Flexible Manufacturing Systems (FMS)

What Will Be Covered Flexible Manufacturing is Defined How “you” can use FMS Nuts and Bolts How FMS works A real world example Summary This is the outline of the Power Point Presentation for FMS. 2

What Is A Flexible Manufacturing System? - “A system that consists of numerous programmable machine tools connected by an automated material handling system” This definition is from the Russell and Taylor Ops. Mgmt. text used in this class. 3

Basic Components of FMS The Basic components of FMS are: Workstations. Automated material Handling and Storage system. Computer Control System.

Application Characteristics of FMS Stand alone NC machines High Flexible Manufacture Systems Medium Product variety Transfer Lines Low Low Medium High Production volume

Flexibility in Manufacturing Basic Flexibility Machine flexibility Material handling flexibility System Flexibility volume flexibility Routing flexibility Expansion flexibility Aggregate Flexibility Program flexibility production flexibility market flexibility

Different Types of FMS Sequential FMS Random FMS Dedicated FMS Engineered FMS Modular FMS

Types of FMS Layouts Progressive Layout: Closed Loop Layout: Best for producing a variety of parts Closed Loop Layout: Parts can skip stations for flexibility Used for large part sizes Best for long process times Progressive Layout: All parts in the production process follow the same progression through the machining station. Closed Loop Layout: Arranged for the general order of processing for a larger variety of parts. Robot centered Layout - Robot centered cell with one or more robots are Used as the material handling systems. 8

FMS Layouts Continued Ladder Layout: Open Field Layout: Parts can be sent to any machine in any sequence Parts not limited to particular part families Open Field Layout: Most complex FMS layout Includes several support stations Ladder Layout: Allows two machines to work on product at the same time. Open Field Layout: Enables material to move along the machine centers in any particular order necessary. 9

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

Factors Influencing the FMS layouts Available of raw material Proximity to market Transport facilities Availability of efficient and cheap labor Availability of Power ,Water and Fuel Atmospheric and climatic condition Social and recreation Facilities

Objective of FMS Decreased Lead Times Increased machine utilization Improved Due Date Reliability Decreased Store Inventors levels Decreased Work in Progress Increased Quality

Advantages and disadvantages of FMS 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. Consistent and better quality. Savings from indirect labors, from reduced errors , rework, repairs and rejects.

Disadvantages Limited ability to adapt to changes in product or product mix . Substantial pre-planning activity Expensive , costing millions of Dollars. Technological problems of exact component positioning. Sophisticated manufacturing systems.

Automated Material Handling Automated Guided Vehicle (AGV) Automated Storage and Retrieval System (ASRS) Conveyors Automated storage and Retrieval systems are often used for stock selection and transport. Automated Guided Vehicles run on cables or electrical bands to move product throughout the plant or f

Components of Flexible Manufacturing Systems NC CNC DNC Robotics AGV ASRS Automated Inspection Cells and Centers NC Machines or numerically controlled machines are controlled by punched tape. Computer Numerical Controlled (CNC) automatically adjusts and is controlled by an attached computer. Direct Numerical Controlled Machines (DNC) is controlled by several NC machines that are controlled by a single computer.

Flexible Automation Ability to accommodate routing changes Ability to adapt to engineering changes in parts Increase in number of similar parts produced on the system Ability to accommodate routing changes Ability to rapidly change production set up Flexible automation is used when the product mix requires a combination of different parts and products to be manufactured from the same system.

FMS Nuts and Bolts Robots

Robots Robots: Programmable Manipulators Can tolerate hostile environments Can work much longer hours than humans Can perform redundant jobs more consistently Robots in the beginning were used mainly for spray painting and welding, now they are also being used for investigative purposes.

Common Uses of Robots Loading and unloading Inspection Spray painting Welding Material handling Inspection Machine Assembly By having robots conduct these often times repetitive tasks we have seen a reduction in job injuries related to these tasks. Robots have made production much quicker and easier on human beings.

Computer Integrated Manufacturing CIM: “The Integration of the total manufacturing enterprise through the use of integrated systems and data communications coupled with new managerial philosophies that improve organizational and personnel efficiency.” This definition is from http://howard.engr.siu.edu/staff2/spoerre/Roblec6.htm

Components of CIM CAD Computer Aided Design CAM Computer Aided Manufacturing CAE Computer Aided Engineering CAD uses computer software to manipulate and change products while in the design stage. CAM uses computer programs to control the automated manufacturing process. CAE links the functional design to the CAD form design.

Manufacturing Technology This part of FMS uses: NC Numerically Controlled Machine CNC Computer Controlled Machine DNC Direct Numerical Controlled NC, CNC and DNC all are used to control the manufacturing process in a Flexible Manufacturing System. Some systems may use all of the these machine types or only one or two.

Challenges with FMS Determining if FMS the best production system for your company (economically and socially) Possible expansion costs associated with implementing FMS Day to day maintenance of FMS operations 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.

Flexible Manufacturing How Does It Work ?

Integration of FMS By employing the components and concepts from Manufacturing Technology, Computer Aided Manufacturing and Robotics, it is possible to develop a Flexible Manufacturing System that will work well in your organization. These are three main areas making up FMS.

Making FMS Work By implementing the components of robotics, manufacturing technology and computer integrated manufacturing in a correct order one can achieve a successful Flexible Manufacturing System Every situation will differ. Sometimes you may be required to implement only robotics or manufacturing technology. These are only suggestions as to making a FMS work.

A Real World Example The Ford Motor Company

Ford’s Problem At Ford Powertrain they faced the following challenges - outdated cell controller - lack of flexibility because of it - causing loss of efficiency This information was found at the following website: http://www.gensym.com/manufacturing/ss_ford.shtml

Solution Implemented a cell control based on an open architecture, commonly available tools, and industry standard hardware, software, and protocols. (3) G2 as they call it uses AGV’s, UNIX work station that communicates via TCP/IP to an Oracle database on a VAX.

Benefits Enabled Ford to mix and match machine tools from different vendors (3) Reduced the number of man-years required to implement the application (3) These benefits were reported from the website listed in the summary http://www.gensym.com/com/manufacturing/ss_ford.shtml

Benefits Continued The budget for the fully automatic closed-loop controller was less than 1/10th the cost for a system built in language. No formal training was required for the floor shop operators It is clear to see from this example that using the technologies discussed in Flexible Manufacturing can greatly enable a company be more productive, efficient and compete better in the market place.

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