1. Flexible Manufacturing Systems (FMS)

2. 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

3. 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

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

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

6. 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

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

8. 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

9. 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

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

11. 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

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

13. 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.

14. 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.

15. 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

16. Components of Flexible Manufacturing SystemsNC
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.

17. 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.

18. FMS Nuts and Bolts
Robots

19. 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.

20. 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.

21. 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

22. 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.

23. 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.

24. 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.

25. Flexible Manufacturing
How Does It Work ?

26. 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.

27. 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.

28. A Real World Example
The
Ford
Motor Company

29. 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:

30. 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.

31. 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

32. 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.

33. THANK YOU