FLEXFLEXIIBLEBLE MANUFACTURMANUFACTURIINGNG SYSTEMSYSTEM

Presented by: Er. Fateh SinghA.PDeptt. of Mechanical

Engineering1

At a Glance In the middle of the 1960s, market

competition became more intense. During 1960 to 1970 cost was the primary

concern. Later quality became a priority. As the market became more and more complex, speed of delivery became something customer also needed.

A new strategy was formulated: Customizability. The companies have to adapt to the environment in which they operate, to be more flexible in their operations and to satisfy different market segments (customizability).

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Thus the innovation of FMS became related to the effort of gaining competitive advantage

The first FMS was patented in 1965 by Theo Williamson who made numerically controlled equipment. Examples of numerically controlled equipment are like a CNC lathes or mills which is called varying types of FMS.

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Flexible Manufacturing System is?

A Flexible Manufacturing System (FMS) is a form of flexible automation in which several machine tools are linked together by a material-handling system, and all aspects of the system are controlled by a central computer.

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

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Equipments of FMS

Primary equipments Work centers

• Universal machining centers• Turning centers• Grinding machines

Process centers• Wash machines• Coordinate measuring machines• Robotic work stations• Manual workstations

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Secondary EquipmentsSupporting Stations• Pallet/fixture load/unload stations• Tool commissioning/setting area

Supporting Equipments• Robots• Pallet/fixture stores• Pallet buffer stations• Tools stores• Raw material stores• Transport system• Transport units(pallets)

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What are the Features of FMS?? An FMS is distinguished from an automated

production line by its ability to process more than one product style simultaneously.

At any moment, each machine in the system may be processing a different part type.

FMS can let us make changes in production schedule in order to meet the demands on different product

New product styles can be introduced into production with an FMS, so long as they are to be used on the products that the system can process.

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Distinguishing Characteristics

An automatic materials handling subsystem links machines in the system and provides for automatic interchange of work pieces in each machine

Automatic continuous cycling of individual machines

Complete control of the manufacturing system by the host computer

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3 Levels of Manufacturing Flexibility 1-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

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2-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

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Process flexibility: a measure of the volume of the set of part types that a system can produce without incurring any setup

Product flexibility:  the volume of the set of part types that can be manufactured in a system with minor setup

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•3-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

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Components of FMS Systems

Robotics Material Handling / Transport Machines Manual / Automated Assembly Cells Computers Controllers Software Networks

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Benefits of FMS

FMS systems are intended to solve the following problems:

Reduced work in process Increased machine utilization Better management control Reduced direct and indirect labor Reduced manufacturing lead-time Consistent and better quality Reduced inventory

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The Disadvantages of FMS

Expensive, costing millions of dollars Substantial pre-planning activity Sophisticated manufacturing systems Limited ability to adapt to changes in

product Technological problems of exact component

positioning and precise timing necessary to process a component

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Future Benefits of FMS Technology will make 100% inspection feasible Computer diagnosis will improve estimation of

machine failure, and guide work crews repairing failures

Minimum human labor in manufacturing systems

Varity of tools with increased computing power Better management software, hardware, and

fixturing techniques Developed standards that will let us install new

machines easily

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FMS according to number of Machines Flexible manufacturing systems can be

distinguished according to the number of machines in the system. The following are typical categories:

Single machine cell (Type I A) Flexible manufacturing cell (usually type II

A, sometimes type III A) Flexible manufacturing system (usually

Type II A, sometimes type III A)

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Single machine cell (Type I A)• A single machine cell consists of one CNC

machining center combined with a parts storage system for unattended operation.

• Completed parts are periodically unloaded from the parts storage unit, and raw workparts are loaded into it

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Flexible manufacturing cell• A flexible manufacturing cell consists of two

or three processing workstations (typically CNC machining centers) plus a part handling system.

• The part handling system is connected to a load/unload station

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Flexible manufacturing system• A flexible manufacturing system has four or

more processing workstations connected mechanically by a common part handling system and electronically by a distributed computer system.

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Some of the distinguishing characteristics of the three categories of flexible manufacturing cells and systems are summarized in figure below

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Flexibility Criteria Applied to the Three Types of Manufacturing Cells and Systems

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FMS Layout Configurations

Progressive or Line TypeLoop TypeLadder TypeOpen field typeRobot centered type

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• Progressive or Line Type

• Loop Type

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• Ladder type Open Field Layout

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Robot Centered Layout

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Differences Between FMS and FMC F.M.System

Has four or more machines

Larger and more sophisticated computer control system

Minimized effect of machine breakdowns

F.M.Cell

Has two or three machines

Simpler computer control system

Limited error recovery by fewer machines

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Application of FMS

Metal-cutting machiningMetal formingAssembly Joining-welding (arc , spot), glueingSurface treatment InspectionTesting

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Conclusions

FMS is a revolution in the field of Manufacturing Technology.

FMS can be designed to meet the specific demand of each company

FMS is used for multitask operation. FMS requires substantial investment of time and

resources

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References

Books Referred:M.P. Groover: “Automation Production

System and Computer Integration Manufacturing”, Prentice-Hall of India Private Limited,2008,Pg.No.:538-560.

R.K. Jain: “Production technology”, Khanna Publications, 2009, Pg.No.:962-974.

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