Flexible Manufacturing System (FMS)

Introduction:
A Flexible Manufacturing System (FMS) is an individual machine or group of machines served by an automated materials handling system that is computer controlled and has a tool handling capability. Flexibility means that a manufacturing system is versatile and adaptable, while also capable of handling relatively high production runs. Versatile means that it can produce a variety of parts and adaptable in that it can be quickly modified to produce a completely different line of parts.

Definition:
A 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. OR FMS consists of a group of processing work stations interconnected by means of an automated material handling and storage system and controlled by integrated computer control system.
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OR FMS is called flexible due to the reason that it is capable of processing a variety of different part styles simultaneously at the workstation and quantities of production can be adjusted in response to changing demand patterns.

Typical FMS Layout:

Objectives Of An FMS:
Decreased Lead Times Increased machine utilization Improved Due Date Reliability Decreased Store Inventors Levels Decreased Work in Progress Increased Quality

Aims Of FMS:
To reduce costs Better utilization of the production equipment Reduction of piece part unit costs To increase Technical Performance To improve Order Development To assist future Corporate Security

Area Of Application Of A FMS:

Flexibility:
Flexibility can be defined as a collection of properties of a manufacturing system that support changes in the production activities.

Flexibility refers to the ability of a manufacturing system to respond effectively to both external & internal changes by having built-in redundancy of versatile equipments.

Machine Flexibility:
This defines the capability of machines to a wide range of production of operations and part styles that may require.

This may be characterized by having a low setup or change over time, ease of machine reprogramming, sufficiently large tool storage capacity and the skill and versatility of machine operators.

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Production Flexibility:
This aspect refers to the range of part styles that can be produced in the system. Depend on: 1. Machine flexibility 2. Range of the machine flexibility

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Mix Flexibility:
This is the ability with which changes in product mix in a given system can be changed. Depends upon: 1. Similarity of parts in the mix 2. Relative work content times of parts produced 3. Machine Flexibility

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Product Flexibility:
This is the ease with which changes in product designs can be accommodated in the system. Depend on: 1. How closely the new part design matches the existing part family 2. The ability for off-line part program preparation 3. Machine flexibility
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Routing Flexibility:
This specifies the capacity to produce parts through alternative workstation sequences in response to equipment breakdowns, tool failures and other interruptions. Depend on: 1. Similarity of parts in the mix 2. Similarity of workstations 3. Duplication of workstations 4. Availability of common tooling
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Volume Flexibility:
This is the ability to economically produce parts in high and low total quantities of production depending upon the market demand. Depend on: 1. The level of manual labour performing production 2. Amount invested in capital equipment

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Expansion Flexibility:
This is the case with which the system can be expanded to increase total production quantities, should the need arise. Depend upon: 1. Expense of adding workstations 2. Type of handling system used 3. Ease with which properly trained workers can be added

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Basic Components Of FMS:

1. Workstations: In present day application these workstations are typically computer numerical control (CNC) machine tools that perform machining operation on families of parts. Flexible manufacturing systems are being designed with other type of processing equipments including inspection stations, assembly works and sheet metal presses. The various workstations are (i) Machining centers (ii) Load and unload stations (iii) Assembly work stations (iv) Inspection stations (v) Forging stations 17 (vi) Sheet metal processing, etc.

2. Automated Material Handling and Storage system: The various automated material handling systems are used to transport work parts and subassembly parts between the processing stations, sometimes incorporating storage into function. The various functions of automated material handling and storage system are (i) Random and independent movement of work parts between workstations (ii) Handling of a variety of work part configurations (iii) Temporary storage (iv) Convenient access for loading and unloading of work parts (v) Compatible with computer control
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3. Computer Control System: It is used to coordinate the activities of the processing stations and the material handling system in the FMS. The various functions of computer control system are: (i) Control of each work station (ii) Distribution of control instruction to work station (iii) Production control (vi) Traffic control (v) Shuttle control (vi) Work handling system and monitoring (vii) System performance monitoring and reporting

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 The FMS is most suited for the mid variety, mid value production range.

Application characteristics of FMS

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Classification of FMS:
By the number of machines in the system 1. Single machine cell 2. Flexible Manufacturing Cell (FMC) 3. Flexible Manufacturing System (FMS) By the level of flexibility: 1. Dedicated FMS 2. Random Order FMS
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Types of FMS layouts:

a) Progressive or Line Type b) Loop Type c) Ladder Type d) Open field type e) Robot centered type

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(a) Progressive or Line Layout:

The machines and handling system are arranged in a line as shown in the Fig. (a). It is most appropriate for a system in which the part progress from one workstation to the next in a well defined sequence with no back flow. The operation of this type of system is very similar to transfer type. Work always flows in unidirectional path as shown in Fig. (a).
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(b) Loop Layout:

The basic loop configuration is as shown in Fig. (b). The parts usually move in one direction around the loop, with the capability to stop and be transferred to any station. The loading and unloading station are typically located at one end of the loop Fig. (b)

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(c) Ladder Layout:

The configuration is as shown in Fig. (c). The loading and unloading station is typically located at the same end. The sequence to the operation/transfer of parts from one machine tool to another is in the form of ladder steps as shown in Fig. (c)

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FMS Layouts

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(d) Open Field layout:

The configuration of the open field is as shown in Fig. (d). The loading and unloading station is typically located at the same end. The parts will go through all the substations, such as CNC machines, coordinate measuring machines and wash station by the help of AGVs from one substation to another.

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(d) Open field FMS

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(e) Robot Centered Layout:

Robot centered cell is a relatively new form of flexible system in which one or more robots are used as the material handling systems as shown in Fig. (e). Industrial robots can be equipped with grippers that make them well suited for handling of rotational parts.

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(e) Robot Centered FMS

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Factors Influencing the FMS Layouts:

Availability of raw material Closeness to market Transport facilities Availability of efficient and cheap labor Availability of power, water and fuel Atmospheric and climatic condition Social and recreation facilities Business and economic conditions
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Benefits of FMS:
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
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Limitations of FMS:
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

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Flexible Manufacturing Cell:

FMC is defined as the logical arrangements of stand alone manual or NC equipment into groups or clusters of machines to process parts by part family. processing parts in the manufacturing cell includes

completing as much as the work piece processing as possible within the cell before moving it to the next sequential processing stock inspection or assembly station.

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Production Flow from cell to cell

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Classification of FMC:
Flexible Manufacturing Cell can be divided into four general categories. 1. Traditional stand-alone NC machine tools 2. Single NC machine cell or Mini cell 3. Integrated multi machine cell 4. FMS

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1. Standalone NC Machine Tools

Standalone NC machine tools are characterized by a limited storage, automatic tool changer and are traditionally operated on a one- to one-machine operator ratio. In many cases, stand-alone NC machine tools have been grouped together in a conventional part family manufacturing cell but still operating on a one-to-one machine to operator ratio.

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 Machines within a cell of this type have some times been painted by a similar color, which further add cell distribution for a particular group of parts and differentiate it from other cells. Some stand-alone NC machines are characterized and operated as a cell by virtue of a change in the machine to operator ratio. These machines are usually redundant and are operated on a two-to-one or in some cases a three-to-one machine to operator ratio.
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2. Single NC Machine Cell or Mini Cell

Single NC machine cell is characterized by automatic work changers with permanently assigning work pallets or conveyors, robot arm mounted to the front of the machine, plus the availability of bulk tool storage. There are many machines with a variety of options, such as automatic probing, broken tool detection and high-pressure coolant control, which pulls into this category. Mini cell is rapidly gaining popularity, functionality and affordability because it can be purchased for a function of the cost of a complete FMS and can be programmed and loaded with parts to run unattended for several hours.
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3. Integrated Multi Machine Cell

Integrated multi machine cell is made of a multiplicity of a metal-cutting machine tool typically of the same type, which have parts, either at the entry of the cell or in front of each machine. Multi machine cells are either serviced by a material handling robot or parts palletized in a two or three machine, in-line system for progressive movement from one machine station to another. Typical applications of a multi machine cell serviced by a robot of high volume production of a small, well defined designstable family parts.
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4. Flexible Manufacturing System

Some times referred to as a flexible manufacturing cell is characterized by multiple machine automated movement of palletized parts to and from processing stations to another work station and is controlled by a central computer.

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Differences Between FMC and FMS

Cells lack central computer with real-time routing, load balancing, and production scheduling logic.

An FMS will be almost invariably connected to higher-level computer within the manufacturing operation.

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 Cells are typically tool capacity constrained. Both the total number of unique limits single and multi machine cells and redundant cutting tools that occupy available tool pockets.

A FMS with automated tool delivery and tool management can be automatically transfer, exchange and migrate tools through centralized computer control and software independent of equipment activity.

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Comparison between FMC and FMS:

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Comparison between FMC and FMS:

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Coordinate Measuring Machine (CMM):

CMM provides contact type inspection. It is a flexible manufacturing device capable of providing a highly accurate dimensional position along three mutually perpendicular axes. This equipment is used in manufacturing industry for post production inspection of a large variety of components and assemblies. It can also be used for checking the dimensions of various tooling such as jigs and fixture, dies and molds, special tools, etc.
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Major elements of CMM:

1. High precision mechanical structure 2. Probing system 3. Machine control Unit 4. CMM software

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1. High precision mechanical structure

It is the main operating unit of a CMM which has the ability to move the sensor probe to be positioned at the required location in X-Y-Z on the part to be measured. This structure has to be very rigid to provide the necessary accuracy for the measurements. It can be controlled either manually or be CNC controlled for precise positioning of the probe. typical accuracies are of the order of (1.7 + 3L/1000) m. For higher accuracy the drive axes are provided with linear glass scales.
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2. Probing system
The touch trigger probe is used to collect the basic information such as x, y, z coordinates of the points where the probe touches the part to measure a particular dimension. It is a sophisticated mechatronic device capable of allowing the CMM to record a number of points on the surface of the part, which need to be quickly measured . It is also possible to have an optoelectronic sensor for non contact inspection in place of the touch trigger probe.
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3. Machine control Unit:

It is essentially a computerized system that serves the purpose of controlling the probe positioning as well as getting the data in terms of the measured point sets which are then utilized by the software for further presentation.

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4. CMM software:
The major component of a CMM is its metrology operating system, which allows it to do the necessary computations on the point sets that were measured and communicated to other equipment in the system. It consists of a number of application software depending upon the industry for the purpose of the special analysis.

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Types of CMM:
1. Cantilever type 2. Bridge type 3. Column type 4. Gantry type 5. Horizontal arm type

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1. Cantilever type
The cantilever construction combines easy access and relatively small floor space requirements. It is typically limited to small and medium sized machines. Parts larger than the machine table can be inserted into the open side without inhibiting full machine travel. Figure shows a cantilever structure.

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Cantilever Structure
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2. Bridge type
The bridge arrangement over the table carries the quill (z-axis) along the x-axis and is sometimes referred to as a travelling bridge. It is claimed that the bridge construction provides better accuracy, although it may be offset by difficulty in making two members track in perfect alignment. This is by far the most popular CMM construction.
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Bridge Structure
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3.Column type
The column type machine is commonly referred to as a universal measuring machine rather than a CMM. These machines are usually considered gage room instruments rather than production floor machine. The direction of movements of the arms are as shown in Figure. The constructional difference in column type with the cantilever type is with x and y-axes movements.
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Column Structure
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4. Gantry type
In a gantry type arrangement, arms are held by two fixed supports as shown in Figure. Other two arms are capable of sliding over the supports. Movements of the x, y and z-axes are also as shown in Figure. The gantry type construction is particularly suited for very large components and allows the operator to remain close to the area of inspection.

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Gantry Structure
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5.Horizontal arm type

Figure shows the construction of a horizontal structure. The open structure of this arrangement provides optimum accessibility for large objects such as dies, models, and car bodies. Some horizontal arm machines are referred to as layout machines. There are some horizontal machines where the probe arm can rotate like a spindle to perform tramming operations. Tramming refers to accurate mechanical adjustment of instrument or machine with the help of tram. Tramming refers to indicating a cylindrical surface of a part in such a manner as to centralize the surface with the spindle of 61 the machine.

Horizontal Arm Structure

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Non-contact CMM:
The touch-trigger probe used in the CMM can be replaced by non-contact probes such as laser probe or digitizing camera for inspecting the parts in a non-contact manner. Because of non-contact nature of operation of these probes, fast and accurate measurements can be obtained. In a laser light probe, laser is used to bounce off the surface of the part sensed by the sensor and the surface location is obtained by optical triangulation. Most of these are used for planar dimensions only.
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Advantages of CMM:
The CMM is a highly flexible measuring machine. It can be practically used for a variety of measurement activities. The time required for inspection gets reduced using a CMM since there is no need to set up the part or establish a reference point for inspection purpose. Since the measurements are done with respect to a single datum, the accuracy of measurement is high. Operator error is minimized. Productivity increases with use of CMM. This is achieved because the setup time is reduced, the time for measuring the data is reduced as also time taken for generating the final inspection report.
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 No offline analysis is to be done for inspection reports, since everything is completed by the computer that is linked with the CMM. Since no inspection fixture are used with CMM, there is a cost saving associated with this. Because of the reliability of the measuring procedure with CMM, there is a reduction in good part rejections.

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Robots:
Definition of an Industrial Robot: A robot is a reprogrammable, multifunctional machine designed to manipulate materials, parts, tools, or specialized devices, through variable programmed motions for the performance of a variety of tasks. OR

An industrial robot is officially defined as an automatically controlled, reprogrammable, multipurpose manipulator

programmable in three or more axes.

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Basic Components of a Robotic System:

1. Structure: The mechanical structure (links, base, etc.). This requires a great deal of mass to provide enough structural rigidity to ensure accuracy under varied payloads. 2. Actuators: The motors, cylinders, etc. that drive the robot joints. This might also include mechanisms for a

transmission, locking, etc. 3. Control Computer: This computer interfaces with the user, and in turn controls the robot joints.
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4. End of Arm Tooling (EOAT): The tooling is provided by the user, and is designed for specific tasks. 5. Teach pendant: One popular method for programming the robot. This is a small hand held device that can direct motion of the robot, record points in motion sequences, and begin replay of sequences. More advance pendants include more functionality.
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Types of Robots:
Robots come in a wide variety of shapes, and configurations. The major classes of robots include, 1. Arms fixed in place, but can reach and manipulate parts and tools 2. Mobile these robots are free to move

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Robotic Arms:
1. Revolute: Revolute rotary joints often driven by electric motors and chain/belt/gear transmissions or by hydraulic cylinders and levers. 2. Prismatic: Prismatic slider joints in which the link is supported on a linear slider bearing, and linearly actuated by ball screws and motors or cylinders.

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Basic Configurations of Robot:

1. Cartesian/Rectilinear/Gantry: Positioning is done in the workspace with prismatic joints. This configuration is well used when a large workspace must be covered or when consistent accuracy is expected from the robot.

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Cartesian/Rectilinear/Gantry
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2. Cylindrical:
The robot has a revolute motion about a base, a prismatic joint for height and a prismatic joint for radius. This robot is well suited to round workspaces.
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3. Spherical:
Two revolute joints and one prismatic joint allow the robot to point in many directions, and then reach out some radial distance.
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4. Articulated/Jointed Spherical/Revolute:
The robot uses 3 revolute joints to position the robot. Generally the work volume is spherical. This robot most resembles the human arm, with a waist, shoulder, elbow, and wrist.
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5. SCARA:
SCARA (Selective Compliance Arm for Robotic Assembly): This robot conforms to cylindrical coordinates, but the radius and rotation is obtained by a two planar links with revolute joints.

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Applications of Industrial Robots:

Welding Applications Spray Painting Applications Assembly Operations Palletizing and Material Handling Dispensing Operations Laboratory Applications Water Jet Cutting Work Cell
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Automated Guided Vehicles (AGVs)

Automated Guided Vehicles (AGVs) are vehicles that are equipped with automatic guidance systems and are capable of following prescribed paths. Unlike traditional robots, AGVs are not manipulators, they are driverless vehicles that are programmed to follow a guide path.

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Types Of AGVs:
Automated guided vehicle systems: Automated guided vehicle systems consists of the computer, software and technology that are the brains behind the AGV. Without computer software systems and communications networks, only the simplest AGV functions can be performed.

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 Camera guided AGVs: Camera guided AGVs are used when precise guidance accuracy is needed, such as in crowded environments and smaller sized facilities. An on-board camera focuses and guides the AGV while performing. Forked AGVs: Forked AGVs are used to pick up and deliver various loads, such as pallets, carts, rolls and others. These can be manually driven as well as used automatically, and have the ability to lift loads to many levels.
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 Inertial guided AGVs: Inertial guided AGVs use a magnet sensing device, a gyroscope that measures the units heading and a wheel odometer that calculates the distance traveled. Magnets mounted beneath the floor are detected by the onboard magnetic sensing device and combine with the first two readings to give an accurate positional location.

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 Large chassis/unit load AGVs: Large chassis/unit load AGVs are used to transport heavier loads with various transfer devices such as roller beds, lift/lower mechanisms and custom mechanisms. Laser guided AGVs: Laser guided AGVs use mounted laser scanners that emit a laser and reflect back from targets. The vehicles location can be determined based on distance to the target and time of reflection information.

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 Optical guided AGVs: Optical guided AGVs use a latex-based photosensitive tape on a facilitys floor for guidance. Distance is measured by use of wheel odometers, which establish stop locations for the AGV along the course. Outrigger AGVs: Outrigger AGVs have two horizontal stabilizing legs (outriggers) to provide lateral support, and are used to handle pallets, rolls and racks.
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 Small chassis AGVs: Small chassis AGVs are able to maneuver through crowded workplaces through laser sensing, while transporting smaller loads. Smart vehicle AGVs: Smart vehicle AGVs are capable of determining their own traffic control and routing without necessitating a central controller.

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 Tug/tow AGVs: Tug/tow AGVs are used to pull trailers and are usually manned by an operator who adds and removes the trailers at designated stops. These can follow a basic loop or a more complicated path. Wire guided AGVs: Wire guided AGVs use a charged wire that is buried beneath the floor for proper guidance and has a small antenna composed of metal coils mounted on their bottoms. The stronger the field between the buried wire and antennae, the higher the voltage induced to the coils.
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AGV in plastics industry handle AGV in chemical industry to handle raw raw materials and finished material materials and finished goods
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Food/Beverage. - AGVs for movement of materials in the process or in the warehouse

Pharmaceutical. -AGVs support cGMP and validation requirements

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Automated Storage And Retrieval Systems (As/Rs)

Automated Storage and Retrieval Systems (ASRS) are means to high density, hands free buffering of materials in distribution and manufacturing environments.

There are several classes of Automated Storage and Retrieval (AS/RS) that are characterized by weight and size handling characteristics.

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Types of AS/RS:
1. Unit Load AS/RS: Unit Load AS/RS machines are generally pallet-handling systems with capacities that vary much like lift trucks. Unit load AS/RS Systems are often quite tall and sometimes support the building shell that contains them. The density, security and labor/machinery savings they provide, make them a good choice in a variety of applications from cold storage to general warehousing.
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Unit load AS/RS

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 Mini Load AS/RS: Mini Load AS/RSoperating on the same principles as the Unit Loads these mini load machines handle smaller and lighter loads. These typically range from metal trays and totes to shipping cartons. Mini loads may be used in traditional stockroom applications but are also well suited as buffers to support manufacturing processes and shipping systems.

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Mini load AS/RS

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 Carousel AS/RS: Carousel AS/RS, the industrial carousel may be integrated with a specific purpose robotic inserter / extractor for small load buffering. Very often, carousel AS/RS is applied in lights-out stockroom. This technology finds itself at the heart of systems varying widely in application from the food industry to the manufacturing floor.

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Carousel AS/RS

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