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

A Closer LookA Closer Look

What Will Be CoveredWhat Will Be Covered

• Flexible Manufacturing DefinedFlexible Manufacturing Defined• How “you” can use FMSHow “you” can use FMS• Nuts and BoltsNuts and Bolts• How FMS worksHow FMS works• A real world exampleA real world example• SummarySummary

What Is A Flexible What Is A Flexible Manufacturing System?Manufacturing System?

Flexible Manufacturing System:Flexible Manufacturing System:

- “A system that consists of numerous - “A system that consists of numerous programmable machine tools connected programmable machine tools connected by an automated material handling by an automated material handling system” system” (2)(2)

History of FMSHistory of FMS

• FMS first proposed in England in 1960’sFMS first proposed in England in 1960’s

• ““System 24” operates 24 hours a daySystem 24” operates 24 hours a day

• Automation is main purpose in beginningAutomation is main purpose in beginning

How You Can Use FMSHow You Can Use FMS

• To reduce set up and queue timesTo reduce set up and queue times• Improve efficiencyImprove efficiency• Reduce time for product completionReduce time for product completion• Utilize human workers betterUtilize human workers better• Improve product routingImprove product routing• Produce a variety of Items under one roofProduce a variety of Items under one roof• Improve product qualityImprove product quality• Serve a variety of vendors simultaneouslyServe a variety of vendors simultaneously• Produce more product more quicklyProduce more product more quickly

Nuts and Bolts of FMSNuts and Bolts of FMS

FMS LayoutsFMS Layouts

• Progressive Layout:Progressive Layout:– Best for producing a variety of partsBest for producing a variety of parts

• Closed Loop Layout:Closed Loop Layout:– Parts can skip stations for flexibilityParts can skip stations for flexibility– Used for large part sizesUsed for large part sizes– Best for long process timesBest for long process times

FMS Layouts ContinuedFMS Layouts Continued

• Ladder Layout:Ladder Layout:― Parts can be sent to any machine in any sequenceParts can be sent to any machine in any sequence― Parts not limited to particular part familiesParts not limited to particular part families

• Open Field Layout:Open Field Layout:― Most complex FMS layoutMost complex FMS layout― Includes several support stationsIncludes several support stations

Automated MaterialAutomated Material HandlingHandling

• Automated Guided Automated Guided Vehicle (AGV)Vehicle (AGV)

• Automated Storage Automated Storage and Retrieval System and Retrieval System (ASRS)(ASRS)

• ConveyorsConveyors

Components of Flexible Components of Flexible Manufacturing SystemsManufacturing Systems

• NCNC• CNCCNC• DNCDNC• RoboticsRobotics• AGVAGV• ASRSASRS

• Automated Automated InspectionInspection

• Cells and CentersCells and Centers

Flexible AutomationFlexible Automation

• Ability to adapt to Ability to adapt to engineering changes engineering changes in partsin parts

• Increase in number Increase in number of similar parts of similar parts produced on the produced on the systemsystem

• Ability to Ability to accommodate accommodate routing changes routing changes

• Ability to rapidly Ability to rapidly change production change production set upset up

FMS Nuts and BoltsFMS Nuts and Bolts

RobotsRobots

RobotsRobots

Robots: Programmable ManipulatorsRobots: Programmable Manipulators

― Can tolerate hostile environmentsCan tolerate hostile environments

― Can work much longer hours than humansCan work much longer hours than humans

― Can perform redundant jobs more consistently Can perform redundant jobs more consistently (1)(1)

Common Uses of RobotsCommon Uses of Robots

• Loading andLoading and unloadingunloading

• Spray paintingSpray painting

• WeldingWelding

• Material handlingMaterial handling

• InspectionInspection

• Machine AssemblyMachine Assembly

Computer Integrated Computer Integrated ManufacturingManufacturing

• CIM: “The Integration of the total CIM: “The Integration of the total manufacturing enterprise through the use of manufacturing enterprise through the use of integrated systems and data communications integrated systems and data communications coupled with new managerial philosophies that coupled with new managerial philosophies that improve organizational and personnel improve organizational and personnel efficiency.” efficiency.” (4)(4)

Components of CIMComponents of CIM

• CAD Computer Aided DesignCAD Computer Aided Design

• CAM Computer Aided ManufacturingCAM Computer Aided Manufacturing

• CAE Computer Aided EngineeringCAE Computer Aided Engineering

Manufacturing TechnologyManufacturing Technology

• This part of FMS uses:This part of FMS uses:

– NC NC Numerically Controlled MachineNumerically Controlled Machine

– CNCCNC Computer Controlled Machine Computer Controlled Machine

– DNC DNC Direct Numerical ControlledDirect Numerical Controlled

Challenges with FMSChallenges with FMS

• Determining if FMS the best production system Determining if FMS the best production system for your company (economically and socially)for your company (economically and socially)

• Possible expansion costs associated with Possible expansion costs associated with implementing FMSimplementing FMS

• Day to day maintenance of FMS operationsDay to day maintenance of FMS operations

Flexible ManufacturingFlexible Manufacturing

How Does It Work ?How Does It Work ?

Integration of FMSIntegration of FMS

FMS

Manufacturing Technology CIM Robotics

Making FMS WorkMaking FMS Work

– By implementing the components of By implementing the components of robotics, manufacturing technology robotics, manufacturing technology and computer integrated and computer integrated manufacturing in a correct order one manufacturing in a correct order one can achieve a successful Flexible can achieve a successful Flexible Manufacturing SystemManufacturing System

A Real World ExampleA Real World Example

TheThe

FordFord

Motor CompanyMotor Company

Ford’s ProblemFord’s Problem

• At Ford Powertrain they faced the At Ford Powertrain they faced the following challengesfollowing challenges

- outdated cell controller- outdated cell controller

- lack of flexibility because of it- lack of flexibility because of it

- causing loss of efficiency - causing loss of efficiency

SolutionSolution

• Implemented a cell control Implemented a cell control based on an open based on an open architecture, commonly architecture, commonly available tools, and industry available tools, and industry standard hardware, software, standard hardware, software, and protocols. and protocols. (3)(3)

BenefitsBenefits

• Enabled Ford to mix and match Enabled Ford to mix and match machine tools from different machine tools from different vendors vendors (3)(3)

• Reduced the number of man-years Reduced the number of man-years required to implement the required to implement the application application (3)(3)

Benefits ContinuedBenefits Continued

• The budget for the fully automatic The budget for the fully automatic closed-loop controller was less than closed-loop controller was less than 1/101/10thth the cost for a system built in the cost for a system built in language.language.

• No formal training was required for No formal training was required for the floor shop operatorsthe floor shop operators

References UsedReferences Used

(1)(1) Class and lecture notes from Class and lecture notes from Dr. Tom Fosters Ops. Mgmt. 345 Dr. Tom Fosters Ops. Mgmt. 345 class. class.

(2)(2) Russell-Taylor text from Dr. Tom Russell-Taylor text from Dr. Tom Fosters Ops. Mgmt 345 class. Pgs Fosters Ops. Mgmt 345 class. Pgs 263-264, 304.263-264, 304.

References UsedReferences Used

(3)(3)http://www.gensym.com/manufacturing/ss_ford.shtmlhttp://www.gensym.com/manufacturing/ss_ford.shtml

(4)(4)http://www.howard.engr.siu.edu/staff2/spoerre/Roblec6.htmhttp://www.howard.engr.siu.edu/staff2/spoerre/Roblec6.htm

ClosingClosing

I would just like to thank you Dr. I would just like to thank you Dr. Foster for your instruction which Foster for your instruction which has made this assignment much has made this assignment much easier, as well as for the authors easier, as well as for the authors that I have gathered information that I have gathered information from for this project. from for this project.