ravinder Kumar

Computer Integrated Manufacturing

(CIM) � Integration of design, manufacture & delivery via computer technology

� CAD - uses software to create & modify designs

� CAM - uses programmable automation in manufacturing

� CAE - links functional design to CAD form design

� CAPP - creates processing instructions for CAM

GT- classifies designs to benefit from prior experience� GT- classifies designs to benefit from prior experience

Dr.Ravinder Kumar

Components Of CIM

Product

design

TQM

Bar codes,

EDI

MRP

GTCAECAD

IGES,

PDES,

DMIS

DFM

CAD/CAM

CAPP

CIM

Manufacture

Process

planning

Systems

management

RoboticsFMSNC/CNC/

DNC

Cells

and centers

Automated

inspection

AGV,

ASRS

JIT/

kanban

DSS/ES/

AI

LAN, TOP,

satellites

MRP

Cellular

manufacturing

MAP,

STEP

CAPP

Dr.Ravinder Kumar

Adoption Of Technology

� Technology Readiness� Need well-designed products & efficient processes

� Technology Design� Know what to automate

� Technology Selection� Technology Selection� Choose the right level

� Technology Integration� Have a strategy for incremental automation

Dr.Ravinder Kumar

An Example

Dr.Ravinder Kumar

And also

Dr.Ravinder Kumar