Upload
ankur-makhija
View
33
Download
4
Embed Size (px)
Citation preview
Flexible Manufacturing System
FLEXIBLE MANUFACTURING SYSTEM
SUBMITTED BY:
RANJIT PASWAN
RAVI YADAV
AMIT-VII
NIFT, B’LORE
SUBMITTED TO:
Mrs. SHIPRA
(Assit. Professor)
NIFT, B’LORE
Flexible Manufacturing System
FMS CONCEPT
Today flexibility means to produce reasonably priced customized products
of high quality that can be quickly delivered to customers.
A flexible manufacturing system (FMS) is a manufacturing system in which
there is some amount of flexibility that allows the system to react in the case
of changes, whether predicted or unpredicted.
Flexible Manufacturing System
FMS CONCEPT CONTIUED….
what is flexibility in manufacturing?
(A)BASIC FLEXIBILITIES
•Machine flexibility - the ease with which a machine can process various
operations
•Material handling flexibility - a measure of the ease with which different
part types can be transported and properly positioned at the various machine
tools in a system
•Operation flexibility - a measure of the ease with which alternative
operation sequences can be used for processing a part type
Flexible Manufacturing System
(B) SYSTEM FLEXIBILITIES
•Volume flexibility - a measure of a system’s capability to be operated
profitably at different volumes of the existing part types
Expansion flexibility - the ability to build a system and expand it
incrementally
Routing flexibility - a measure of the alternative paths that a part can
effectively follow through a system for a given process plan
Process flexibility - a measure of the volume of the set of part types that a
system can produce without incurring any setup
FMS CONCEPT CONTIUED….
Flexible Manufacturing System
(C) AGGREGATE FLEXIBILITIES
Program flexibility - the ability of a system to run for reasonably long periods
without external intervention
Production flexibility - the volume of the set of part types that a system can
produce without major investment in capital equipment
Market flexibility - the ability of a system to efficiently adapt to changing
market conditions
Product flexibility - the volume of the set of part types that can be
manufactured in a system with minor setup
FMS CONCEPT CONTIUED….
Flexible Manufacturing System
APPROACH FLEXIBILITY MEANING
MANUFACTURING
•The capability of producing different parts without major retooling
•A measure of how fast the company converts its process (es) from making an old line of products to produce a new product
•The ability to change a production schedule, to modify a part, or to handle multiple parts
OPERATIONAL
•The ability to efficiently produce highly customized and unique products
CUSTOMER
•The ability to exploit various dimension of speed of delivery
STRATEGIC
•The ability of a company to offer a wide variety of products to its customers
CAPACITY
•The ability to rapidly increase or decrease production levels or to shift capacity quickly from one product or service to another
DIFFERENT APPROACHES OF FMS
Flexible Manufacturing System
•Flexible Manufacturing Module (FMM). Example : a NC machine, a pallet changer and a part buffer;
•Flexible Manufacturing (Assembly) Cell (F(M/A)C). Example : Four FMMs and an AGV (automated guided vehicle);
•Flexible Manufacturing Group (FMG). Example : Two FMCs, a FMM and two AGVs which will transport parts from a Part Loading area, through machines, to a Part Unloading Area;
•Flexible Production Systems (FPS). Example : A FMG and a FAC, two AGVs, an Automated Tool Storage, and an Automated Part/assembly Storage;
•Flexible Manufacturing Line (FML). Example : multiple stations in a line layout and AGVs.
DIFFERENT LEVEL OF FMS
Flexible Manufacturing System
ADVANTAGE OF IMPLEMENTATION
•Faster, lower- cost changes from one part to another which will improve capital utilization
•Lower direct labor cost, due to the reduction in number of workers
•Reduced inventory, due to the planning and programming precision
•Consistent and better quality, due to the automated control
•Lower cost/unit of output, due to the greater productivity using the same number of workers
•Savings from the indirect labor, from reduced errors, rework, repairs and rejects
Flexible Manufacturing System
DISADVANTAGE OF IMPLEMENTATION
•Limited ability to adapt to changes in product or product mix (ex. machines
are of limited capacity and the tooling necessary for products, even of the
same family, is not always feasible in a given FMS)
•Substantial pre-planning activity
•Expensive, costing millions of dollars
•Technological problems of exact component positioning and precise timing
necessary to process a component
•Sophisticated manufacturing systems
Flexible Manufacturing System
CONCLUSION
FMSs complexity and cost are reasons for their slow acceptance
by industry. In most of the cases FMCs are favored.
Flexible Manufacturing System
Global market (European,US), which is known for its small sized orders and even shorter lead times
Small orders as the start up losses and frequent changes make it difficult
for a factory to run cost effectively with progressive bundle system
The need of the hour is of flexible manufacturing systems that provide
high performance and quick response in a cost effective manner.
Flexible manufacturing System helps a company in :Developing a quick response system.
Developing human capital with decision making power and collaborative capabilities.
Reduction of work in progress.
Utilizing work areas more effectively.
NEED OF FMS IN APPAREL INDUSTRY
Flexible Manufacturing System
It is a contained, manageable work unit that includes an empowered work
team, equipment, and work to be executed. Modules frequently operate as
mini factories with teams responsible for group goals and self-management.
The number of teams in a plant varies with the size and needs of the firm
and product line
Different names used to identify FMS apparel production systems,
Modular manufacturingCellular manufacturing unitsCompact work teamsFlexible work groups, Self-directed work teamsToyota sewing system (tss)
The basic premise is similar among these systems, although the organization and implementation may vary.
INTRODUCTION
Flexible Manufacturing System
Teams may be used to perform all the operations or a certain portion of
the assembly operations depending on the organization of the module and
processes required.
A team-based system operators are given the responsibility for operating
their module to meet goals for throughput and quality.
A FMS System operates as a Pull System, with demand for work coming
from the next operator in line to process the garment.
Teams usually operate as ‘Stand-up’ or ‘Sit-down’ units.
INTRODUCTION contued…..
Flexible Manufacturing System
A module may be divided into several work zones based on the sequence
of operations and the time required for each operation
A general thumb rule to determine the no. of operator required is,
average number of operations required for a style being produced and divide by three
Work flow within a module may one of the following:
Single-piece hand-off,
Kanban
Bump-back system
INTRODUCTION contued…..
Flexible Manufacturing System
SINGLE-PIECE HAND-OFF
Machines are arranged in a very tight configuration
As soon as an operation is completed the part is handed to the next operator
Operations need to be well balanced, usually only one garment component between each operation
If a small bundle is used between operation, an operator will complete the operation on the entire bundle and carry the bundle to the next operation
An operator may follow a component or bundle for as many operations as they have been trained or until the adjacent operator is ready to assume work on the bundle.
Flexible Manufacturing System
KANBAN
Uses a designated work space between operations to balance supply with demand
The designated space will hold a limited number of completed components (two or three) in queue for the next operation
If the designated space is full, there is no need to produce more until it is needed or the space empties.
When the space is full the operator can assist with other operations that may be slow.
Flexible Manufacturing System
BUMP-BACK SYSTEM (TSS)It was developed by the Toyota Sewn Product Management System
Probably the most widely used type of team-based manufacturing
It is a stand-up module with flexible work zones and cross-trained operators
Operators may be cross-trained on up to four different successive operations
Operators shift from operation to operation until the next operator is ready
to begin work on the garment.
Flexible Manufacturing System
The operator who has been relieved of the garment will then move back to
the beginning of the work zone and take over work on another garment
This approach enables continuous work on a garment and allows each
operator to perform several different operations
This arrangement frequently uses a 4-to-l ratio of machines to operators
BUMP-BACK SYSTEM (TSS) contued…..
Flexible Manufacturing System
ADVANTAGES OF FMS
High flexibility
Fast throughput times
Low wastages
Reduced Absenteeism
Low work in process
Increased employee ownership of the production process
Empowered employees
Improved Quality
Flexible Manufacturing System
DISADVANTAGES OF FMS
A high capital investment in equipment.
High investment in initial training.
High cost incurred in continued training
Flexible Manufacturing System
DETERMINATION OF TEAM SIZE
The Key points that should taken care of while deciding upon the number of operators are:
The technical characteristics of the product, that is the S.A.M and
complexity
Expected Production Capacity.
Poly Functionality requirements.
Module continuity and stability in important to adapt with its flexibility
requirements so no changes should be made to the team after setting it up
Flexible Manufacturing System
DETERMINATION OF TEAM SIZE contued..
The team has to be self managed and identification between the team
members is a must to develop the team spirit. So, the team size should not
be exceed a certain limit.
The level of flexibility expected would also be a critical issue since more
number of workers would bring down the flexibility by reducing the poly
functionality requirements.
Module team Size =
Expected Production Capacity * S.A.M of Garment/ Working hours per day
Flexible Manufacturing System
The total machine requirement for the Module will have the total number of
work stations along with all the attachments, work aids and auxiliary
equipment requirements.
Number of SNLS machines required for the Module = Expected Production Capacity*Total SNLS S.A.M / Working Hours per day
Here SNLS is one of the example only, this formula can be used to calculate any type of machine requirement
MACHINE REQUIREMENT
Flexible Manufacturing System
CONCLUSION
•Modular production system is a new concept which has evolved as natural
progression in accordance to the apparel market needs
•Modular Production System brings along with itself benefits like Low
inventory, quick response through reduced throughput time and flexibility to
style changes.
•This brings a feeling of self belief and belongingness to the employee
towards the company.
Flexible Manufacturing System
BIBLIOGRAPHY
1) Flexible manufacturing system
By: DR. Rajesh Bheda
2) Graduation project
BY: Abhinay Shrivastava at Lagoona Clothings
3) www.Apparelsearch.com
4) www.apparelkey.com
5) www.epnet.com