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FlexibilityThe capability of the manufacturing system to
adapt successfully to changing environmental conditions and process requirements.
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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.
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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.
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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
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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
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Computer Integrated ManufacturingComputer Information Systems utilizing a shared
manufacturing database for engineering design, manufacturing engineering, factory production, and information management.
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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.
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AdvantagesIncreased output and enhanced productivity.Improved and uniform quality.Reduced cost.Fewer accidents.Better production control.Lost Prerogatives gained.Dangerous and unpleasant tasks.
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Advantages Contd…Reduced InventoriesGreater operating flexibilityReduced lead time and scrapImproved reliabilityDesign freedom
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DisadvantagesHeavy capital investmentDisplacement of labourBenefit of employee suggestion lostTighter specification may be neededCosts of supply failure increasesSlack season would be disastrousDehumanizationProblems of developing countries
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Flexibility Without AutomationIt is usually referred to as “attaining the effect of
automation without the expense” Preautomation Modular Design Standardization
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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.
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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.
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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.
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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.
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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…
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