Flexible Manufacturing System (FMS)

A flexible manufacturing system (FMS) is a highly automated GT machine cell, consisting of a

group or processing workstations (usually CNC machine tools), interconnected by an automated
material handling and storage system, and controlled by a distributed computer system.
The reason the FMS is called flexible is that it is capable of processing a variety of different part
styles simultaneously at the various workstations, and the mix of part styles and quantities of
production can be adjusted in response to changing demand patterns.
The FMS is most suited for the mid-variety, mid-volume production range.

Components of FMS
There are several basic components of an FMS

Workstations.
Material handling and storage systems.
Computer control system.
People are required to manage and operate the system.

Requirements of FMS
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.

DISADVANTAGES OF FSM

Limited ability to adapt to changes in product or product mix (ex. machines are of
limited capacity and the tooling necessary for products, even of the same family, is not
always feasible in a given FMS)
Substantial pre-planning activity
Expensive, costing millions of dollars
Technological problems of exact component positioning and precise timing necessary to
process a component
Sophisticated manufacturing systems

PAKISTAN AERONAUTICAL COMPLEX KAMRA

A Symbol of Excellence in Aviation
PAC Kamra use Flexible Manufacturing System because of:

FASTER, LOWER- COST CHANGES FROM ONE PART TO ANOTHER WHICH WILL IMPROVE
CAPITAL UTILIZATION
LOWER DIRECT LABOR COST, DUE TO THE REDUCTION IN NUMBER OF WORKERS
REDUCED INVENTORY, DUE TO THE PLANNING AND PROGRAMMING PRECISION
CONSISTENT AND BETTER QUALITY, DUE TO THE AUTOMATED CONTROL
LOWER COST/UNIT OF OUTPUT, DUE TO THE GREATER PRODUCTIVITY USING THE SAME
NUMBER OF WORKERS
SAVINGS FROM THE INDIRECT LABOR, FROM REDUCED ERRORS, REWORK, REPAIRS AND
REJECTS

INTRODUCTION
Pakistan Aeronautical Complex (PAC) is an organization which comprises of four colocated factories which virtually take care of maintenance of all operational assets of Pakistan
Air Force (PAF) for the purpose of effective control and efficient working.

Co-located Factories
Aircraft Rebuilt Factory (ARF)
ARF was established in the early 70s in collaboration with The Peoples Republic of China.
Initially, the factory started overhauling of F-6 aircraft and with an ever growing sphere of
responsibility, the factory undertook the task of overhauling of A - 5III, FT - 5, Y - 12, K - 8 and F 7 aircraft variants. Since its inception, ARF has evolved into a Centre of Excellence for
maintenance, repair and overhauling Chinese aircraft, standing tall amongst MRO organizations
in the world.

 Aircraft Manufacturing Factory (AMF)

AMF was established in 1975 to undertake manufacturing of a primary flying trainer
aircraft under license from SAAB SCANIA of Sweden. The aircraft was named Mushshak,
(meaning proficient) and was produced from the kits provided by SAAB. After
successfully producing 92 Mushshak aircraft, AMF acquired the status of Original
Equipment Manufacturer (OEM) in 1981

Mirage Rebuilt Factory (MRF)

Mirage Rebuild Factory was established in 1974 for in-country overhauling of Mirage aircraft
and has ever since evolved into a center of excellence for maintenance, repair and overhaul of
military aircraft and jet engines. With a number of quality accreditations and certifications to its
acclaim, MRF is trusted by leading aviation industries and air forces of the world
To cater for the needs of all these tasks the complex provides comprehensive
aviation standard testing & manufacturing at one place.
Our area of study

is Avionics Production Factory (APF).

Avionics Production Factory (APF)

Avionics
Avionics are the electronic systems used on aircraft, artificial satellites, and spacecraft.
Avionic systems
It includes communications, navigation, the display and management of multiple
systems, and the hundreds of systems that are fitted to aircraft to perform individual functions.
These can be as simple as a searchlight for a police helicopter or as complicated as the tactical
system for an airborne early warning platform.

Introduction to APF kamra

Avionics setup of PAC known as Avionics Production Factory (APF) was initially established as
the Radar Maintenance Centre (RMC) in 1983 for overhaul / rebuild of ground based radar

systems. In 1989, its capability was enhanced to handle avionics along with ground based
radars.
Today APF, with its state of the art facilities, can undertake production of different types of
avionics as well as commercial electronics equipment while ensuring high quality standards as
per requirements of Aerospace Standard AS9100 Rev C.

Avionic Production Facility

The avionics production facility at APF can be divided into six major segments:

Design & Development.

Avionics Integration.
Production Line.
Testing Line.
Specific System Department.
Environmental Stress Screening facilities.

Design & Development

APF can undertake design and development of avionics systems based on user requirements and
provides complete solution from initial concept to product support throughout its service life.
The prototype avionics systems are designed using Computer Aided Design and Simulation
tools.
Avionics Integration
The developed system prototypes are functionally tested and integrated in the Dynamic
Simulation and Integration Laboratory known as DSI. This facility can also undertake integration
of Off the Shelf (OTS) systems with an avionics suite.
Production Line
APF is a Qualified Production Vendor for various companies and its Generic Production Line
employs stuffing of surface mounted and through whole electronic components on bare printed
circuit boards.
Testing Line
PCB stuffing is a multi-stage process involving PCB inspection, cleaning and drying before these
are ready for components installation. The processed bare boards are then passed through
automated assembly line which installs the components. The completed PCBs are inspected
using Optical and X-ray inspection systems for faults before being passed for testing. The
standard of workmanship during complete production process conforms to requirements of IPC
600 and 610 D standard.
Specific System Department
When PCBs have been stuffed with components and tested, these undergo conformal coating
before being fed to Specific System Department. Here these shop repairable units (SRUs) along
with other components, electrical & mechanical wiring and harness assemblies are put together
as a Line Replaceable Unit (LRU) for final testing of system. Since the processes require unique
procedures for each system, there are separate assembly and testing areas for every system.
Environmental Stress Screening facilities
Once a system is ready, it is passed over for Environment Stress Screening where these systems
are exposed to practical military environment, with the help of thermal climatic chambers and
shakers. The aim of this strenuous testing is to ensure that the equipment conforms to actual
aircraft environment as per requirements of Military Standard 810 D. The systems that pass
through this process are guaranteed to perform reliably when put into operation.

Manufacturing Products of Avionics Products Factory (APF)

Radar Warning Receiver (RWR)

Radar Warning Receiver (RWR) is being co-produced in collaboration with M/s CEIEC China and
is designed to provide the pilot with real time and unambiguous threat warning over 360
degrees thus reducing vulnerability of the combat aircraft to radar associated weapons.
Currently two different models of RWR are available i.e. BM/KJ-8602 RWR and BM/KJ-8602A
RWR. PAC also provides the life cycle maintenance of these two RWR models to PAF.

Global Attitude Heading reference System (GAHRS)

Global Attitude Heading Reference System (GAHRS) is an avionics subsystem of JF-17 aircraft
which provides high performance measurement of aircraft attitude by using highly reliable
optical fiber gyroscopes and accelerometers. GAHRS is a backup system of Inertial Navigation
System (INS). In case of INS failure, it provides roll, pitch and heading information to Weapon
Mission Management Computer (WMMC) using RS 422 interface.

Identification of Friend or Foe (IFF)

Identification of Friend or Foe (IFF) system is solid state, airborne and selective transponder
being co-produced in collaboration with M/s JIUZHOU China. It is used for identification of friend
or foe. The system is compatible which civil ATC radar beacon system for air traffic control. PAC
also provides the life cycle maintenance support to the JZ/YD 125 IFF system.

Light Warning System (LWS)

Light warning system is used to display emergency warning signals. It's main purpose is to draw
the pilot's attention to the warning signals for a proper timely action. It has a Built in Test
Function for checking its serviceability and provides four warning levels according to degree of
emergency related to flight safety and mission plan.
Back Up Acquisition Computer (BAC)

BAC is a backup computer for avionics systems and provides flight critical information to the
pilot in case of main bus / mission management computer failure. BAC accepts data from flight
critical systems on a separate RS 422 data line and communicates the same to Multi-Function
Displays. It also provides excitation voltage to hydraulic and brake sensors.
Weapon Mission Management Computer (WMMC)

WMMC is a central computer for JF17 aircraft avionic system control and management. The
basic tasks of WMMC are multiplex data bus communication management, mission planning
and flight program management, fire control calculation, navigation assistance, audio alarming,
integrated display managing (including digital map display control) and pilot interface control
for avionics systems.
Data Transfer Unit (DTU)

Data transfer unit is an avionics sub system of JF-17 aircraft. DTU is used for mission planning,
subsystem initialization and recording of vital in-flight operational and technical data. Data
transfer unit communicates with mission computer. It uploads the mission planning data to
avionics sub-systems and retrieves in flight data via Rs422 interface. Retrieved data is used for
operation and technical analysis.
Audio Control Box (ACB)

Audio Control Box (ACB) is the hub of audio signals management. It receives audio signals from
on-board systems like mission computer, communication, navigation and weapon systems and
routes these audio signals to pilot headset / recording systems.
Up Front Control Panel (UFCP)

UFCP is a man-machine interface (MMI) for the avionics sub-systems in JF-17 aircraft. The basic
functions include setting, altering and displaying the navigation/communication system's
parameters. It communicates with Weapon and Mission Management Computers (WMMC) via
RS 422 communication link.

Avionics Activation Panel (AAP)

AAP is used to simplify pilot's operation by centrally activating / deactivating avionics

subsystems in JF-17 aircraft. It has the provision for individual or group activation of avionics
sub-systems