www.a2zmba.com

FlexibilityThe capability of the manufacturing system to

adapt successfully to changing environmental conditions and process requirements.

www.a2zmba.com

Definition of FMSA flexible manufacturing system (FMS) is an

arrangement of machines.... interconnected by a transport system. The transporter carries work to the machines on pallets or other interface units so that work-machine registration is accurate, rapid and automatic. A central computer controls both machines and transport system...

It is a computer controlled process technology suitable for producing a moderate variety of products in moderate volumes.

www.a2zmba.com

www.a2zmba.com

Characteristics of an FMSAll products are variations of a stable basic

design.All products utilize the same family of

components.The number of components is only moderate.The volume of each component is moderate.

www.a2zmba.com

Requirements for FMS with Automation• Machine Attachments• Computer Integrated Manufacturing (CIM)• Computer Aided Design (CAD)• Computer Aided Manufacturing (CAM)• Robotics and Robots• Group Technology• N/C Machines• Automated Quality Control Systems• Automatic Storage and Retrieval Systems (ASRS)• Automatic Identification Systems (AIS)• Automatic Assembly Systems• Automatic Process Control

www.a2zmba.com

Machine AttachmentsAttachments or inexpensive add-ons to machines

that reduce human effort and time required to perform operations.Eg: Magazine feed attachments, quick cutting and grasping devices for lathes, strip feeders for stamping machines etc.

www.a2zmba.com

Numerically Controlled (N/C) MachinesMachines with control systems that read

instructions and translate them into machine operations.

Eg: Lathes, boring mills, curing machines, weaving machines etc.

www.a2zmba.com

RoboticsRobot is a programmable machine that is capable

of moving materials and performing routine, repetitive tasks which have manipulators and possess human like physiological characteristics.

Robotics is the science of selecting Robots to various applications.

Eg: Machines that weld, paint, assemble, inspect for quality, grasp, transport and store.

www.a2zmba.com

Automated QC InspectionAutomated machines that perform part or all of

the inspection process.

Eg: Electronic circuit checks, computer driven function checks, weighting robots, flexible inspection etc.

www.a2zmba.com

Automatic Identification Systems (AIS)Technologies used in automatic acquisition of

product data for entry into a computer.

Eg: Bar-Coding systems, inventory counting, data entry for shop floor control etc.

www.a2zmba.com

Automated Process ControlsComputer Systems that receive data on the

production process and send adjustments to process settings.

Eg: Control Systems for rolling mills in manufacturing etc.

www.a2zmba.com

CAD/CAMComputer Aided Design are the Computer

software programs that allow a designer to carry out geometric transformations rapidly.

Computer Aided Manufacturing (CAM) are the Manufacturing systems utilizing computer software programs that control the actual machine on the shop floor.

www.a2zmba.com

Automated Storage and Retrieval SystemsASRS are the systems meant for receiving orders

for materials from anywhere in operations, collecting materials from locations within a warehouse and delivering the materials to work stations in operations.

Three major elementsComputer and communication SystemsAutomated Material handling and Delivery

Systems Storage and Retrieval Systems in warehouse

www.a2zmba.com

Computer Integrated ManufacturingComputer Information Systems utilizing a shared

manufacturing database for engineering design, manufacturing engineering, factory production, and information management.

www.a2zmba.com

Group TechnologyA way of organizing and using data for

components that have similar properties and manufacturing requirements.

GT results inReduced item handling and movement times.Reduced Change over times.Reduced idle wait time of items at the machine.Reduced work in process.

www.a2zmba.com

AdvantagesIncreased output and enhanced productivity.Improved and uniform quality.Reduced cost.Fewer accidents.Better production control.Lost Prerogatives gained.Dangerous and unpleasant tasks.

www.a2zmba.com

Advantages Contd…Reduced InventoriesGreater operating flexibilityReduced lead time and scrapImproved reliabilityDesign freedom

www.a2zmba.com

DisadvantagesHeavy capital investmentDisplacement of labourBenefit of employee suggestion lostTighter specification may be neededCosts of supply failure increasesSlack season would be disastrousDehumanizationProblems of developing countries

www.a2zmba.com

Flexibility Without AutomationIt is usually referred to as “attaining the effect of

automation without the expense” Preautomation Modular Design Standardization

www.a2zmba.com

PreautomationThis attacks one of the Shingo’s 7 wastes, the

waste of processing itself.It makes no sense in automating a stage of

production process when that stage adds no value to the product.

Preautomation studies reveal unneeded equipment and activities that can be eliminated rather than automated.

www.a2zmba.com

Modular Design:The creation of products from some combination of basic, preexisting subsystems.

Standardization:Use of uniform standardized components in the products. Eg: screws, spark plugs, nuts & bolts etc.

www.a2zmba.com

Industrial ExamplesThe General Motors Fairfax plant in Kansas city,

Missouri, produces Pontiac Grand Prixs.Earlier, for producing cars with different colours

it took time for shutting down the painting area so that it could be cleared of dust and scrubbed.

Today GM has reduced the production line delays by using Technologies such as airtight chambers and high powdered vacuum suctions.

www.a2zmba.com

Industrial Examples Contd…General Motors, in a joint venture with Toyota at

the NUMMI (New United Motors Manufacturing Inc.) plant outside San Francisco.

NUMMI has installed a new press line with Exchange of die techniques like IED, OED, SMED and OTED.

It has reduced the time taken for die exchange from hours/days to minutes.

www.a2zmba.com

ConclusionFactories of the future will have stress on high product quality, greater emphasis on flexibility, fast delivery of customer orders, extensive use of CAD/CAM for product design, structural changes etc.

To fulfill all these requirements Flexible Manufacturing Systems (FMS) has to play a very important role…

www.a2zmba.com