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Ch8 FMS
Ch8 FMS
(FMS) by Ed Red
an automated, mid-volume, mid-variety, central computer-controlled manufacturing system Nanua Singh, Computer-Integrated Design and Manufacturing, John Wiley & Sons, 1996
References: 1. Nanua Singh, Computer-Integrated Design and Manufacturing, John Wiley & Sons, 1996 2. Mikell Groover, Automated Production Systems and Computer-Integrated Manufacturing, Prentice-Hall, 2nd edition, 2001
ME 482 - Manufacturing Systems
Objectives
To review modern flexible manufacturing systems (FMS): - Group technology (GT) - Manufacturing cells - Automated part handling equipment (AGVs, etc.) - Control software - Analysis models To consider application conditions (student presentations) To test understanding of the material presented
FMS characteristics
A manufacturing cell used to implement group technology (GT) robotsmachine tools Independent machines performing multiple operations and having automated tool interchange capabilities Automated material-handling between stations (move parts between machines and fixturing stations) Hierarchical computer control architectures Often include CMM, inspection and part washing devices
ME 482 - Manufacturing Systems
GT requirement:
Parts can be grouped into part families!
Similar manufacturing process requirements (manufacturing attributes), but with different design attributes
Turned, drilled, milled..
GT example
For the part shown determine the form code in the Opitz parts classification and coding system.. Solution: With reference to Figure 15.6, the five-digit code is developed as follows: Length-to-diameter ratio, L/D = 1.5 External shape: stepped on both ends with screw thread on one end Internal shape: part contains a through-hole Plane surface machining: none Auxiliary holes, gear teeth, etc.: none The partss form code in the Opitz system is ME 482 - Manufacturing Systems Digit 1 = 1 Digit 2 = 5 Digit 3 = 1 Digit 4 = O Digit 5 = O
15100
FMS
Highly automated GT manufacturing cell, consisting of a group of processing workstations, interconnected by an automated material handling and storage system, and controlled by a distributed computer system (Groover defn) What does flexible mean? 1. Can identify and operate on different part/product styles 2. Quick changeover of process/operating instructions 3. Quick changeover of physical setup FMS operations: 1. Processing operations, or 2. Assembly operations
ME 482 - Manufacturing Systems
Single machine
3.
Loop layout
FMS layouts
1. In-line layout
3. Material handling system 4. Work in process (WIP) and storage capacity (FMS storage
capacity must be compatible with WIP)
5. Tooling (numbers and types of tools at each station, tool duplication) 6. Workpiece monitoring (status of various systems)
4. Part grouping
5. Tool management 6. Pallet and fixture allocation
ME 482 - Manufacturing Systems
2. Queueing models
3. Discrete event Discrete event simulation Used to model manufacturing cell simulation (simulation) 4. Heuristic
or material handling system, as events occur at discrete approachesin time and affect the status and performance of the moments system, e.g., parts arriving at the machine.
Li = Sj Sk tijk fijk pj
Workload of the handling system is the mean transport time (tn+1) multiplied by the average number of transports to complete part process. Average number of transports (nt) is the mean number of operations in the process routing minus 1:
nt = Si Sj Sk fijkpj 1
Workload of handling system is Ln+1 = nt tn+1
ME 482 - Manufacturing Systems
difficult interpretation!
Load
Unload
U = Si Ui/(n+1)
The overall FMS utilization is weighted by the number of servers at each station (not including handling stations)
Us = Si siUi/ Si si Number of busy servers at other than the bottleneck station determined from
Bi = Rmax Li
ME 482 - Manufacturing Systems
nt = (4.5 - 1)(0.1) + (5.2 - 1)(0.2) + (3.5 -1)(0.3) + (3.333 - 1)(0.4) = 2.783 L5 = (2.873)(3.5) = 10.06 min. part handling station!
Now calculate Li/si to identify bottleneck: L1/s1 = 6.0/1 = 6.0 L2/s2 = 19.0/3 = 6.333 L3/s3 = 14.4/2 = 7.2 the bottleneck! Rmax = 2/14.4 = 0.1389 pc/min. (8.333 pc/hr) L4/s4 = 4.0/1 = 4.0 L5/s5 = 10.06/2 = 5.03
ME 482 - Manufacturing Systems
Overall FMS utilization (exclude part handling): U1 = [1(0.833) + 3(0.879) + 2(1.0) + 1(0.555)]/7= 0.861 ME 482 - Manufacturing Systems
(86.1%)
(m = 1,.....M)
(j = 1,.......Jk)
ckjm = unit processing cost to perform jth operation on kth part on mth machine; else, set the cost to infinity (set high) tkjm = unit processing time to perform jth operation on kth part on mth machine; else, set the time to infinity (set high)
ME 482 - Manufacturing Systems
Assume operations can be performed on alternative machines. Part can be manufactured along a number of routes. For example, if a part has three operations and if the first, second, and third operations can be performed as: - operation 1 on two machines - operation 2 on three machines - operation 3 on two machines
then a set of alternative process plans (l L, where L is the total number of alternative plans) would include 2 x 3 x 2 = 12 possible processing routes. Define akljm = 1 if in plan l the jth operation on the kth part is performed on the mth machine; else, set the factor to 0
ME 482 - Manufacturing Systems
where Z1 is the objective function and Xkl is a decision variable representing the number of units of part k to be processed using plan l. Constraints: Demand for parts must be met: Can not exceed machine capacity:
Sl Xkl
dk
"k bm "m
" k, l
Sl Xkl
dk
"k bm "m
" k, l
"m
Sl Xkl
dk
"k bm "m
" k, l
FMS