FMS -

Flexible Manufacturing Systems

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 Components Of CIM
IGES,
CAD CAE GT DFM PDES,
DMIS

TQM
Product
design CAD/CAM
Bar codes,
EDI

MRP CAPP
Systems Process
JIT/ management CIM planning
Cellular
kanban manufacturing
DSS/ES/
AI MAP,
Manufacture STEP
LAN, TOP,
satellites

NC/CNC/ AGV, Automated Cells

FMS Robotics
DNC ASRS inspection and centers

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 What is FMS?
FMS ( flexible manufacturing systems)

- a highly automated GT machine cells,

consisting of a group of processing
workstations (CNC M/C tools),
interconnected by an automated handling
and storage systems, controlled by a
distributed computer system.

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 Why it is called as FMS?

Since
- It is capable of processing a variety of different

part configurations simultaneously at different

work stations.
- Adjusting the mix of part variety and quantity
in response to changing demand patterns.
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 FMS – flexible machining systems
- The machining process is the largest applied
area for FMS technology.
- Allowing for wide range of possible
applications beyond machining.
- Relies on the principle of Group Technology.
- Most suited for the mid-variety and mid-
volume.
- Designed to produce parts within a defined
range of part shapes, sizes and processes.
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 Application characteristics of
Flexible Manufacturing Systems

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Types of Automation

Program.
Automation

Flexible
Part Automation
Variety

Manual

Automation

Production Quantity

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 THE APPLICATION OF FMS AND GROUP
TECHNOLOGY OF PROCESS CHOICE
Increase in
variety Numerically Controlled
(N.C.) Machines
Job Group Technology
Low vol.
Batch F.M.S.
High vol. Dedicated
Batch Lines
Line

Increase in volume
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BENEFITS of FMS
 Increased Machine utilization
 Less no of Machines required
 Lower Lead times
 Reduced floor space area
 Higher response to the changes
 Reduced inventories
 Reduced labor requirements
 Ease for UNATTENDED operation
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What makes it Flexible?
 The ability to identify and distinguish among
the different parts / shapes processed
 Quick changeover of operation instructions
 Quick changeover to physical set up.

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 To qualify as being flexible
Criteria to be satisfied are,
1) Can the systems process different parts in
a non batch mode? [Part variety test]
2) Can it readily accept the changes in
schedules? [ Schedule change test]
3) Can it recover from malfunctions / break
downs? [Error recovery test]
4) Can new parts be introduced with relative
ease? [New part test]
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 Types of Flexibility
Each FMS is designed for sp. application
(parts / processes).

Hence FMS is
Custom engineered and Unique.

Flexibility types:
Machine flexibility, Production flexibility,
Mix flexibility, Product flexibility,
Routing flexibility, Volume flexibility,
Expansion flexibility.
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 FMS Classification
FMS classifications,
According to the operations
(i) Processing operations
(ii) Assembly operations
According to Number of Machines:
(i) Single Machine cell ( 1CNC + Sto. Sys.)
(ii) FMC ( 2 / 3 W/s + Hldg. Sys. + L / UL)
(iii) FMS ( 4 / more W / S + Common Hldg
+ Dist. Control systems)

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FMS Classification ( contd.)
According to LEVEL of Flexibility
a) Random order FMS
For more Variety of PART configurations and
Quantity.

b) Dedicated FMS
For limited variety of parts styles.

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FMS Components

1) Workstations
2) Material Handling and Storage
Systems
3) Computer control Systems
4) People

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Flexible Manufacturing System
Computer
control
room
Tools

Conveyor

Machine Machine

Pallet

Load Unload

Terminal Finished 16
Parts
goods
WORKSTATIONS
A system intended for doing a set / sequence of
operations
- Depends upon the TYPE of WORK to be
accomplished by the system.
Types:
LOAD / UNLOAD stations:
Machining Stations:
1) CNC machining centers: Vertical, Horizontal
2) Other processing stations:
3) Assembly stations:
CNC machining centers:
- Vertical centers, Horizontal centers.
Horizontal centers possess the features that make
it compatible with FMS.
Such Features are: ATC, ATS, Palletized WPs,
APC,CNC and ability for DNC.
Machining centers
- are mainly for NON-Rotational Parts.

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 CNC machining centers (contd.)
For Rotational Parts:
- Turning Module is available.
For multi tooth rotational operations, Mill-Turns
are used.
- Milling Modules and Drilling Modules are
special purpose centers.
- Milling module can be Vertical Spindle,
Horizontal spindle or Multi Spindle types.
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 Other Processing Stations

Sheet Metal operations and Press working

operations like Punching, Piercing,
Shearing, Forming and Bending
Operations.
Forging process
Welding unit,
Painting unit and etc.,
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Other Processing Stations Contd.,
Assembly operations, ( Programmable part
placement machines)
Inspection processes ( CMM & MACHINE
VISION )
Other activities: Cleaning , Palletizing and
Central Coolant Delivery systems etc.,)

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MATERIAL HANDLING AND Storage
systems
Functions:
- Random / Independent movement between
stations
- Handle a variety of parts
- Temporary storage
- Convenient access for loading and unloading
parts
- Compatible with computer control
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Types of Handling systems
Primary systems & Secondary systems
Primary systems:
Movement from one place to other place
( conveyors, AGVs, etc)
Secondary systems:
Movement of parts within the same destination
[Loading and Unloading]
( Transfer devices and APC etc.,)
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Automated Handling and AS/RS

Automated Material Handling

systems
 Conveyer systems
 AGVs
 Monorails and RGVs,
 Cranes and Hoists

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 CONVEYORS
a) Powered conveyors b) Non Powered conveyors
Powered:
Power mechanism is contained in a fixed path.
(Using Belts, Ropes, Chains, Rollers and other devices
to propel the loads in a fixed path)
Used commonly in automated systems.
Non-Powered:
This mechanism is not in fixed path.
Manual movement to push the loads along a path (or)
Gravity movement from elevated conditions
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 Types of Conveyors
 Roller conveyors
 Skate wheel conveyors
 Belt conveyors
 Cable conveyors (Chain, Slat, in-flow towline,
Overhead trolley, Power & Free OHT)
 Cart on Track conveyors
 Screw conveyors
 Chutes, Ramps and Tubes (driven by GRAVITY)

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Conveyors Operations and Features
i) CONTINUOUS MOTION Conveyors:
( move at a constant velocity along a path)
e g: Belt, Roller, Skate, OHT and Slat conveyors
ii) ASYNCHRONOUS Conveyors:
( Operates with a stop and go motion in which
loads are carried in containers, (Hooks,
Baskets, Carts) Move between stations and
then stop and remain station until released)
e g: Overhead trolley, Power & Free OHT, Cart
on Track conveyors
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 Automated Guided Vehicles (AGVs)
 A material handling system that uses
independently operated ( self operated) vehicles
guided along the defined pathways.
 Powered by on-board batteries.
 Pathways are UNOBTRUSIVE
 Appropriate where different matls. are moved
from various load points to various unload points.
 Best suitable for AMH in BATCH and MASS
production systems. (First developed in1954)
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 AGVs ( contd.,)
Types: a) Driverless trains b) Pallet Trucks
c) UNIT load carriers

DRIVERLESS TRAINS:
Consists of towing vehicle that pulls one or more trailers to
form a train.
Common application: Moving heavy payloads over a large
distances in warehouses or factories with or without
intermediate pick up and drop off along the route.
(LARGE QUANTITY for LARGE DISTANCE)

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 AGV Pallet Trucks:
 Used to move palletized loads along pre defined path.
 Pallets are loaded on the vehicle using forks.
 Worker drives the pallet truck to the guide path,
program its destination and the vehicle proceeds
automatically to the destination for unloading.
Eg: Fork lift AGVs
This vehicle can achieve significant vertical movement
of its forks to reach loads on racks and shelves.

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 UNIT load carrier AGVs
Used to move UNIT loads from one station to the
other.
Often equipped with automated loading and
unloading of pallets, totes pans by powered
rollers, moving belts mechanized lift platforms.
Types: Light load carriers (to move small loads of
single loads, small baskets / tote pans)
Assembly line units ( to carry partially
completed subassembly through a sequence of
W/S to build the part.)
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APPLICATIONS in FMS
1. Material Handling
2. Storage and Distribution ( AS / RS)
3. Assembly applications
4. FMS
5. Office Mail delivery
6. Hospital Material Transport

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VEHICLE GUIDANCE
Guidance system is the method by which AGV
pathways are defined and the vehicles are
controlled to follow the pathways.

TYPES:
A) Imbedded Guide wires
B) Paint Stripes
C) Self Guided vehicles

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 Imbedded Guide wires
 Electrical wires are placed in small channel cut
in the floor surface ( 3 -12 mm wide and 13 – 26
mm deep) and sealed with cement to eliminate
discontinuity.
 The wire is connected to the frequency
generator.
 A Magnetic field is induced along the pathway.
 This magnetic filed is tracked by the magnetic
sensors for the travel of the vehicle.
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Imbedded Wire guides ( contd.,)
Two sensors are attached to the AGV on either side.
When the Vehicle is located in such a way that the
guide wire is directly between the two coils, The
intensity of the field measured by each coil is
equal.
When the vehicle strays to one side / if the wire
changes the direction, the field intensity by the
two coils is different. This difference is used to
steer the motor to make required changes in the
vehicle direction to equalize the signals, thereby
tracking the wire.
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 PAINT STRIPES:
The vehicle is provided with optical sensor to track the
path.
The stripes can be Taped, Sprayed or Painted on the floor.
A wide stripe of paint containing fluorescent particles that
reflects UV light source.
An on board sensor detects the reflected light in the strip
and controls the steering mechanism to follow it.
Paint strips are useful when the installation of wires in the
floor is not practical and where electrical noise renders
the system unreliable.
LIMTATION:
Strip gets deteriorated with TIME. Hence strip must be
kept CLEAN and Periodically PAINTED. 36
Robots in Material Handling:
Robots can do
both primary and Secondary handling
activities

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 Materials Handling Applications
• The movement of parts, tools, materials, and
equipment in a facility
• The cost of materials handling can be extreme,
especially when the materials are easily damaged,
hazardous, bulky, or have to be oriented correctly
• Material Handling factors favoring automation
– The rate of handling is about 15 or less pieces per
minute
– The load weight is less than 1000 lb
– The orientation of the objects to be grasped is consistent

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 Material Feeders
• Some robots may be more adept (and more expensive) at picking up
randomly oriented parts, but most inexpensive pick-and-place robots
require a fixed-part orientation arranged by a material feeder:
– Bowl feeders -- use vibratory action to move items from the bottom
of the bowl up an internal ramp, being positioned using gravity
devices along the way
– Autoscrewdrivers -- feed screws, nuts, rivets, and studs using an
air/vacuum system to hold the part
– Gravity feeders -- consist of ramps or tubes which hold the parts
and are used for parts that are not conducive to vibratory feeding

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Loading/unloading parts to/from the machines
– The robot unloading parts from die-casting machines

– The robot loading a raw hot billet into a die, holding it during
forging and unloading it from the forging die
– The robot loading sheet blanks into automatic presses

– The robot unloading molded parts formed in injection

molding machines
– The robot loading raw blanks into NC machine tools and
unloading the finished parts from the machines

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 Automated Storage systems
Conventional systems need HUMAN intervention.
Mechanized and automated systems are to
downsize / eliminate the amount of human
intervention.
Represents a significant investment and new /
different variety of doing activites.
Two major classifications: 1. AS/RS
2. Carousel storage
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Automated Storage systems., (contd)
Merits:
1. High throughput rates
2. Facilitates use of computerized inventory control
3. Facilitates the interface to automated Matl. Hldg.
Demerits:
1. High Cost involved
Applications:
- WIP storage
- Final product warehousing and Distribution center
( unit load storage and handling)
- Order Picking
- Kitting of parts for electronic assembly 42
 AS / RS
A storage system that performs storage and retrieval
operations with speed and accuracy under a defined
degree of automation.
AS/RS consists of one / more storage aisles service
by S/R machines ( cranes).
AS/RS classifications:
- Unit Load AS/RS - Deep Lane
- Miniload AS /RS - Man-on-Load
- Automated item retrieval systems
- Vertical Lift Storage Modules (VLSM)
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Computer control system functions
 Control of each workstation
 Distribution of control instructions to each workstation
 Production control
 Traffic control
 Shuttle control
 Work handling system monitoring
 Tool control
 System performance and monitoring

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System Reports

 Utilisation reports

 Production reports

 Status reports

 Tool reports

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System Reports
 Volume of work to be produced by the system

 Variation in process routings

 Physical characteristics of the workparts

 Part families defined according to product commonality

 FMS manpower requirements

 Appropriate production volume range

 Minimum number of machines/FMS: 4

 Minimum normal tolerance on work in an FMS: +/- 0.05

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Hierarchical control of an FMS

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