Flexible Manufacturing Systems

(FMS)

By Mr. Ankush B. Khansole

 Flexible Manufacturing Systems (FMS)
 External changes such as change in product design and
production system.
 Optimizing the manufacturing cycle time 3.Reduced
production costs
 Overcoming internal changes like breakdowns etc.
 Lower cost per unit produced
 Greater labour productivity
 Greater machine efficiency
 Improved quality
 Increased system reliability
 Reduced parts inventories
 Introduction
1. A FMS consists of a group of programmable
production machines interconnected by means
of an automated material handling and
storage
system and controlled by an integrated
computer system to produce a variety of parts
at non- uniform product rates, batch sizes and
quantities .
2. A FMS is characterised by the following:
Variety of products ,small volume of products,
Less manufacturing lead time ,high quality ,
Low cost.
 Flexible manufacturing system

A flexible manufacturing
system is an automated
Machine cell , consisting of
a group of processing
work stations,
interconnected
with automated
material handling and
storage system.
 FMS Equipment

1. In general FMS equipments consists of the

following components:
1.Manufacturing system. 2.Tool
handling and storage.
3.Material handling and storage.
4.Computer control system.
 1.Manufacturing System

1. The machining system consists of CNC Machine

tools (including Horizontal centre, Vertical centre ,
Turning centre) that can perform machining operations
on part families.

2. However FMS also include ASSEMBLY STATIONS,

SHEET METAL PRESSES , INSPECTION STATIONS

3. Manufacturing system capable of performing

several operations on the work piece automatically
• Machining centres consist of an automatic tool
changing and tool storage , pallet changer, CNC
Control and DNC control.
• Assembly workstations are used for assembly
products typically made in batches
• Industrial robots are usually considered to be the
most appropriate as automated workstations
• INSPECTION STATIONS are incorporated into
FMS by including an inspection operation at a
given work station or by designating a specific
station for inspection.
• SHEET METAL PROCESSING MACHINES consist
of press working operations such as punching ,
shearing and bending and forming processes
1.Manufacturing system.
 2. Material Handling and Storage
1. This system facilitates the timely supply of un machined work
pieces from the storage to the machining centres and transport of
the machined parts from machining centres to the desired
locations.
2. Functions of material handling and storage system are
a) Random , Independent movement of work pieces between
work stations
b) Accommodation of different part configurations:
• Example : For prismatic parts , the fixture is located on the top of
pallet and is designed to accommodate different part configurations
• Forrotational parts, industrial robots are used to load and unload
the machine tools and to transfer parts between workstations.
c) Compatibility with computer control: The handling
system is allowed to control directly by the computer to
direct to workstation, load and unload workstation.
The material handling equipments consists
of 1.load/unload stations(palletising)
2.Robotics
3. AGV (AUTOMATICALLY GUIDED
VECHICLE)
4. AS/RS (Automatic storage and Retrieval
system)
 Automatically guided vehicle (AGV)
• An automatically guided vehicle
(AGV) is a material handling
system which uses independently
operated , self – propelled
vehicles that are guided along
defined pathways in the floor.
• This vehicles are power by means
of on- board batteries.
• A typical AGVS unit load carrier is
shown.
• It is equipped for automatic
loading and unloading by means
of Powered rollers , Moving belts ,
Mechanised lift platforms or other
devices.
 3.Tool Handling storage
1. In a FMS , various
cutting tools are
loaded onto the
machine at
intervals depending
upon their
utilisation.
2. The cutting tools are
stored in auxiliary tool
storage from where the
required tools can be
transferred to the main
tool magazine.
3. Such storage units include drums ,chains, discs and other forms.
4. There is limit to the maximum number of tools available at the machine
tool (20-120).
 4.FMS Control System

• All the elements in an FMS , Machine tools , Material

handling units and cutting tools are to be controlled in real
– time.
• A computer is used to control the operation of FMS
• Functions performed by the FMS computer control are:
1. Control of workstations
2. Production control.
3.Traffic control.
4.Shuttle control. (secondary part handling system)
5.Tool control. (Tool location Accounting and Tool life
Monitoring)
6. Scheduling.
7. System performance and Monitoring
 FMS Layouts
• The FMS layouts are Broadly Classified into
the Following Five categories:
1.IN – Line.
2.Loop.
3.Ladder.
4.Open – field. 5.Robot –
centred cell.
 1.In – line or progressive FMS layout
• It is most appropriate for systems in which
the work parts progress from one
workstation (WS) to the next in a well –
defined sequence with no back flow.
2.LOOP FMS Layout:
• In this layout work part usually flow in one direction
along the loop with the capability at any
workstation
• The load/unload stations are located at one end of
the loop.
 3.Ladder FMS Layout :
1. This type of layout contains rungs on which
workstations are located
2. This layout reduces the average distance travelled to
transfer work parts between stations.
 4.Open – field FMS layout
1. The open field layout configuration consists of Loops
,ladders, and sliding organised to achieve the desired
processing requirements
2. This is appropriate for a large family of parts.
5.Robot – centred FMS layout
• In this the robot is located at the approximate centre of the
layout and the other workstations are arranged around it
• Industrial robot equipped with grippers may be used for
the handling of rotational parts.
• The type of layout is well – suited for handling of cylindrical
or disk shaped parts.
11.To reduce set up and queue times
12.Improve efficiency
13.Reduce time for product completion
14.Utilize human workers better
15. Improve product routing
16.Produce a variety of Items under one roof
17.Improve product quality
18.Serve a variety of vendors simultaneously
19.Produce more product more quickly
20.Adaptability to CAD/CAM operations
21.Shorter lead times
1. Expensive.
2. Substantial pre-planning activity.
3.Cost to implement,
4.Substantial pre-planning
5.Requirement of skilled labour
6.Complicated system
CHALLENGES
4. Determining if FMS the best production system
for your company
5.Possible expansion costs associated with implementing
FMS
 Benefits of FMS
1. Greater flexibility
2. Higher machine utilisation
3. Reduced work-in- progress
4. Lower manufacturing lead times
5. Higher labour productivity
 Metal-cutting machining Metal forming Assembly
 Joining-welding (Arc , Spot)
 Surface treatment
 Inspection
 Testing