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Submitted by :

Chithralekha R

S4 MBA

CET

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One of the most important aspects of WCM.

The ability to adjust to meet the customer needs

without compromising the capabilities of the

company

avoid buying or using equipment monuments

one of the principles of lean manufacturing to help

reduce waste FMS can be tweaked, adjusted, or rebuilt to fit the

needs of other products & hence cost effective.

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The idea of an FMS was proposed in England

(1960s) under the name "System 24",

System 24 :a flexible machining system that could

operate without human operators 24 hours a dayunder computer control.

From the beginning the emphasis was

on automation rather than the "reorganization of

workflow".

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A flexible manufacturing system (FMS) is a

manufacturing system in which there is some

amount of flexibility that allows the system to react

in the case of changes, whether predicted orunpredicted.

Highly automated GT machine cell, consisting of a

group or processing workstations (usually CNC

machine tools), interconnected by an automated

material handling and storage system, and

controlled by a distributed computer system.

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Flexibility in manufacturing means

the ability to deal with slightly or greatly mixed

parts, allow variation in parts assembly and

variations in process sequence

change the production volume change the design of certain product being

manufactured.

The FMS is most suited for themid-variety, mid-

volume production range

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Three capabilities that a manufacturing system must possess to be a

flexible.

1. The ability to identify and distinguish among the different part stylesprocessed by the system.

2. Quick changeover of operating instructions, and

3. Quick changeover of physical setup.

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Machine flexibility, covers the system's ability to be

changed to produce new product types, and ability to

change the order of operations executed on a part.

Routing flexibility, which consists of the ability to use

multiple machines to perform the same operation on a part,

as well as the system's ability to absorb large-scale

changes, such as in volume, capacity, or capability.

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LAYOUTS

Progressive 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 time

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Ladder 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 station

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FMS

ManufacturingTechnology CIM Robotics

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Robots: Programmable Manipulators

Can tolerate hostile environments

Can work much longer hours than humans

Can perform redundant jobs more consistently

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Loading and unloading

Spray painting

Welding

Material handling

Inspection

Machine Assembly

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CIM:

The Integration of the total manufacturing

enterprise through the use of integrated systems and

data communications coupled with new managerialphilosophies that improve organizational and

personnel efficiency.

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CAD Computer Aided Design

CAM Computer Aided Manufacturing

CAE Computer Aided Engineering

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This part of FMS uses:

NC Numerically Controlled Machine

CNC Computer Controlled Machine

DNC Direct Numerical Controlled

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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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The work machines which are often automated CNC

machines are connected by a material

handling system to optimize parts flow and the

central control computer which controls materialmovements and machine flow.

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production of small sets of products like those from

a mass production.

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high flexibility in managing manufacturing resources like time and effort

in order to manufacture a new product.

Lower cost per unit produced, less waste

fewer workstations

quicker changes of tools, dies, and stamping machinery

reduced downtime

better control over quality

reduced labor

more efficient use of machinery

work-in-process inventory reduced

increased capacity

Greater labor productivity,

Adaptability to CAD/CAM operations.

Shorter lead times

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Cost to implement,

Substantial pre-planning required

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Consists of

robots

Computer-controlled Machines

Numerical controlled machines (CNC)

instrumentation devices

computers

sensors

other stand alone systems such as inspection

machines.

A TYPICAL FMS

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ATYPICAL FMS.

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Tests of Flexibility

To qualify as being flexible, a manufacturing system should satisfy

several criteria. The following are four reasonable tests of flexibility

in an automated manufacturing system:Part variety test. Can the system process different part styles in a

non batch mode?.

Schedule change test. Can the system readily accept changes in

production schedule, and changes in either part mix or production

quantity.

Error recovery test. Can the system recover quickly from

equipment breakdowns, so that the production is not completely

disrupted.

New part test. Can new part designs be introduced into theexisting product mix with relative ease.

If the answer to all of these questions is YES for a given

manufacturing system, then the system can be considered flexible.

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Types of Flexibility in Manufacturing

C i f F C i i f Fl ibili i M f i S d h S

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Comparison of Four Criteria of Flexibility in a Manufacturing System and the Seven

Types of Flexibility

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Number of Machines

Flexible manufacturing systems can be

distingished according to the number ofmachines in the system. The following are

typical categories:

Single machine cell (Type I A)

Flexible manufacturing cell (usually type II A,

sometimes type III A)Flexible manufacturing system (usually Type

II A, sometimes type III A)

Si l M hi C ll (SMC)

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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

workparts are loaded into it

Fl ibl M f t i C ll (FMC)

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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.

Fl ibl M f t i S t (FMS)

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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.

S f th di ti i hi h t i ti f th th t i f fl ibl

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Some of the distinguishing characteristics of the three categories of flexible

manufacturing cells and systems are summarized in figure below

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Flexibility Criteria Applied to the Three Types of Manufacturing Cells and

Systems

Level of Flexibility

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Level of Flexibility

Another classification of FMS is according to the level of flexibility designed

into the system. Two categories are distinguished here:

Dedicated FMS

Random-order FMS

A dedicated FMSis designed to produce a limited variety of part styles, and the

complete universe of parts to be made on the system is known in advance.

A random-order FMSis more appropriate when1. the part family is large,

2. there are substantial variations in part configurations,3. there will be new part designs introduced into the system and engineering changes in

parts currently produced, and

4. the production schedule is subjected to change from day-to-day.

A comparison of dedicated and random order FMS types

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Acomparison of dedicated and random-order FMS types

Flexibility Criteria Applied to Dedicated FMS and Random order FMS

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Flexibility Criteria Applied to Dedicated FMS and Random-order FMS

Components of FMS

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p

There are several basic components of an FMS:

1. Workstations.

2. Material handling and storage systems.

3. Computer control system.

4. People are required to manage and operate the system

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1.Workstations

Following are the types of workstations typically found in

an FMS:

1. Load/Unload Stations.

2. Machining Stations.

3. Other processing Stations. (punching, shearing,

welding, etc.)

4. Assembly Station.

5. Other Stations and Equipment. (Inspection, Vision, etc)

2 M i l H dli d S S

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2.Material Handling and Storage System

Functions of the Handling System

1. Independent movement of work parts between stations.2. Handle a variety of work part configurations.

3. Temporary storage.

4. Convenient access for loading and unloading work parts.

5. Compatible with computer control.

Material Handling Equipment

The material handling function in an FMS is often shared between

two systems:

Primary handling system establishes the basic layout of the FMS

and is responsible for moving work parts between stations in the

system. (Conveyor)

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Secondary handling system consists of transfer devices,

automatic pallet changing, and similar mechanisms located atthe workstations in the FMS.

The function of the secondary handling system is to transfer

work from the primary system to the machine tool or otherprocessing station and to position the parts with sufficient

accuracy and repeatability to perform the process or assembly

operation.

Material Handling and Storage System contd..

C t C t l S t

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Computer Control System

The FMS includes a distributed computer system that is interfaced

to

the workstations, Material handling system, and

Other hardware components.

A typical FMS computer system consists of a central computer andmicrocomputers.

Microcomputers controlling the individual machines and other

components.

The central computer coordinates the activities of thecomponents to achieve smooth overall operation of the system

H R

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Human Resources

Human are needed to manage the operations of the FMS. Functions

typically performed by human includes:

Loading raw work parts 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, and

Programming and operating the computer system.

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The

Ford

Motor Company

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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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Implemented a cell control based on an open

architecture, commonly available tools,

and industry standard hardware, software, and

protocols.

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Enabled Ford to mix and match machine tools from

different vendors

Reduced the number of man-years required to

implement the application The budget for the fully automatic closed-loop

controller was less than 1/10th the cost for a systembuilt in language.

No formal training was required for the floor shopoperators

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