FMS (Flexible Manufacturing System)_Rev1.0

8/4/2019 FMS (Flexible Manufacturing System)_Rev1.0

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FMS (Flexible Manufacturing

System)PRESENTED BY :

Suffian Bin Ayob


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Contents

Introduction

Why use F.M.S.?

What Is F.M.S.?

Components of F.M.S.

FMS Layout

Example Of FMS application

FMS Photo

Advantages of FMS application


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Introduction

Since the dawn of civilisation, man has been continuously trying toease and improve his work by developing better tools.

This process started with the development of stone tools and willculminate into development of a totally automated factory.

This factory would be able to do all the things associated with a

product, right from designing it to packaging. Since the human operator tends to be the weakest link in theproduction process, the need for automation has been feltthroughout the industry.

A Flexible Manufacturing System (F.M.S.) is a part of this processand a step towards complete automation of the factory.

A F.M.S. is a form of flexible automation in which several machinetools are linked together by a material-handling system, and allaspects of the system are controlled by a central computer.


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Why use F.M.S.?

The current market scenario is such that a customer has therequirement to demand a wide variety of good quality product at avery short notice.

The traditional systems of product manufacture like Transfer Linesystem were unable to cope up with the market requirements.

The Transfer Line system of manufacture had a very highproduction level but offered limited flexibility. On the other hand, Workshop system of product manufacture

offered a very high degree of flexibility but had a very low productionlevel.

These systems were unable to satisfy the requirements of variety,

quantity and speed at the same time. This lead to the work of development of a system, which combinesthe seemingly conflicting objectives of high flexibility and highproductivity.


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Why use F.M.S.?

The emergence of F.M.S. technology has proved to be anideal solution to this problem.

With the help of F.M.S. we are able to produce a widevariety of products without making any changes in thehardware set-up.

As a result of this the changeover time between twoproducts can be reduced to the time required by themachine tools to receive the necessary instructions.

It also reduces the lead-time drastically.

This is of prime importance as lead-time is equated withthe cost of the product. It is a market-sensitive technology as it can produce the

required proportion of product variety quickly andefficiently.


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Figure 1: - Volume versus variety capabilities of variousManufacturing Systems,

Courtesy Material and Processes in Manufacture, Lindberg


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What Is F.M.S.

A flexible manufacturing system (FMS) is a configuration ofcomputer-controlled, semi-independent workstations wherematerials are automatically handled and machine loaded.

An FMS is a type of flexible automation system that builds on theprogrammable automation of NC and CNC machines.

Programs and tooling setups can be changed with almost no loss ofproduction time for moving from production of one product to thenext.

Such systems require a large initial investment ($5 to $20 million)but little direct labor to operate. An FMS system has three keycomponents:

1. Several computer-controlled workstations, such as CNC machinesor robots, that perform a series of operations2. A computer-controlled transport system for moving materials and

parts from one machine to another and in and out of the system3. Loading and unloading stations


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What is FMS?

an automated, mid-volume, mid-variety, central computercontrolled manufacturing system Activities covered: machining, sheet metal working,

welding, fabricating, assembly Physical components:

Potentially independent NC machine tools capable ofperforming multiple functions and having automated toolinterchange capabilities

Automated material handling system to move partsbetween machine tools and fixturing stations

All the components are hierarchically computer controlled Equipment such as coordinate measuring machines and

part-washing devices


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Components of F.M.S.

A FMS consists of:

Physical subsystem/Hardware

a) Workstations: NC machine tools, inspection equipment,part-washing devices, load & unload area.

b) Storage-retrieval systems (AS/RS)

c) Material handling systems

Control subsystem/Software

a) Control hardware

b) Control software


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FMS Layout

Raw

materialstorage

(FloorSpace)

Raw material storage(Roller Conveyor)


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Figure (1) shows the layout of a typical FMS, which produces turningand machining centers.

Specific characteristics of this FMS include the following: The computer control room (right) houses the main computer, which

controlsthe transporter and sequence of operations.

Three CNC machines, each with its own microprocessor, control thedetails of the machining process.

Two AGVs, which travel around a 200-foot-long oval track, movematerials on pallets to and from the CNCs.When the AGVs batteries run low, the central computer directs

them to certain spots on the track for recharging. Indexing tables lie between each CNC and the track. Inbound pallets

from an AGV are automatically transferred to the right side of thetable, and out-bound pallets holding finished parts are transferred tothe left side for pickup.


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A tool changer located behind each CNC loads andunloads tool magazines.Each magazine holds an assortment of tools.A machine automatically selects tools for the next specific

operation. Changing from one tool to another takes only 2minutes. Two load and unload stations are manually loaded by

workers; loading takes10 to 20 minutes.An automatic AS/RS (upper right) stores finished parts.

The AGV transfers parts on its pallet to an indexing table,which then transfers them to the AS/RS.The process is reversed when parts are needed forassembly into finished products elsewhere in the plant.


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FMS PHOTO


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FMS PHOTO


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FMS PHOTO


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ADVANTAGES OF FMS

APPLICATION

1) A faster response to market changes in designor the creation of new designs

2) Improved product quality

3) Direct and indirect labour costs are reduced

4) Production Planning is improved

5) Machine utilisation levels are improved

6) The work in progress inventory is improvedsince the time spent in the systems is reduced.


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KEBAIKAN APLIKASI FMS

1. Proses pembuatan cepat.

2. Tidak memerlukan pekerja yang ramai.

3. Pengurangan inventori komponen.

4. Masa penyediaan pendek untuk membuat produk baru.

5. Kualiti produk stabil.

6. Pengurangan kos pengeluaran.

7. Pengurangan masa kitaran.

8. Menambahkan produktiviti.

9. Menukar rekabentuk dan produk baru dengan cepat.

10. Menarik minat tenaga kerja mahir kerana tempat loji initidak kotor dan membosankan.


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Glossary

Numerically Controlled(NC) MachinesLarge machine tools programmed to produce small- tomedium-sized batches of intricate parts.

Computerized Numerically Controlled (CNC) MachinesStand-alone pieces of equipment, each controlled by itsown microcomputer.

Industrial Robots

Versatile,computer-controlled machines programmed toperform various tasks.


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materials handling

The processes of moving, packaging, and storing aproduct.

automated guided vehicle(AGV)

A small, driverless,battery-driven truck that movesmaterials between operations, following instructions fromeither an onboard or a central computer.

Most older models follow a cable installed below the floor,

but the newest generation follows optical paths and cango anywhere with aisle space and a relatively smoothfloor


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automated guided vehicle(AGV)

A small, driverless,battery-driven truck thatmoves materials between operations, following

instructions from either an onboard or a centralcomputer.

Most older models follow a cable installed belowthe floor, but the newest generation followsoptical paths and can go anywhere with aislespace and a relatively smooth floor


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automated storage and retrieval system(AS/RS)

A computer-controlled method of storing and

retrieving materials and tools using racks,bins,and stackers.

flexible manufacturing system (FMS)

A configuration of computer-controlled,semi-independent workstations where materials areautomatically handled and machine loaded.

Documents

FMS (Flexible Manufacturing System)_Rev1.0