The FMS & Cell Grouping

Nilesh J. Shirbhate
Mechanical Engineering Department
Jawaharlal Darda Institute of Engineering & Technology,
Yavatmal
Types of Manufacturing Systems
 Mass Production
 Capability of producing large volumes of a product at a
lower cost, but very inflexible in terms of the product
types which can be produced (e.g., transfer lines).

 Batch Production
 Capability of producing a variety of different product
types, but at a high cost (e.g., Process shops).

 Job Production
 Capability of producing one job at a time. Facilities are
arranged to produce specialize job.

STTP on Flexible Manufacturing Systems 2

Batch Production
 Types of Layouts
 Process Layout

 Cell Layout

STTP on Flexible Manufacturing Systems 3

Definition of FMS
 Refers to a set of computer
numerically control (CNC) machine
tools and supporting workstations that
are connected by an automated
handling system and are controlled by
a central computer (Askin, 1993)

STTP on Flexible Manufacturing Systems 4

What is an FMS?
 A flexible manufacturing system (FMS) is
a manufacturing system in which there is
some amount of flexibility that allows the
system to react in the case of changes,
whether predicted or unpredicted.
 Two categories of flexibility
 Machine flexibility, covers the system's ability
to be changed to produce new product types, and
ability to change the order of operations executed
on a part.
 Routing flexibility, which consists of the ability
to use multiple machines to perform the same
operation on a part, as well as the system's ability
to absorb large-scale changes, such as in volume,
capacity, or capability.

STTP on Flexible Manufacturing Systems 5

FMS and FMC
 Early FMSs were large and very complex, consisting
of dozens of CNCs and sophisticated material
handling systems. They were very automated, very
expensive and controlled by incredibly complex
software. There were only a limited number of
industries that could afford investing in a traditional
FMS as described above.
 Currently, the trend in FMS is toward small versions
of the traditional FMS, called flexible
manufacturing cells (FMC).
 Today two or more CNC machines are considered a
flexible cell and two more more cells are considered a
flexible manufacturing system.
 Thus, a Flexible Manufacturing System (FMS)
consists of several machine tools along with part and
tool handling devices such as robots, arranged so that it
can handle any family of parts for which it has been
designed and developed.

STTP on Flexible Manufacturing Systems 6

The Manufacturing Cell
 A flexible manufacturing cell (FMC)
consists of two or more CNC
machines, a cell computer , material
handling equipments, measurement
equipments and a robot.
 The cell computer (typically a
programmable logic controller) is
interfaced with the microprocessors of
the robot and the CNCs.

STTP on Flexible Manufacturing Systems 8

Fundamental Issue in Cell Development
 Main issue with FMC is design of cell.
 Cells are arranged on the basis of part
families.
 Part family is group of parts to
manufacture, which posses some
design or manufacturing similarities.
 Part Families share set-up ideas and
equipment (Family Fixtures).
 Member of part family visits cell.

STTP on Flexible Manufacturing Systems 9

What is group technology?
Group technology (GT) is a manufacturing philosophy
that seeks to improve productivity by grouping parts and
products with similar characteristics into families and
forming production cells with a group of dissimilar
machines and processes.

 Group technology was introduced by Frederick Taylor in

1919 as a way to improve productivity.

 One of long term benefits of group technology is it helps

implement a manufacturing strategy aimed at greater
automation.

STTP on Flexible Manufacturing Systems 10

 Building the FMC Facility

Before
Grouping

After
Grouping

STTP on Flexible Manufacturing Systems 11

Grouping Methods
 Using Process Similarity methods:
 Create Machine – Part Matrices
 Compute machine ‘pairwise’ Similarity
Coefficient comparisons:

xij
Sij =
(x ij + x jj )
here:

xij is # of parts (in matrix) visiting

both machines of the pair

x
jj
is # of parts visiting one but not both machines

STTP on Flexible Manufacturing Systems 12

Example:
Part ‘Number’

X 1 2 3 4 5 6
Machine ID

A 1 1

B 1 1

C 1 1

D 1 1 1

E 1 1 1

STTP on Flexible Manufacturing Systems 13

Computing Similarity Coefficients:
 Total Number of similarity coefficient
is:
 [(N-1)N]/2 = [(5-1)5]/2 = 10
 For 25 machines (typical number in a small

Job Shop): 300 Sij’s

 Here they are:
1
S AB = = .33
1+ 2
0
S AC = =0
0+4
2
S AD = = .67
2 +1

STTP on Flexible Manufacturing Systems 14

 0
S AE = =0 Here, if the similarity
0+5
0 coefficient is 0 .33 consider for
S BC = =0 grouping (clustering)
0+4
2 This criteria means clustering:
S BD = = .67
2 +1 A&D, A&B, B&D
0
S BE = =0 C &E
0+5
0 Declustering:
SCD = =0
0+5 A&C, A&E, B&C, B&E and C&D,
2 D&E
SCE = = .67
2 +1
0
S DE = =0
0+6

STTP on Flexible Manufacturing Systems 15

 Examining our Matrix and our freshly
clustered ‘machine cells,’ we develop 2 part
families:
 For the Cell A/D/B: Part Numbers 2, 3 & 5
 For the Cell C/E: Part Numbers 1, 4 & 6
 Care must be taken (in most cases) to
assure that each cell has all the machines it
needs – sometimes a couple of families need
a key machine
 In this case, the manager must decide to either
replicate the common machine or share it
between the cells creating a bottleneck and
scheduling problem for each cell
 This is typically one of the cost problems in CMS
systems

STTP on Flexible Manufacturing Systems 16

Summarizing:
 Make Machine/Part Matrix
 Compute Similarity Coefficients
 Cluster Machines with positive (0 .33) Sij’s
 Determine Part Families for the clusters
(cells)
 Decide if machine replication is cost effective
 Re-layout facility and Cross Train workforce
 Court customers to grow part families on
Cell-by-Cell basis

STTP on Flexible Manufacturing Systems 17

Other Grouping Methods:
 Rank order Clustering (grouping)
 This method automates the cluster study by
computing Binary weights from a machine –
part matrix
 It orders parts and machine cells
‘automatically’ by structuring and computing
the matrix with binary weights
 It implies a computer algorithm for solving the
clustering problem
 It may not solve if machines are needed by
more than one family – forces intelligence in
application and hand scanning after several
ordering iterations

STTP on Flexible Manufacturing Systems 18

Rank Order Clustering Method:
1. For each row of the machine/part matrix (M/P/M)
read the pattern of cell entries as a binary word.
Rank the rows by decreasing binary value. Equal
values stay in same order.
2. Ask if newly ranked rows in the matrix are the same
as previous order? – Yes (STOP) No (continue)
3. Re-form the M/P/M with rows in new descending
order. Now rank the columns by decreasing binary
word weight. Columns of equal weight are left where
they are
4. Are current column weights the same as current
column order? Yes (STOP), No (continue)
5. Re-form the matrix column order per rank order
(highest to left) and return to #1.

STTP on Flexible Manufacturing Systems 19

Lets try it with our earlier problem:

Part ‘Number’
X 1 2 3 4 5 6
Machine ID

A 1 1
B 1 1
C 1 1
D 1 1 1
E 1 1 1

STTP on Flexible Manufacturing Systems 20

Step 1:
Machine ID Part Numbers D. Equiv Rank

1 2 3 4 5 6
B. Wt: 25 24 23 22 21 20

A 1 1 23+21 = 5
10
B 1 1 24+23 = 4
24
C 1 1 25+22=36 2

D 1 1 1 24+23+21 3
= 26
E 1 1 1 25+22+20 1
=37

Step 2: Must Reorder!

STTP on Flexible Manufacturing Systems 21

Step 3:
Part Number
B. WT. 1 2 3 4 5 6
Machine ID
E 24 1 1 1
C 23 1 1
D 22 1 1 1
B 21 1 1
A 20 1 1
D. Equiv 24+23 22+21= 22+21+ 24+23= 22+20= 24=16
= 24 6 20=7 24 5

Rank 1 5 4 2 6 3

Step 4: Must Reorder

STTP on Flexible Manufacturing Systems 22

 Great

Back at Step 1: Cluster

Result!

Part Number D. Eqv Rank

1 4 6 3 2 5
B Wt: 25 24 23 22 21 20
Machine ID

E 1 1 1 25+24+ 1
23=56
C 1 1 25+24= 48 2

D 1 1 1 22+21+ 20 3
=7
B 1 1 22+21=6 4
A 1 1 22+20=5 5

Order stays the same: STOP!

STTP on Flexible Manufacturing Systems 23

Alternative means to Develop
Cells/Families:
 Most often companies rely on Classification
and Coding (C&C) systems for analyzing
their part mix
 These codes can be general purpose or
company specific

Name of
system
TOYOD
STTP on Flexible Manufacturing Systems 24
Classification and Coding Schemes

. . . .
. . . .
. . . .
n-1

STTP on Flexible Manufacturing Systems 25

STTP on Flexible Manufacturing Systems 26
The Cell Controller
 The functions of the cell controller
include work load balancing, part
scheduling, and material flow control.
 The supervision and coordination
among the various operations in a
manufacturing cell is also performed by
the cell computer.
 The software includes features
permitting the handling of machine
breakdown, tool breakage and other
special situations.

STTP on Flexible Manufacturing Systems 27

The Cell Robot
 In many applications, the cell robot
also performs tool changing and
housekeeping functions such as chip
removal, staging of tools in the tool
changer, and inspection of tools for
breakage or expressive wear. When
necessary, the robot can also initiate
emergency procedures such as system
shut-down.

STTP on Flexible Manufacturing Systems 28

The FMS
FMS Components
 Most FMS systems comprise of three
main systems
 Work machines (typically automated CNC
machines) that perform a series of
operations;
 An integrated material transport system
and a computer that controls the flow of
materials, tools, and information (e.g.
machining data and machine
malfunctions) throughout the system;
 Auxiliary work stations for loading and
unloading, cleaning, inspection, etc.

STTP on Flexible Manufacturing Systems 30

FMS Goals
 Reduction in manufacturing cost by lowering
direct labor cost and minimizing scrap, re-
work, and material wastage.
 Less skilled labor required.
 Reduction in work-in-process inventory.
 Reduction in production lead time permitting
manufacturers to respond more quickly to
the variability of market demand.
 Better process control resulting in consistent
quality.

STTP on Flexible Manufacturing Systems 31

Benefits of GT and FMS (Companies
Reporting):
 20% Report reduction in floor space
 45% Report reduced scrap
 80% Report reduced production and
quality costs
 69% Report reduced set-up time (cost)
 70% Report reduced throughput time
(even more report better predictability
of delivery)

STTP on Flexible Manufacturing Systems 32

 82% Report reduced numbers of
overdue orders
 42% Report reduced raw-materials
inventory
 62% Report reduced WIP
 33% Report increased employee
output/time unit (productivity
improvement)

Note: ‘Reported’ by companies in a survey of adopters of GT by R. R. Lindeke, PhD,2005

STTP on Flexible Manufacturing Systems 33

Advantages 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

STTP on Flexible Manufacturing Systems 34

Disadvantages of FMS
 Limited ability to adapt to changes in product
or product mix (e.g., 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 in millions
 Technological problems of exact component
positioning and precise timing necessary to
process a component
 Sophisticated manufacturing systems

STTP on Flexible Manufacturing Systems 35

 Thank you

STTP on Flexible Manufacturing Systems 36

OPTIZ CLASSIFICATION SYSTEM

STTP on Flexible Manufacturing Systems 37