Flexible Manufacturing Flexible Manufacturing SystemsSystems

Tom FosterTom FosterBoise State UniversityBoise State University

Flexible Manufacturing Flexible Manufacturing Systems (FMS)Systems (FMS)

• An FMS is a “reprogrammable” manufacturing An FMS is a “reprogrammable” manufacturing system capable of producing a variety of products system capable of producing a variety of products automatically. Conventional manufacturing automatically. Conventional manufacturing systems have been marked by one of two distinct systems have been marked by one of two distinct features:features:– The capability of producing a variety of different The capability of producing a variety of different

product types, but at a high cost (e.g., job shops).product types, but at a high cost (e.g., job shops).– The capability of producing large volumes of a The capability of producing large volumes of a

product at a lower cost, but very inflexible in product at a lower cost, but very inflexible in terms of the product types which can be terms of the product types which can be produced (e.g., transfer lines).produced (e.g., transfer lines).

• An FMS is designed to provide both of these An FMS is designed to provide both of these features.features.

FMS ComponentsFMS Components

• Numerical Control (NC) machine Numerical Control (NC) machine toolstools

• Automated material handling system Automated material handling system (AMHS)(AMHS)– Automated guided vehicles (AGV)Automated guided vehicles (AGV)– ConveyorsConveyors– Automated storage and retrieval systems Automated storage and retrieval systems

(AS/RS)(AS/RS)• Industrial RobotsIndustrial Robots• Control SoftwareControl Software

Flexible Manufacturing SystemFlexible Manufacturing System

PartsFinishedgoods

Load Unload

Computercontrolroom

Terminal

Machine Machine

Tools

Conveyor

Pallet

Classification of FMS-Classification of FMS-related Problemsrelated Problems

• Strategic analysis and economic justification, which Strategic analysis and economic justification, which provides long-range, strategic business plans.provides long-range, strategic business plans.

• Facility design, in which strategic business plans Facility design, in which strategic business plans are integrated into a specific facility design to are integrated into a specific facility design to accomplish long-term managerial objectives.accomplish long-term managerial objectives.

• Intermediate-range planning, which encompasses Intermediate-range planning, which encompasses decisions related to master production scheduling decisions related to master production scheduling and deals with a planning horizon from several days and deals with a planning horizon from several days to several months in duration.to several months in duration.

• Dynamic operations planning, which is concerned Dynamic operations planning, which is concerned with the dynamic, minute-to-minute operations of with the dynamic, minute-to-minute operations of FMS.FMS.

FMS ProblemsFMS Problems

• Pa rt t ype sele ct ionPa rt t ype sele ct ion (Askin) - selecting parts that will be (Askin) - selecting parts that will be produced in the FMS over some relatively long planning produced in the FMS over some relatively long planning horizon.horizon.

• Pa rt s ele ctio nPa rt s ele ctio n (Stecke) - from the set of parts that have (Stecke) - from the set of parts that have current production requirements and have been selected current production requirements and have been selected for processing in the FMS, select a subset for immediate for processing in the FMS, select a subset for immediate and simultaneous processing.and simultaneous processing.

• Mac hi ne gro upi ngMac hi ne gro upi ng (Stecke) - partition machines into (Stecke) - partition machines into groups where each machine in a group can perform the groups where each machine in a group can perform the same set of operations.same set of operations.

• Lo adi ngLo adi ng (Stecke) - allocate the operations and required (Stecke) - allocate the operations and required tools of the selected part types among the machine tools of the selected part types among the machine groups.groups.

• Con trolCon trol - provide instructions for, and monitor the - provide instructions for, and monitor the equipment in the FMS so that the production goals equipment in the FMS so that the production goals identified by the above problems are met.identified by the above problems are met.

Information TechnologyInformation Technology

• Management information system Management information system (MIS)(MIS)

–move large amounts of datamove large amounts of data• Decision support system (DSS)Decision support system (DSS)

–add decision making supportadd decision making support• Expert systemExpert system

–recommend decision based on recommend decision based on expert knowledgeexpert knowledge

Decision Support Decision Support SystemSystem

Information:reportsmodel resultswhat if? analysis

Computersystem:dataprocessing

Data

Quantitativetechniques

Personnel

Accounting

Production

Marketing

Distribution

Other areas

Decisions

Management Information System

What -if? analysis

ManagementDecision Support System

Artificial IntelligenceArtificial Intelligence

• Neural networksNeural networks–emulate interconnections in brainemulate interconnections in brain

• Genetic algorithmsGenetic algorithms–based on adaptive capabilities in based on adaptive capabilities in naturenature

• Fuzzy logicFuzzy logic–simulate human ability to deal simulate human ability to deal with ambiguitywith ambiguity

Advanced Advanced CommunicationsCommunications• Electronic data interchange (EDI)Electronic data interchange (EDI)• InternetInternet• Wireless communicationsWireless communications• Teleconferencing Teleconferencing & telecommuting& telecommuting• Bar codingBar coding• Virtual realityVirtual reality

Manufacturing Manufacturing TechnologyTechnology• Numerically controlled (NC) Numerically controlled (NC)

machinesmachines–controlled by punched tapecontrolled by punched tape

• Computer numerical controlled (CNC)Computer numerical controlled (CNC)–controlled by attached computercontrolled by attached computer

• Direct numerical control (DNC)Direct numerical control (DNC)– several NC machines controlled by several NC machines controlled by single computersingle computer

Automated Material Automated Material HandlingHandling

• ConveyorsConveyors• Automated guided vehicle (AGV)Automated guided vehicle (AGV)• Automated storage & retrieval Automated storage & retrieval

system (ASRS)system (ASRS)

Flexible Manufacturing Flexible Manufacturing Systems (FMS)Systems (FMS)

• Programmable machine toolsProgrammable machine tools• Controlled by common computer Controlled by common computer

networknetwork• Combines flexibility with Combines flexibility with

efficiencyefficiency• Reduces setup & queue timesReduces setup & queue times

RoboticsRobotics

• Programmable manipulatorsProgrammable manipulators• Follow specified pathFollow specified path• Better than humans with Better than humans with

respect to respect to –hostile environmentshostile environments–long hourslong hours–consistencyconsistency

Robot PartsRobot Parts

• ControllerController–hardware, software, power sourcehardware, software, power source

• ManipulatorManipulator–robot armrobot arm

• End-effectorEnd-effector–““hand”hand”

Computer Integrated Computer Integrated Manufacturing (CIM) Manufacturing (CIM)

• Integration of design, manufacture & delivery via Integration of design, manufacture & delivery via computer technologycomputer technology

• CAD - uses software to create & modify designsCAD - uses software to create & modify designs• CAM - uses programmable automation in CAM - uses programmable automation in

manufacturingmanufacturing• CAE - links functional design to CAD form designCAE - links functional design to CAD form design• CAPP - creates processing instructions for CAMCAPP - creates processing instructions for CAM• GT- classifies designs to benefit from prior GT- classifies designs to benefit from prior

experienceexperience

Components Of CIM Components Of CIM

CIM

Productdesign

Manufacture

Processplanning

Systemsmanagement

RoboticsFMSNC/CNC/

DNCCells

and centersAutomatedinspection

AGV,ASRS

JIT/kanban

DSS/ES/AI

LAN, TOP,satellites

TQM

Bar codes,EDI

MRP

GTCAECADIGES,PDES,DMIS

DFM

Cellularmanufacturing

MAP,STEP

CAD/CAM

CAPP

Adoption Of TechnologyAdoption Of Technology

• Technology ReadinessTechnology Readiness• Need well-designed products & efficient Need well-designed products & efficient

processesprocesses

• Technology DesignTechnology Design• Know what to automate Know what to automate

• Technology SelectionTechnology Selection• Choose the right levelChoose the right level

• Technology IntegrationTechnology Integration• Have a strategy for incremental automationHave a strategy for incremental automation