Class Presentation Fms (1)
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Flexible Manufacturing Systems (FMS)• An FMS is a “reprogrammable” manufacturing system
capable of producing a variety of products automatically. Conventional manufacturing systems have been marked by one of two distinct features:– The capability of producing a variety of different
product types, but at a high cost (e.g., job shops).
– The capability of producing large volumes of a product at a lower cost, but very inflexible in terms of the product types which can be produced (e.g., transfer lines).
• An FMS is designed to provide both of these features.
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Definition of Flexible Manufacturing System
Flexible Manufacturing System:
- “A system that consists of numerous programmable machine tools connected by an automated material handling system”
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Characteristics of FMS
• It is an attempt to solve production problems of mid-volume and mid-variety parts.
• It is designed to process several parts in the given mix simultaneously.
• It is equipped with sophisticated flexible machine tools.
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Characteristics of FMS (cont.)
• Parts are transferred from machine to machine by a computer controlled Material Handling System (MHS).
• It consists of three sub-systems: the machining system, the material handling system and the control system.
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Production TechnologyFlexible Manufacturing Systems
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10 100 1000 10000 100000 1000000
10
100
1000Work cells
CIM
Focusedautomation
Dedicatedautomation
Volume
Prod
ucts FlexibleManufacturing
System
Generalpurpose
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How You Can Use 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
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FMS Components
• Numerical Control (NC) machine tools• Automated material handling system
(AMHS)– Automated guided vehicles (AGV)– Conveyors– Automated storage and retrieval systems
(AS/RS)• Industrial Robots• Control Software
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Flexible Manufacturing System
PartsFinished
goods
Load Unload
Computercontrolroom
Terminal
Machine Machine
Tools
Conveyor
Pallet
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Manufacturing Technology
• Numerically controlled (NC) machines–controlled by punched tape
• Computer numerical controlled (CNC)–controlled by attached computer
• Direct numerical control (DNC)– several NC machines controlled by single computer
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Automated Material Handling
• Conveyors• Automated guided vehicle (AGV)• Automated storage & retrieval
system (ASRS)
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Robotics
• Programmable manipulators• Follow specified path• Better than humans with respect
to –hostile environments–long hours–consistency
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Robot Parts
• Controller–hardware, software, power source
• Manipulator–robot arm
• End-effector–“hand”
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• Machines that hold, move, or grasp items
• Perform monotonous or dangerous tasks
• Used when speed, accuracy, or strength are needed
© 1984-1994 T/Maker Co.
Production TechnologyRobots
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Common Uses of Robots
• Loading and unloading
• Spray painting
• Welding
• Material handling
• Inspection
• Machine Assembly
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• Material handling machines
• Used to move parts & equipment in manufacturing
• May be used to deliver mail & meals in service facilities
© 1984-1994 T/Maker Co.
Production TechnologyAutomatic Guided Vehicles (AGV)
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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.” (4)
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Components of CIM
• CAD Computer Aided Design
• CAM Computer Aided Manufacturing
• CAE Computer Aided Engineering
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Challenges with FMS
• Determining if FMS is the best production system for your company (economically and socially)
• Possible expansion costs associated with implementing FMS
• Day to day maintenance of FMS operations
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• Using automated machines (DNC) & materials handling equipment together
• Often connected to centralized computer
• Also called automated work cell
Computer
Machine 1
Machine 2
Robotor AGV
Auto ToolChg.
Auto ToolChg.
Production TechnologyFlexible Manufacturing
Systems (FMS)
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Production TechnologyFMS - Pros & Cons
• Advantages– Faster, lower-cost changes from one part to
another– Lower direct labor costs– Reduced inventory– Consistent, and perhaps better quality– FMS in a batch production system offers
several flexibilities, like: machine flexibility, process flexibility, product flexibility, routing flexibility, volume flexibility and expansion flexibility.
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Production TechnologyFMS - Pros & Cons
• Disadvantages– Limited ability to adapt to product or
product mix changes– Requires substantial preplanning and
capital expenditures– Technological problems of exact
component positioning and precise timing
– Tooling and fixture requirements
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Flexible Manufacturing
How Does It Work ?
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Integration of FMS
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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
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A Real World Example
TheFord
Motor Company
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Ford’s Problem
• At Ford Powertrain they faced the following challenges
- outdated cell controller- lack of flexibility because of it- causing loss of efficiency
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Solution
• Implemented a cell control based on an open architecture, commonly available tools, and industry standard hardware, software, and protocols.
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Benefits
• Enabled Ford to mix and match machine tools from different vendors
• Reduced the number of man-years required to implement the application
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Benefits Continued
• The budget for the fully automatic closed-loop controller was less
• No formal training was required for the floor shop operators
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Computer-Integrated Manufacturing
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Summing Up (FMS)
• Programmable machine tools• Controlled by common computer
network• Combines flexibility with efficiency• Reduces setup & queue times
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Manufacturing Technology
• This part of FMS uses:
– NC Numerically Controlled Machine
– CNC Computer Controlled Machine
– DNC Direct Numerical Controlled
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Robots
Robots: Programmable Manipulators
― Can tolerate hostile environments
― Can work much longer hours than humans
― Can perform redundant jobs more consistently (1)