FLEXIBLE MANUFACTURING SYSTEMS(FMS)CONTENTSIntroduction to FMSHistory of FMSWhy FMS ?Basic components of FMSFMS equipmentTypes of FMSLayouts of FMSFlexibility in FMSApplications of FMSAdvantagesDisadvantageChallenges with FMSConclusion

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

What is FMS ?

History of FMSThe 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 timeReduced production costs Overcoming internal changes like breakdowns etc.What makes it flexible???The ability to identify and distinguish among the different part styles processed by the system. Quick changeover of operating instructions, andQuick changeover of physical setupClassification of FMSFlexible manufacturing systems can be distinguished according to the number of machines in the system. The following are typical categories:

Single machine cell Flexible manufacturing cell Flexible manufacturing system

Single Machine Cell (SMC)A single machine cell consists of one CNC machining center combined with a parts storage system for unattended operation.

Completed parts are periodically unloaded from the parts storage unit, and raw work parts are loaded into it

Flexible Manufacturing Cell (FMC)A flexible manufacturing cell consists of two or three processing workstations (typically CNC machining centers) plus a part handling system.

The part handling system is connected to a load/unload station

Flexible Manufacturing System (FMS)

A flexible manufacturing system has four or more processing workstations connected mechanically by a common part handling system and electronically by a distributed computer system.

Basic components of FMSWorkstations Automated Material Handling and Storage systems Computer Control SystemWorkstation

Substations1. Load/Unload Stations2. Machining Stations3. Other processing stations4. Assembly

Computer controlProgrammable logic Controller

PLC:The FMS includes a distributed computer system that is interfaced to the workstations,Material handling system, andOther hardware components.

A typical FMS computer system consists of a central computer and microcomputers. Microcomputers controlling the individual machines and other components. The central computer coordinates the activities of the components to achieve smooth overall operation of the system

Material handling system AGV

Allied Signals Flexible Manufacturing System

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

Types of FMSSequential FMSRandom FMSDedicated FMSEngineered FMSLayouts of FMSProgressive or Line TypeLoop TypeLadder TypeOpen field typeRobot centered type

1.Progressive Layout

2. Loop Layout

3.Ladder Type Layout 4.Open Field Layout

5. Robot Centered LayoutFlexibility in FMSFlexibility 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 FMSMetal-cutting machiningMetal formingAssemblyJoining-welding (arc , spot), glueingSurface treatmentInspectionTesting

29Human ResourcesHuman are needed to manage the operations of the FMS. Functions typically performed by human includes:Loading raw workparts into the system,Unloading finished parts (or assemblies) from the system,Changing and setting tools,Equipment maintenance and repair, NC part programming in a machining system, andProgramming and operation the computer system.

FMS at Vought Aircraft

Advantages of FMSTo reduce set up and queue timesImprove efficiencyReduce time for product completionUtilize human workers betterImprove product routingProduce a variety of Items under one roofImprove product qualityServe a variety of vendors simultaneouslyProduce more product more quickly

Disadvantages of FMSExpensive.Substantial pre-planning activity.

Processing of Gear 1 by Conventional Manufacturing System.

Processing of Gear 2 by Flexible Manufacturing SystemThe 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 FMSDetermining if FMS the best production system for your company

Possible expansion costs associated with implementing FMS

39Conclusion FMS is a revolution in the field of Manufacturing Technology.FMS can be designed to meet the specific demand of each companyFMS is used for multitask operation.FMS requires substantial investment of time and resources.THANK YOU