Flexible Manufacturing Systems: an Overview

Department of Aviation and Technology College of Engineering San Jose State University

What is an FMS?
Highly automated GT (group technology) machine cell. Consists of:
a group of processing workstations

Interconnected by
an automated material handling and storage system

Controlled by
a distributed computer system

Flexible Manufacturing Systems Overview

What Makes it Flexible?

the ability to identify and distinguish among the different part or product styles processed by the system quick changeover of operating instructions quick changeover of physical setup

Flexible Manufacturing Systems Overview

Is it a Flexible Cell?

Flexible Manufacturing Systems Overview

Tests of Flexibility
Part variety test
Process of different part styles

Schedule change test

Acceptance of changes in production schedule and quantities

Error recovery test

Recovery from equipment breakdowns

New part test

Incorporation of new parts into existing product
Flexible Manufacturing Systems Overview

Types of FMS ~ Types of Flexibility

Machine flexibility
Capability to adapt a given machine to a variety of operations and part styles

Routing flexibility
Capacity to produce parts in alternate sequences

Volume flexibility
Production of high and low quantities

Production flexibility
Range of part styles

Mix flexibility
Produce same parts in different proportions

Expansion flexibility
Expand to increase total production

Product flexibility
Introduction of new products
Flexible Manufacturing Systems Overview

Rationale for FMS

Companies want groups of machine tools that will make up a system that can operate continuously and with minimal attention from human labor Looking for a more flexible, cost-efficient means of manufacturing Need consistency in production, concurrent with an ability to produce a variety of parts

Flexible Manufacturing Systems Overview

Pioneers in FMS use

In the United States: Around the World:

Ingersoll-Rand Co. Caterpillar John Deere General Electric Co.

Germany Russia Japan Fuji Xerox

Flexible Manufacturing Systems Overview

FMS Components
Material Handling and Storage System Programming Language and Network Infrastructure Workstations Human labor
Flexible Manufacturing Systems Overview

Material Handling and Storage System

Functions:
Movement of work-parts between stations Handle configurations Temporary storage Access for loading and unloading Compatible with computer control

Functions are shared between two systems:

Primary handling system Secondary handling system

Flexible Manufacturing Systems Overview

Programming Language and Network Infrastructure

Used for computer control of system Links system components AND controls them Allows the system to perform the following operations automatically or semi-automatically:
Workstation control Distribution of control instructions Production control Traffic control Shuttle control Workpiece monitoring Tool control Performance monitoring diagnostics
Flexible Manufacturing Systems Overview

Workstations
Load/unload stations
Physical interface between the FMS and the entire company

Processing stations
Pressworking operations

Assembly
Replace or reduce substantially the need for manual labor

Machining Stations
CNC machine tools

Flexible Manufacturing Systems Overview

FMS Benefits
Economic Benefits
Reduced direct labor requirements Fewer machines required Operating time

Productivity Benefits
Increased machine utilization Reduction in factory floor space Higher labor productivity Unattended production and reduced manpower needs

Flexible Manufacturing Systems Overview

FMS Implementation
Planning and Design Issues
Part family (GT) considerations Processing requirements Physical characteristics Production volume Types of workstations FMS layout (cell and facility design and planning)
Flexible Manufacturing Systems Overview

FMS implementation
Operational Issues
Scheduling Machine loading Part routing Part grouping Tool management Pallet and fixture allocation

Flexible Manufacturing Systems Overview

Conclusions
FMS can be designed to specifically meet the needs of each particular company FMS made up of various different techniques FMS is inherently flexible adaptable to changing production needs FMS requires a substantial investment of both time and resources
Flexible Manufacturing Systems Overview