FLEXFLEXIIBLEBLE MANUFACTURMANUFACTURIINGNG SYSTEMSYSTEM
Presented by: Er. Fateh SinghA.PDeptt. of Mechanical
Engineering1
At a Glance In the middle of the 1960s, market
competition became more intense. During 1960 to 1970 cost was the primary
concern. Later quality became a priority. As the market became more and more complex, speed of delivery became something customer also needed.
A new strategy was formulated: Customizability. The companies have to adapt to the environment in which they operate, to be more flexible in their operations and to satisfy different market segments (customizability).
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Thus the innovation of FMS became related to the effort of gaining competitive advantage
The 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.
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Flexible Manufacturing System is?
A Flexible Manufacturing System (FMS) is a form of flexible automation in which several machine tools are linked together by a material-handling system, and all aspects of the system are controlled by a central computer.
An FMS is a “reprogrammable” manufacturing system capable of producing a variety of products automatically
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Equipments of FMS
Primary equipments Work centers
• Universal machining centers• Turning centers• Grinding machines
Process centers• Wash machines• Coordinate measuring machines• Robotic work stations• Manual workstations
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Secondary EquipmentsSupporting Stations• Pallet/fixture load/unload stations• Tool commissioning/setting area
Supporting Equipments• Robots• Pallet/fixture stores• Pallet buffer stations• Tools stores• Raw material stores• Transport system• Transport units(pallets)
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What are the Features of FMS?? An FMS is distinguished from an automated
production line by its ability to process more than one product style simultaneously.
At any moment, each machine in the system may be processing a different part type.
FMS can let us make changes in production schedule in order to meet the demands on different product
New product styles can be introduced into production with an FMS, so long as they are to be used on the products that the system can process.
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Distinguishing Characteristics
An automatic materials handling subsystem links machines in the system and provides for automatic interchange of work pieces in each machine
Automatic continuous cycling of individual machines
Complete control of the manufacturing system by the host computer
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3 Levels of Manufacturing Flexibility 1-Basic Flexibilities Machine Flexibility - The ease with which a
machine can process various operations Material Handling Flexibility -A measure of
the ease with which different part types can be transported and properly positioned at the various machine tools in a system
Operation Flexibility - A measure of the ease with which alternative operation sequences can be used for processing a part type
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2-System flexibilities Volume Flexibility : A measure of a system’s
capability to be operated profitably at different volumes of the existing part types
Expansion Flexibility: The ability to build a system and expand it incrementally
Routing Flexibility: A measure of the alternative paths that a part can effectively follow through a system for a given process plan
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Process flexibility: a measure of the volume of the set of part types that a system can produce without incurring any setup
Product flexibility: the volume of the set of part types that can be manufactured in a system with minor setup
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•3-Aggregate Flexibilities
Program Flexibility: the ability of a system to run for reasonably long periods without external intervention
Production Flexibility: the volume of the set of part types that a system can produce without major investment in capital equipment
Market Flexibility: the ability of a system to efficiently adapt to changing market conditions
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Components of FMS Systems
Robotics Material Handling / Transport Machines Manual / Automated Assembly Cells Computers Controllers Software Networks
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Benefits of FMS
FMS systems are intended to solve the following problems:
Reduced work in process Increased machine utilization Better management control Reduced direct and indirect labor Reduced manufacturing lead-time Consistent and better quality Reduced inventory
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The Disadvantages of FMS
Expensive, costing millions of dollars Substantial pre-planning activity Sophisticated manufacturing systems Limited ability to adapt to changes in
product Technological problems of exact component
positioning and precise timing necessary to process a component
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Future Benefits of FMS Technology will make 100% inspection feasible Computer diagnosis will improve estimation of
machine failure, and guide work crews repairing failures
Minimum human labor in manufacturing systems
Varity of tools with increased computing power Better management software, hardware, and
fixturing techniques Developed standards that will let us install new
machines easily
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FMS according to number of Machines Flexible manufacturing systems can be
distinguished according to the number of machines 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)
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Single machine cell (Type I A)• 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
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Flexible manufacturing cell• 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
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Flexible manufacturing system• 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.
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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
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FMS Layout Configurations
Progressive or Line TypeLoop TypeLadder TypeOpen field typeRobot centered type
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• Progressive or Line Type
• Loop Type
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• Ladder type Open Field Layout
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Robot Centered Layout
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Differences Between FMS and FMC F.M.System
Has four or more machines
Larger and more sophisticated computer control system
Minimized effect of machine breakdowns
F.M.Cell
Has two or three machines
Simpler computer control system
Limited error recovery by fewer machines
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Application of FMS
Metal-cutting machiningMetal formingAssembly Joining-welding (arc , spot), glueingSurface treatment InspectionTesting
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Conclusions
FMS is a revolution in the field of Manufacturing Technology.
FMS can be designed to meet the specific demand of each company
FMS is used for multitask operation. FMS requires substantial investment of time and
resources
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References
Books Referred:M.P. Groover: “Automation Production
System and Computer Integration Manufacturing”, Prentice-Hall of India Private Limited,2008,Pg.No.:538-560.
R.K. Jain: “Production technology”, Khanna Publications, 2009, Pg.No.:962-974.
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