Flexible Manufacturing Systems

What is FMS?
• FMS is a highly automated machine cell, consisting of a
group of processing workstations(usually CNC machine
tools). These are interconnected by material handling
and storage system, and controlled by a distributed
computer system.
– FMS is called flexible since it is capable of processing a
variety of different part styles simultaneously at 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.
 Flexible Manufacturing Systems
What makes a system flexible?
• For a system to be flexible it must possess three
capabilities:
1. The ability to identify and distinguish among the
different part or production styles processed by the
system
2. Quick changeover of operating instruction, and
3. Quick changeover of physical setup.
• Flexibility is an attribute that applies to both
manual, where manual workers cause the
system’s flexibility, and automated systems.
 Flexible Manufacturing Systems
For a system to qualify as being flexible, it should satisfy
the following test criteria:
1. Part variety test. Can the system process different
part styles in a nonbatch mode?
2. Schedule change test. Can the system readily accept
changes in production schedule, and 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 relative ease?
If the answer to the above is ‘yes’, then the system is
flexible.
 Flexible Manufacturing Systems

• To develop the concept of flexibility in an automated

manufacturing system, consider a machine cell consisting
of two CNC machine tools that are loaded and unloaded by
an industrial robot from a parts carousel, as depicted in
Figure above.
 Flexible Manufacturing Systems
• The cell operates unattended for extended periods of
time.
• Periodically, a worker must unload completed parts
from the carousel and replace them with new
workparts.
• By any definition, this is an automated manufacturing
cell, but is it a flexible manufacturing cell?
• One might argue that yes, it is flexible, since the cell
consists of CNC machine tools, and
• CNC machines are flexible because they can be
programmed to machine different part configurations.
• However, if the cell only operates in a batch mode, i.e.,
the same part style is produced by both machines in
several units, then it does not qualify as FM.
 Types of FMS
• Each FMS is designed for a specific
application, that is, a specific family of parts
and processes.
• Therefore, each FMS is custom engineered;
• each FMS is unique.
• Given these circumstances, one would expect
to find a great variety of system designs to
satisfy a wide variety of application
requirements.
 Types of FMS
• Machine flexibility
• Production flexibility
• Mix flexibility
• Product flexibility
• Routing flexibility
• Volume flexibility
• Expansion flexibility
 Machine flexibility
Definition
• Capability to adapt a given machine (workstation)
in the system to a wide range of production
operations and part styles. The greater the range
of operations and part styles, the greater the
machine flexibility.
Depends of factors such as:
• Setup or changeover time.
• Ease of machine reprogramming (ease with which
part programs can be downloaded to machines).
• Tool storage capacity of machines.
• Skill and versatility of workers in the system
 Production Flexibility
Definition
• The range or universe of part styles that can
be produced on the system.
Depends of factors such as:
• Machine flexibility of individual stations.
• Range of machine flexibilities of all stations in
the system.
 Mix Flexibility
Definition
• Ability to change the product mix while
maintaining the same total production quantity;
that is, producing the same parts only in different
proportions.
Depends of factors such as:
• Similarity of parts in the mix.
• Relative work content times of parts produced.
• Machine flexibility.
 Product Flexibility
Definition
• Ease with which design changes can be
accommodated. Ease with which new
products can be introduced.

Depends of factors such as:

• How closely the new part design matches the
existing part family.
• Off-line part program preparation.
• Machine flexibility.
 Routing Flexibility
Definition
• Capacity to produce parts through alternative
workstation sequences in response to equipment
breakdowns, tool failures, and other interruptions at
individual stations.

Depends of factors such as:

• Similarity of parts in the mix.
• Similarity of workstations.
• Duplication of workstations.
• Cross-training of manual workers.
• Common tooling.
 Volume flexibility
Definition
• Ability to economically produce parts in high
and low total quantities of production, given
the fixed investment in the system.

Depends of factors such as:

• Level of manual labor performing production.
• Amount invested in capital equipment.
 Expansion Flexibility
Definition
• Ease with which the system can be expanded to
increase total production quantities.

Depends of factors such as:

• Expense of adding workstations.
• Ease with which layout can be expanded.
• Type of part handling system used.
• Ease with which properly trained workers can be
added.
 Types of FMS
• Flexible manufacturing systems can be
distinguished according to the kinds of
operations they perform:
1. processing operations or
2. assembly operations.
• Two other ways to classify FMSs are by:
1. number of machines and
2. level of flexibility.
 Types of FMS
• TABLE 2: Comparison of Four Criteria of Flexibility in a
Manufacturing System and the Seven Types of Flexibility
 Number of Machines
Flexible manufacturing systems can be distinguished
according to the number of machines in the system.
The following are typical categories:
• single machine cell
• flexible manufacturing cell, and
• flexible manufacturing system
 Single machine cell (SMC)
• A single machine cell (SMC) consists of one
CNC machining center combined with a parts
storage system for unattended operation,
• Completed parts are periodically unloaded
from the parts storage unit, and raw work
parts are loaded into it.
• The cell can operate in either a batch mode or
a flexible mode or in combinations of the two.
 Flexible manufacturing cell (FMC)
• FMC consists of two or three process in
workstations (typically CNC machining centers
or turning centers) plus a part handling
system.
• The part handling system is connected to a
load/unload station.
• The handling system usually includes a limited
parts storage capacity.
• A flexible manufacturing cell satisfies the four
flexibility tests discussed previously.
 Flexible manufacturing system (FMS)
• FMS has four or more processing workstations
• The workstations are connected mechanically by a
common part handling system, and
• electronically by a distributed computer system.
• The distinction between an FMS and an FMC is:
1. The number of machines: an FMC has two or three
machines, while an FMS has four or more, and
2. The FMS generally includes nonprocessing workstations
that support production but do not directly participate in
it.
3. The computer control system of an FMS is generally
larger and more sophisticated; it includes functions such
as diagnostics and tool monitoring
 Types of FMS

• Single machine cell consisting of one CNC machining center and parts
storage unit.
 Types of FMS

• A flexible manufacturing cell consisting of three identical processing

stations (CNC machining centers), a load/unload station, and a part
handling system.
 Types of FMS

• Features of the three categories of flexible cells and systems.