1

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.

2

Definition of Flexible Manufacturing System

Flexible Manufacturing System:

- “A system that consists of numerous programmable machine tools connected by an automated material handling system”

3

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.

4

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.

5

Production TechnologyFlexible Manufacturing Systems

11

10 100 1000 10000 100000 1000000

10

100

1000Work cells

CIM

Focusedautomation

Dedicatedautomation

Volume

Prod

ucts FlexibleManufacturing

System

Generalpurpose

6

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

7

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

8

Flexible Manufacturing System

PartsFinished

goods

Load Unload

Computercontrolroom

Terminal

Machine Machine

Tools

Conveyor

Pallet

9

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

10

Automated Material Handling

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

system (ASRS)

11

Robotics

• Programmable manipulators• Follow specified path• Better than humans with respect

to –hostile environments–long hours–consistency

12

Robot Parts

• Controller–hardware, software, power source

• Manipulator–robot arm

• End-effector–“hand”

13

• 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

14

Common Uses of Robots

• Loading and unloading

• Spray painting

• Welding

• Material handling

• Inspection

• Machine Assembly

15

• 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)

16

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)

17

Components of CIM

• CAD Computer Aided Design

• CAM Computer Aided Manufacturing

• CAE Computer Aided Engineering

18

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

19

• 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)

20

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.

21

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

22

Flexible Manufacturing

How Does It Work ?

23

Integration of FMS

24

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

25

A Real World Example

TheFord

Motor Company

26

Ford’s Problem

• At Ford Powertrain they faced the following challenges

- outdated cell controller- lack of flexibility because of it- causing loss of efficiency

27

Solution

• Implemented a cell control based on an open architecture, commonly available tools, and industry standard hardware, software, and protocols.

28

Benefits

• Enabled Ford to mix and match machine tools from different vendors

• Reduced the number of man-years required to implement the application

29

Benefits Continued

• The budget for the fully automatic closed-loop controller was less

• No formal training was required for the floor shop operators

30

Computer-Integrated Manufacturing

31

Summing Up (FMS)

• Programmable machine tools• Controlled by common computer

network• Combines flexibility with efficiency• Reduces setup & queue times

32

Manufacturing Technology

• This part of FMS uses:

– NC Numerically Controlled Machine

– CNC Computer Controlled Machine

– DNC Direct Numerical Controlled

33

Robots

Robots: Programmable Manipulators

― Can tolerate hostile environments

― Can work much longer hours than humans

― Can perform redundant jobs more consistently (1)