05 05

FLEXIBLE FLEXIBLE
MANUFACTURING MANUFACTURING
SYSTEMS SYSTEMS (FMS) (FMS) SYSTEMS SYSTEMS (FMS) (FMS)
Presentasi Kuliah
TKI-313 Sistem Produksi
Jurusan Teknik Universitas Muhammadiyah Surakarta
Dosen : Much Djunaidi
Model Variations Model Variations
Single model case Single model case One product or model is One product or model is
produced that is identical from one unit to the next produced that is identical from one unit to the next
Batch model case Batch model case Different products or models Different products or models
produced in batches produced in batches produced in batches produced in batches
(Requires changeover between models) (Requires changeover between models)
Mixed model case Mixed model case Different products or models Different products or models
produced on same line or equipment with no produced on same line or equipment with no
changeovers between models changeovers between models
Requirements for Unattended Operation Requirements for Unattended Operation
for Single and Batch Model Cases for Single and Batch Model Cases
oo Programmed work cycle Programmed work cycle
oo Parts storage subsystem Parts storage subsystem
oo Automatic transfer of work Automatic transfer of work--pieces between pieces between
storage subsystem and production machine storage subsystem and production machine
oo Periodic attention of worker Periodic attention of worker
Requirements for Unattended Operation Requirements for Unattended Operation
for Single and Batch Model Cases for Single and Batch Model Cases
oo Resupply and removal of work Resupply and removal of work--pieces, tool pieces, tool
changes, minor repairs, maintenance changes, minor repairs, maintenance changes, minor repairs, maintenance changes, minor repairs, maintenance
oo Built Built- -in safeguards to protect the system itself in safeguards to protect the system itself
and the work units processed by the system and the work units processed by the system
Requirements for Mixed Model Case Requirements for Mixed Model Case
Flexible Manufacturing Systems (FMS) Flexible Manufacturing Systems (FMS)
Identification of different models Identification of different models
oo No problem for human workers No problem for human workers
oo For automated system, some means of For automated system, some means of
product identification is required product identification is required
Requirements for Mixed Model Case Requirements for Mixed Model Case
Flexible Manufacturing Systems (FMS) Flexible Manufacturing Systems (FMS)
Quick changeover of operating instructions Quick changeover of operating instructions
oo For automated system, change part program For automated system, change part program
Quick changeover of physical setup Quick changeover of physical setup
oo Change tooling and fixtures in very short time Change tooling and fixtures in very short time
o Presently, the plant either (1) produces parts in batches, or
(2) uses manned GT cells and management wants to
automate
FMS technology can be applied in FMS technology can be applied in
situations similar to those for cellular situations similar to those for cellular
manufacturing: manufacturing:
o It must be possible to group a portion of the parts made in
the plant into part families, whose similarities permit them
to be processed on the machines in the flexible
manufacturing system
o The parts or products made by the facility are in the mid-
volume, mid-variety production range. The appropriate
production volume range is 5000 to 75,000 parts per year
High High
Stand Stand- -alone alone
CNC machines CNC machines
Medium Medium
Flexible Flexible
manufacturing manufacturing
systems systems
Transfer Transfer
Low Low
Transfer Transfer
lines lines
Low Low Medium Medium High High
Production Volume Production Volume
Application characteristics of flexible manufacturing systems.
Differences between implementing a Differences between implementing a
manually operated machine cell and a manually operated machine cell and a
flexible manufacturing system are: flexible manufacturing system are:
The FMS requires a significantly greater capital The FMS requires a significantly greater capital
investment because new equipment is being investment because new equipment is being investment because new equipment is being investment because new equipment is being
installed rather than existing equipment being installed rather than existing equipment being
rearranged rearranged
The FMS is technologically more sophisticated for The FMS is technologically more sophisticated for
the human resources who must make it work the human resources who must make it work
Benefits that can be expected from a FMS Benefits that can be expected from a FMS
include: include:
Increased machine Increased machine utilisation utilisation
Fewer machines required Fewer machines required
Reduction in factory floor space required Reduction in factory floor space required
Greater responsiveness to change. Greater responsiveness to change.
Benefits cont Benefits cont
oo Reduced inventory requirements Reduced inventory requirements
oo Lower manufacturing lead times Lower manufacturing lead times oo Lower manufacturing lead times Lower manufacturing lead times
oo Reduced direct Reduced direct labour labour requirements and higher requirements and higher
labour labour productivity productivity
oo Opportunity for unattended production Opportunity for unattended production
What is a FMS? What is a FMS?
A A flexible manufacturing system flexible manufacturing system is a highly is a highly
automated GT machine cell, consisting of a group of automated GT machine cell, consisting of a group of
processing workstations, interconnected by an processing workstations, interconnected by an
automated material handling and storage system, automated material handling and storage system,
and controlled by a distributed computer system. and controlled by a distributed computer system.
FMS is called FMS is called flexible flexible because it is capable of because it is capable of FMS is called FMS is called flexible flexible because it is capable of because it is capable of
processing a variety of different part styles processing a variety of different part styles
simultaneously at the various workstations, and the simultaneously at the various workstations, and the
mix of part styles and quantities of production can be mix of part styles and quantities of production can be
adjusted in response to changing demand patterns. adjusted in response to changing demand patterns.
A FMS relies on the principles of group technology.
No manufacturing system can be completely flexible.
There are limits to the range of parts or products
that can be made in a FMS.
A FMS is designed to produce parts (or products)
within a defined range of styles, sizes, and processes. within a defined range of styles, sizes, and processes.
In other words, it is capable of producing a single
part family or a limited range of part families.
A more appropriate term for FMS would be flexible flexible
automated manufacturing system automated manufacturing system. .
The word automated automated would distinguish this
technology from other manufacturing systems that
are flexible but not automated, such as a manned
GT machine cell.
The word flexible flexible would distinguish it from other
manufacturing systems that are highly automated
but not flexible, such as a conventional transfer line.
Automated Manufacturing Cell Automated Manufacturing Cell
Machine Tool
Parts Carousel
Machine Work
table
Parts Carousel
Robot
1. Part variety test. Can the system process different
To qualify as being flexible, a manufacturing To qualify as being flexible, a manufacturing
system should satisfy several criteria. system should satisfy several criteria.
Four reasonable tests of flexibility:
1. Part variety test. Can the system process different
part styles in a non-batch mode?
2. Schedule change test. Can the system readily
accept changes in production schedule: changes in
either part mix or production quantities?
3. Error recovery test. Can the system recover
gracefully from equipment malfunctions and
breakdowns, so that production is not completely
disrupted?
4. New part test. Can new part designs be
introduced into the existing product mix with introduced into the existing product mix with
relative ease?
o Can machine different part configurations in a mix
rather than in batches;
o Permits changes in production schedule and part
Arobotic work cell satisfies the criteria if it: Arobotic work cell satisfies the criteria if it:
o Permits changes in production schedule and part
mix;
o Is capable of continuing to operate even though
one machine experiences a breakdown - for
example, while repairs are being made on the
broken machine, its work is temporarily reassigned
to the other machine; and
Cont. Cont.
to the other machine; and
o Allows development of new parts to be written
off-line and then downloaded to the system for
execution.
Manufacturing flexibility: Manufacturing flexibility:
Flexibility Flexibility
type type
Definition Definition Dependant on.. Dependant on..
Machine Machine
flexibility flexibility
Capability to adapt a given Capability to adapt a given
machine (workstation) in machine (workstation) in
the system to a wide the system to a wide
range of production range of production
operations and part styles. operations and part styles.
The greater the range of The greater the range of
Setup or changeover time. Setup or changeover time.
Ease of machine reprogramming Ease of machine reprogramming
(ease with which part programs (ease with which part programs
can be downloaded to can be downloaded to
machines). machines).
The greater the range of The greater the range of
operations and part styles, operations and part styles,
the greater the machine the greater the machine
flexibility. flexibility.
machines). machines).
Tool storage capacity of Tool storage capacity of
machines. machines.
Skill and versatility of workers in Skill and versatility of workers in
the system. the system.
Production Production
flexibility flexibility
The range or universe of The range or universe of
part styles that can be part styles that can be
produced on the system. produced on the system.
Machine flexibility of individual Machine flexibility of individual
stations. stations.
Range of machine flexibilities of Range of machine flexibilities of
all stations in the system. all stations in the system.
Mix Mix
flexibility flexibility
Ability to change the product Ability to change the product
mix while maintaining the mix while maintaining the
same total production same total production
quantity; that is, producing quantity; that is, producing
the same parts only in the same parts only in
different proportions. different proportions.
Similarity of parts in the mix. Similarity of parts in the mix.
Relative work content times of Relative work content times of
parts produced parts produced
Machine Flexibility Machine Flexibility
Product Product
flexibility flexibility
Ease with which design Ease with which design
changes can be changes can be
accommodated. Ease with accommodated. Ease with
which new products can be which new products can be
How closely the new part How closely the new part
design matches the existing design matches the existing
part family. part family.
Off Off--line part program line part program
which new products can be which new products can be
introduced. introduced.
Off Off--line part program line part program
preparation. preparation.
Machine flexibility Machine flexibility
Routing Routing
flexibility flexibility
Capacity to produce parts Capacity to produce parts
through alternative station through alternative station
sequences in response to sequences in response to
equipmt breakdowns, tool equipmt breakdowns, tool
failures, and other failures, and other
interruptions at individual interruptions at individual
stations. stations.
Similarity of parts in the mix Similarity of parts in the mix
Similarity of workstations Similarity of workstations
Duplication of workstations Duplication of workstations
Cross Cross--training of manual training of manual
workers. workers.
Common tooling. Common tooling.
Volume Volume
flexibility flexibility
Ability to economically Ability to economically
produce parts in high and produce parts in high and
low total quantities of low total quantities of
production, given the fixed production, given the fixed
investment in the system. investment in the system.
Level of manual labour Level of manual labour
performing production. performing production.
Amount invested in capital Amount invested in capital
equipment. equipment.
Expansion Expansion
flexibility flexibility
Ease with which the Ease with which the
system can be expanded to system can be expanded to
increase total production increase total production
quantities. quantities.
Expense of adding Expense of adding
workstations. workstations.
Ease with which layout can be Ease with which layout can be
expanded. expanded. expanded. expanded.
Type of part handling system Type of part handling system
used. used.
Ease with which properly Ease with which properly
trained workers can be added. trained workers can be added.
FMSs can be distinguished according to the FMSs can be distinguished according to the
number of machines. number of machines.
Single machine cell - One CNC machining center
combined with a parts storage system for unattended
operation.
Flexible manufacturing cell - Consists of two or three
processing stations plus a parts handling system
connected to a load/unload station.
Flexible manufacturing system - Four or more
processing workstations connected mechanically by a
common parts handling system and electronically by
a distributed computer system.
Differences between FMC and FMS Differences between FMC and FMS
Number of machines: a FMC has two or three Number of machines: a FMC has two or three
machines, while a FMS has four or more. machines, while a FMS has four or more.
FMS generally includes non FMS generally includes non--processing processing
workstations that support production but do not workstations that support production but do not workstations that support production but do not workstations that support production but do not
directly participate in it (e.g., part/pallet washing directly participate in it (e.g., part/pallet washing
stations, coordinate measuring machines) stations, coordinate measuring machines)
Computer control system of a FMS is generally Computer control system of a FMS is generally
larger and more sophisticated, often including larger and more sophisticated, often including
functions not always found in a cell, such as functions not always found in a cell, such as
diagnostics and tool monitoring. diagnostics and tool monitoring.
Flexibility criteria applied to the 3 types of Flexibility criteria applied to the 3 types of
manufacturing cells and systems. manufacturing cells and systems.
System type System type Part variety Part variety
Schedule Schedule
change change
Error recovery Error recovery
New New
part part
Single Single
machine cell machine cell
(SMC) (SMC)
Yes, but processing Yes, but processing
sequential, not sequential, not
simultaneous simultaneous
Yes Yes Limited recovery Limited recovery
due to only one due to only one
machine machine
Yes Yes
Flexible mfg Flexible mfg
cell (FMC) cell (FMC)
Yes, simultaneous Yes, simultaneous
production of production of
different parts different parts
Yes Yes Error recovery Error recovery
limited by fewer limited by fewer
machines than machines than
FMS FMS
Yes Yes
Flexible mfg Flexible mfg
system system
(FMS) (FMS)
Yes, simultaneous Yes, simultaneous
production of production of
different parts different parts
Yes Yes Machine Machine
redundancy redundancy
minimises effect minimises effect
of machine of machine
breakdowns breakdowns
Yes Yes
Another classification of FMS is by its level Another classification of FMS is by its level
of flexibility: of flexibility:
Dedicated FMS
Designed to produce a limited variety of part
styles, and the complete universe of parts to be
made on the system is known in advance.
Part family is likely to be based on product Part family is likely to be based on product
commonality rather than geometric similarity. commonality rather than geometric similarity.
made on the system is known in advance.
Dedicated FMS cont
Product design is stable, so the system can be
designed with a certain amount of process
specialization to make the operations more efficient.
The machine sequence may be identical or nearly
identical for all parts processed, and so a transfer line identical for all parts processed, and so a transfer line
may be appropriate, in which the workstations
possess the necessary flexibility to process the
different parts in the mix (flexible transfer line)
Random Order FMS Random Order FMS
More appropriate when the part family is large, More appropriate when the part family is large,
substantial variations in part configurations, new substantial variations in part configurations, new
part designs introduced into the system and part designs introduced into the system and
engineering changes in parts currently produced, engineering changes in parts currently produced,
and production schedule is subject to change. and production schedule is subject to change. and production schedule is subject to change. and production schedule is subject to change.
More flexible than the dedicated FMS. More flexible than the dedicated FMS.
General purpose machines to deal with the General purpose machines to deal with the
variations in product variations in product
More sophisticated computer control system is More sophisticated computer control system is
required. required.
Flexibility criteria applied to dedicated FMS Flexibility criteria applied to dedicated FMS
and random and random--order FMS order FMS
System System
type type
Part variety Part variety Schedule Schedule
change change
Error Error
recovery recovery
New part New part
Dedicated Dedicated
FMS FMS
Limited. All parts Limited. All parts
known in known in
Limited Limited
changes can changes can
Limited by Limited by
sequential sequential
New part New part
introduction introduction FMS FMS known in known in
advance. advance.
changes can changes can
be tolerated. be tolerated.
sequential sequential
processes. processes.
introduction introduction
is difficult. is difficult.
Random Random--
order order
FMS FMS
Substantial part Substantial part
variations variations
possible. possible.
Frequent Frequent
and and
significant significant
changes changes
possible. possible.
Machine Machine
redundancy redundancy
minimizes minimizes
effect of effect of
machine machine
breakdowns breakdowns
System System
designed for designed for
new part new part
introductions introductions
Basic Components of a FMS: Basic Components of a FMS:
Workstations Workstations
Material handling and storage system Material handling and storage system
Computer control system Computer control system
People are required to manage and operate People are required to manage and operate
the system. the system.
Workstations Workstations
Load/Unload Stations Load/Unload Stations -- Physical interface: FMS and Physical interface: FMS and
factory. factory.
Machining Stations Machining Stations -- Most common is the Most common is the CNC CNC
machining centre machining centre..
Other Processing Stations Other Processing Stations sheet sheet--metal fabrication, metal fabrication, Other Processing Stations Other Processing Stations sheet sheet--metal fabrication, metal fabrication,
forging. forging.
Assembly Assembly -- Industrial robots, component placement Industrial robots, component placement
machines. machines.
Other Stations and Equipment Other Stations and Equipment --inspection stations, inspection stations,
cleaning stations, central coolant delivery and chip cleaning stations, central coolant delivery and chip
removal systems. removal systems.
Material Handling and Storage System Material Handling and Storage System
Functions of the Handling System Functions of the Handling System
oo Random, independent movement of Random, independent movement of workpieces workpieces
between stations. between stations.
oo Handle a variety of Handle a variety of workpiece workpiece configurations. configurations.
Temporary storage. Temporary storage. oo Temporary storage. Temporary storage.
oo Convenient access for loading and unloading Convenient access for loading and unloading
workpieces workpieces..
oo Compatible with computer control Compatible with computer control..
FMS Layout Configurations FMS Layout Configurations
oo In In- -line layout line layout
oo Loop layout Loop layout
Ladder layout Ladder layout oo Ladder layout Ladder layout
oo Open field layout Open field layout
oo Robot Robot--centered cell centered cell
FLEXIBLE MANUFACTURING FLEXIBLE MANUFACTURING
SYSTEMS (FMS) SYSTEMS (FMS) SYSTEMS (FMS) SYSTEMS (FMS)
This resource was created Leicester College and released as an open educational resource through the Open
Engineering Resources project of the Higher Education Academy Engineering Subject Centre. The Open
Engineering Resources project was funded by HEFCE and part of the JISC/HE Academy UKOER programme.
Flexbile Manufacturing Systems Flexbile Manufacturing Systems
Engineering Resources project was funded by HEFCE and part of the JISC/HE Academy UKOER programme.
2009 Leicester College
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