“FLEXIBLE MANUFACTURING SYSTEM”

CONTENTS Introduction to FMS History of FMS Why FMS ? Basic components of FMS FMS equipment Types of FMS Layouts of FMS Flexibility in FMS Applications of FMS Advantages Disadvantage Challenges with FMS Conclusion References

What is FMS ? A flexible manufacturing system is a automated machine cell, consisting of a group of processing workstations, interconnected with automated material handling and storage system.

History of FMS 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.

Why FMS ? External changes such as change in product design and production system. Optimizing the manufacturing cycle time Reduced production costs Overcoming internal changes like breakdowns etc.

Basic components of FMS Workstations Automated Material Handling and Storage systems Computer Control System

Workstation Substations 1. Load/Unload Stations 2. Machining Stations 3. Other processing stations 4. Assembly

Material handling system AGV

Computer control Programmable logic Controller

Allied Signal’s Flexible Manufacturing System

A 5 machines FMS for machining:-photo courtesy of Cincinnati Milacron

Types of FMS Sequential FMS Random FMS Dedicated FMS Engineered FMS

Layouts of FMS Progressive or Line Type Loop Type Ladder Type Open field type Robot centered type

1.Progressive Layout 2. Loop Layout

3.Ladder Type Layout 4.Open Field Layout

5. Robot Centered Layout

Flexibility in FMS Flexibility in manufacturing means the ability to deal with slightly or greatly mixed parts, to allow variation in parts assembly and variations in process sequence, change the production volume and change the design of certain product being manufactured.

Continue….. To be flexible, a manufacturing system must posses the following capabilities: Identification of the different production units to perform the correct operation. Quick changeover of operating instructions. Quick changeover of physical setups of fixtures, tools and other working units.

Application of FMS Metal-cutting machining Metal forming Assembly Joining-welding (arc , spot), glueing Surface treatment Inspection Testing

FMS at Vought Aircraft

Advantages of FMS To reduce set up and queue times Improve efficiency Reduce time for product completion Utilize human workers better Improve product routing Produce a variety of Items under one roof Improve product quality Serve a variety of vendors simultaneously Produce more product more quickly

Disadvantages of FMS Expensive. Substantial pre-planning activity.

Processing of Gear 1 by Conventional Manufacturing System.

Processing of Gear 2 by Flexible Manufacturing System

The processing of Gear by FMS saves approximately 100 seconds per gear including pre & post processing adjustments. This means if number of gears to be produced increases this will save lot of time and increase productivity of the manufacturer. This will help in earning more profit. Hence FMS is more beneficial than conventional manufacturing system.

Comparison

Challenges with FMS Determining if FMS the best production system for your company Possible expansion costs associated with implementing FMS These challenges must never be overlooked when deciding whether or not to implement a FMS system. In order to get the best possible results you must answer the these questions within your own firms.

Conclusion 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.

References Technical Papers: Guixiu Qiao, Robert Lu, CharlesMclean: “Flexible manufacturing system for mass customization manufacturing”, International Journal of Flexible Manufacturing Systems, Volume 14, pp173-187. . Jim Browne, Didier Dubois, Keith Rathmill, Suresh P. Sethi, Kathryn E. Stecke :“Classification of FMS”, International Journal of Flexible Manufacturing Systems,Volume 13, Issue 4,Paper No. 367, pp 114-117, (1984). Antonio Grieco, Quirico Semeraro, Tullio Tolio: “A Review of Different Approaches to the FMS Loading Problem”, International Journal of Flexible Manufacturing Systems,Volume 13, Issue 4, pp 361-384, October 2001.

Books Referred: Case study: 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. Case study: Ajay Singholi, Deepti Chhabra, Sampada Bagai: “Performance Evaluation and Design of Flexible Manufacturing System”, Global Journal of Enterprise Information System, Volume 2, Issue 1, pp 24-34, 2010.

THANK YOU