VISVESWARAIAH TECHNOLOGICAL UNIVERSITY

BELGAUM, KARNATAKA

SHRI B.V.V SANGHA’S

BASAVESHWAR ENGINEERING COLLEGE

BAGALKOT-587102

2008-2009

DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING

A Seminar Report On

FLEXIBLE MANUFACTURING SYSTEM

Seminar Guide: H.O.D:

Dr. S.T. Dundur Dr. S.T. Dundur

Submitted By:

Miss. Trupti Vilas Mane

USN: 2BA05IP028

SHRI B.V.V SANGHA’S

BASAVESHWAR ENGINEERING COLLEGE

BAGALKOT-587102

Department of Industrial and Production Engineering

CERTIFICATE

This is to certify than the seminar work entitled “FLEXIBLE MANUFACTURING SYSTEM” is a bonafide work

carried out by Miss. Trupti Vilas Mane, in partial fulfillment for the award of the degree of Bachelor of

Engineering in INDUSTRIAL AND PRODUCTION of Visweswaraya Technological University, Belgaum during the

year 2008-2009.it is certified that all corrections/suggestions indicated for internal assessment have been

incorporated in the report deposited in the department library. The seminar report deposited in the department

library .The seminar report has been approved as it satisfies the academic requirements in respect of seminar

work prescribed for the Bachelor of Engineering Degree.

Seminar Guide: H.O.D:

Dr. S.T. Dundur Dr. S.T. Dundur

Submitted By:

Miss. Trupti Vilas Mane

USN: 2BA05IP028

CONTENTS:

1. Definition

2. Introduction

3. Integration of FMS

4. Components of FMS

5. How FMS works

6. A real world example

7. Applications and benefits of FMS

8. Conclusion

FLEXIBLE MANUFACTURING SYSTEM

Definition:

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

INTRODUCTION:

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 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.

INTEGRATION OF FMS:

Computer Integrated Manufacturing:

Definition:

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

Components of CIM:

1. CAD/ CAM (Computer Aided Design)/(Computer Aided Manufacturing):

The use of computer and digital technology to generate manufacturing control data, plans and operations

The computer graphics that CAD provides allows designers to create electronic images which can be portrayed in two dimensions or as a three dimensional solid component or assembly which can be rotated as it is viewed. In CAD system, the images are created using basic geometric elements such as point, lines, circles and curves. These can be modified rotated and transformed on the CRT screen according to the commands given by the designer. These finally lead to the creation of the desired image in the system, which is stored in a proper fashion. In CAD both the design and manufacturing ted into one activity. CAD system not only automates certain design and manufacturing phases, but also automates the transition from design to manufacturing activity, along with the design process itself. The manufacturing data base is nothing but the integrated CAD/CAM database. It consists of all the data of the component generated during design like geometry details, BOM, parts list, material specification.

2. CAE Computer Aided Engineering:

In a CAE system, the computer and its software handles most aspects of the manufacturing operation. Information from the CAD/CAM design database is used to analyze functional characteristics of a product and simulate its performance under various conditions. This allows engineers and designers to detect and fix potentially costly design flaws.

Robotics:

“An industrial robot is a programmable, multifunctional manipulator, designed to move materials, parts, tools, or special devices through variable programmed motions for the performance of a variety of tasks”

An industrial robot is a general purpose, programmable machine having certain anthropomorphic characteristics, like the arm. Moreover, a robot can be programmed, that is a set of instruction can be given, which it can execute with the help of its components mainly arm, gripper and sensors. In industries robots are widely used for assembling, painting, welding, material handling, etc.

It can work in dangerous environment, it can repeat the same set of instructions and it can work tirelessly.

Manufacturing system:

Manufacturing system divides into five groups

Project:

In this type Products are complex. Production quantities are often just one unit. Products are usually similar and are not identical. Layout is fixed-position and Product remains in one location and production equipment and parts are moved to it. Production and assembly equipment must be mobile and very few robot applications are found in this type.

Job type:

In this type Production quantities (lot sizes) are small Size and weight of parts are small in this type. Pats are moved or routed between fixed production work cells for manufacturing processing. Most often used are lathes, mills, grinders etc, Production equipment layout is job shop layout or process layout Less than 20% repeat production on the same part Noncomplex products. Intensive movement of the product between machines. Opportunities for Robotic applications are present but limited by the high variation in parts and products.

Repetitive: In this type Orders for repeat business is 100%. Customer contracts for multiple years. It gives High product volume with production quantities vary over large range and Little variation in the routings of parts between production machines Plant layout – either Special-purpose production machines, automated systems with robots are integrated into the process

Line: In this type Delivery time required by the customer is often shorter than the total time to build all individual parts of the product and Product has many different options or models. Inventory of subassemblies is usually present Plant Layout is Product-flow layout Robots are frequently used to perform assembly tasks.

Continuous:

In this type time required for manufacture is longer than customer waiting time. Demand is predictable and Product inventory is always present. High production volumes Products have few options Plant layout is limited to one or just a few different products. Plant layout is Product-flow type and Robots can handle high-speed high-volume operation of this type

COMPONENTS OF FMS:

Numerically controlled (NC) machines:Numerical control refers to the use of coded numerical information in the automatic control of equipment. It can be defined as a kind of programmable automation in which the process is controlled by numbers, letters and symbols. The numbers are arranged as a program of instruction for a particular job. When the job is changed, the program of instruction is to be changed. This capability to change the program of instructions for each new job is what gives NC its flexibility.

Computer numerical control(CNC):The idea of computer numerical control is to position a computer right at the machine tool. The main feature of CNC is that one independant computer is used to control one NC machine. This is the system with stored program to perform all the basic NC functions. The basic arrangement of CNC is similar to conventional NC machines. However the hardwired controller is replaced by a computer and suitable software programs to control the NC achines.

Direct numerical control (DNC):Is a method where a single computer controls many numerical control machine tools. These machine tools may or may not be of a similar nature. The only computer used here is called central coputer and is hardwired to the controller of one or more NC machines on the shop floor. The computer in DNC is designed to receive information from all machine tools, their status and send instuctions to each machine tool for the desired kind of operation.

Robotics:İn many aspects an industrial robot is similar to an NC machine. It uses a similar technology as that of NC technology to activate its arm and gripper. However the NC machine works on offline programming, with the machine operation command stored in a punched tape or in separate system. But in robot an online programming is used, with the set of instruction being stored in a robot memory unit.

Automated guided vehicle (AGV):Automated Guided Vehicles are used to consistently and predictably transport loads of material to places that might otherwise be serviced by fork lift trucks, conveyor, or manual cart transport. They are typically used where high volumes of repetitive movement of material is required, but where little or no human decision making skill is required to perform the movement. They are especially useful in serving processes where change is constant, and barriers – such as conveyors – are undesirable.

Automated Storage/Retrieval Systems (ASRS):AS/RS refers to a variety of computer-controlled methods for automatically depositing and retrieving loads from defined storage locations. Handling and storage systems integrated into the manufacturing and distribution processes.AS/RS used for storage of (typically heavy loads of) finished goods, work-in-process, raw material, and supplies. AS/RS are used widely in both Manufacturing and Distribution operations to hold and buffer the flow of material moving through the process to the ultimate end-user. Overall, the objective of using an AGV is to eliminate the cost and variance of the human operator in a process that adds no value to the end product – movement between processes.

HOW FMS WORKS:

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

Most FMS systems comprise of three main systems. The work machines which are often automated CNC machines are connected by a material handling system to optimize parts flow and the central control computer which controls material movements and machine flow

A REAL WORLD EXAMPLE:

“The ford motor company”

Ford’s Problem:

At Ford Power train they faced the following challenges

Outdated cell controller Lack of flexibility because of it Causing loss of efficiency

Solution:

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

Benefits:

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

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

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

• No formal training was required for the floor shop operators

APPLICATION AND BENEFITS OF FMS:

1. To reduce set up and queue times

2. Improve efficiency

3. Reduce time for product completion

4. Utilize human workers better

5. Improve product routing

6. Produce a variety of Items under one roof

7. Improve product quality

8. Serve a variety of vendors simultaneously

9. Produce more product more quickly

CONCLUSION:

This paper has outlined a vision for a computing environment for engineering manufacturing systems. Such an engineering environment would provide an integrated set of tools to improve the productivity of manufacturing and industrial engineers.