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

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Flexible Manufacturing Systems� Computer-aided design

� (CAD)

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

� Integrated Information Network

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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

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Flexible Manufacturing System

Computer

control

room

Machine Machine

Tools

Conveyor

Pallet

PartsFinished

goods

Load Unload

Terminal

Pallet

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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

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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

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Advanced Communications

� Electronic data interchange (EDI)

� Internet

� Wireless communications

� Teleconferencing

& telecommuting

� Bar coding

� Virtual reality

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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

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Automated Material Handling

� Conveyors

� Automated guided vehicle (AGV)

� Automated storage & retrieval system (ASRS)

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Flexible Manufacturing Systems (FMS)

� Programmable machine tools

� Controlled by common computer network

� Combines flexibility with efficiency

� Reduces setup & queue times

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Robotics

� Programmable manipulators

� Follow specified path

� Better than humans with respect to �hostile environments

�long hours�long hours

�consistency

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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

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And also

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