M S RAMAIAH INSTITUTE OF

TECHNOLOGY
BANGALORE

SUBJECT SEMINAR
OF
FLEXIBLE MANUFACTURING SYSTEM
(IMS652)

UNIT 4 FMS SOFTWARE

FMS SOFTWARE
 FMS SOFTWARE IS AN INVISIBLE ELEMENT
AND IS THE ESSENTIAL GLUE THAT THE FMS
EQUIPMENT TOGETHER AND FORMS A
SYSTEM.
 FMS COMPUTER IS THE “HEART” OF FMS,
THEN FMS SOFTWARE IS IT’S “LIFE BLOOD”.
GENERAL STRUCTURE AND REQUIREMENT

 OPERATING SYSTEM :- IT IS A SET OF

CONTROLLED PROGRAM TO MANAGE THE
OVERALL FUNCTION OF THE HARDWARE.
IT CAN PROVIDE SUPERVISORY CONTROL
OVER THE APPLICATION SOFTWARE.
eg :- MS-DOS, UNIX, WIN98, 2000, XP,etc.
 APPLICATION SOFTWARE :- FOR FMS IT IS
COMPLEX, HIGHLY PROPRIETORY. IT IS
USUALLY DEVELOPED.
FUNCTION OF FMS SOFTWARE

 NC PART PROGRAM DOWNLOAD.

 TAFFIC AND MATERIAL-HANDELING
MANAGEMENT.
 WORK ORDER GENERATION.
 WORKPIECE SCHEDULING.
 SIMULATION & TOOL MANAGEMENT.
ADVANTAGES OF FMS SOFTWARE

 SEGMENTING THE REQUIRED SOFTWARE

INTO MODULES.
 IT ALLOWS PHASE INSTALLATION .
 EASIER TRACKING FOR ENHANCEMENT OR
MODIFICATION CHANGES.
PERMITS THE FUNCTIONS TO BE
PERFORMED
 OPERATIONAL DATA COLLECTION.
 SCHEDULING AND SIMULATION OF SYSTEM
ACTIVITIES.
 WORKPIECE LOAD BALANCING.
 REMORT DISTRIBUTION OF NC PROGRAM TO
MANUFACTURIN CONTROL UNITS.
 AUTOMATED TOOL AND WORKPIECE DELIVERY.
 MANAGEMENT OF FIXTURE, PALLET & TOOL
DATA.
PERMITS THE FUNCTIONS TO BE
PERFORMED
 ASSIGNMENT OF WORKPIECE
OPERATIONAL SEQUENCES.
 AUTOMATED WORKPIECE INSPECTION.
 SYSTEM CONTROL OF WORKPIECE ENTRY
AND EXIT.
 ERROR DIAGNOSTIC OUTPUT & DISPLAY
OF SYSTEM MAINTANENCE AND TROUBLE
SHOOTING.
REQUIREMENT OF FMS SOFTWARE

 COMPLETE INSTALLATION AND

FUNCTIONALITY OF ALL FMS COMPONENT AND
DATA LINE.
 COMPLETE AND PROVEN NC & CMM PART
PROGRAMS.
 ASSEMBLED AND PROVEN FIXTURES.
 AVAILABIE TOOLING MATERIAL.
 FIXTURE & PALLET ASSIGNMENT AND
IDENTIFICATION.
 COMPLETED WORK ORDER CREATION.
FUNCTIONAL DESCRIPTIONS
 FMS SOFTWARE PERFORM VARIETY OF
OPERATION THAT ARE INVOKED BY
COMMAND ENTERED BY AUTHORISED
SYSTEM USERS AT VARIOUS TERMINALS.
EXTENSIVE MONITORING AND REPORTING,
UPDATING OF A COMMON DATABASE ARE
DONE ON A REAL TIME BASIS BY VARIOUS
SENSING DEVICES.
DIFFERENT MODULES IN SOFTWARE

 WORK ORDER PROCESSING :-

THE PRIMARY FUNCTION OF THIS
SOFTWARE IS TO BE THE VEHICLE BY
WHICH VARIOUS WORKPIECE PRODUCTION
SCHEDULES AND PROCESSING SEQUENCE
ARE IMPLEMENTED, CONTROLLED AND
MANAGED WITHIN THE SYSTEM.
DIFFERENT MODULES IN SOFTWARE

 DATA DISTRIBUTIION AND COLLECTION :-

THE SOFTWARE WRITTEN FOR THIS MODULE IS
BASICALLY SENDS DATA TO AND RECEIVES FROM THE
MACHINE CONTROL UNIT.
 SYSTEM DIAGNOSTICS AND MAINTENANCE :-
THIS MODULE PROVIDES DIAGNOSTICS FOR
SCHEDULING AND UNSCHEDULING MAINTENANCE AND
TROUBLE SHOOTING OF SYSTEM COMPONENETS.
 TOOL MANAGEMENT :-
THE TOOL MANAGEMENT SOFTWARTE MODULES
RESPONSIBLE FOR STORING, MANAGING AND UPDATING
CUTTING TOOL DATA FILE.
DIFFERENT MODULES IN SOFTWARE

 TRAFFIC MANAGEMENT AND CONTROL :-

THE TRAFFIC MANAGEMENT AND CONTROL
FUNCTIONS,CONTROLS AND MONITORS THE
MOVEMENT OF TOOLS AND WORKPIECE
BETWEEN PROCESSING,PARKING AND LOAD-
UNLOAD STATION IN THE FMS.
 QUALITY CONTROL MANAGEMENT :-
IT PROVIDES THE CAPABILTY TO COLLECT,
STORE, RETRIEVE AND ACHIEVE WORKPIECE
INSPECTION DATA.
DIFFERENT MODULES IN SOFTWARE

 FIXTURE AND WORKPIECE CONTROL :-

IT WORKS WITHIN COJUNCTION WITH THE WORK
ORDER PROCESSING MODULE.
IT IS USED TO CONTROL THE STATUS OF ALL
FIXTURES AND PARTS KNOWN TO THE SYSTEM.
 PLANNING, SCHEDULING AND SIMULATION :-
THIS MODULE PROVIDES THE USER WITH THE
CAPABILITY TO DO PRODUCTION PLANNING AND
WORKPIECE SCHEDULING IN ADVANCE OF ACTUAL
DUE DATES AND TO STIMULATE THE RESULTS.
OPERARTIONAL OVERVIEW
 WORKPIECE ENTRY INTO AN FMS GENERALLY REQUIRES THE
FOLLOWING STEPS TO TAKE PLACE :-
1.SYTEM RESOURCE STARTS AND CHECK OUT,
2.VERIFY WORKPIECE AND MEASURING PART PROGRAM IDENTITY,
3.GROUP SIMILAR PROCESSING STATION,
4.ADD AND IDENTIFY REQUIRED PALLETS AND FIXTURES,
5.ASSIGN AND MATCH FIXTURES TO PALLETS,
6.ASSIGN REQUIRED TOOLING,
7.CREATE DETAIL PART WORK ORDER(ROUTING),
8.APPROVE AND AUTHORIZE THE WORK ORDER,
9.START WORK-ORDER PROCESSING(SYSTEM ENTRY),
10.STOP WORK-ORDER PROCESSING(SYSTEM EXIT).
COMPUTER SIMULATION
 SIMULATION IS A POWERFUL ANALYTICAL
SOFTWARE TOOL THAT IS USED TO MIMIC
THE BEHAVIOR OF A SYSTEM.
 SIMULATION MODEL MAINLY CLASSIFIED
INTO TWO TYPES :-
1.PHYSICAL
2.MATHEMATICAL
COMPUTER SIMULATION
 SIMULATION ANALYSIS IS PERFORMED BY THE
SYSTEM MANAGER ON THE FMS COMPUTER TO
DEVELOP MODEL AND EXAMINE ALTERNATIVES
IN ORDER TO :-
1.OPTIMIZE PRODUCTION SCHEDULE
2.MAXIMUM RESOURCE UTILIZATION
3.MULTIPLE PART PRODUCTION DUE DATES
4.INCREASE PRODUTION
5.BALANCE MACHINE LOAD
6.BALANCE TOOL REQUIREMENTS
PHASES OF A SIMULATION ANALYSIS

 VARIOUS PHASES OF AN SIMULATION

ANALYSIS ARE :-
PHASE1. PROBLEM FORMULATION AND
SETTING OF OBJECTIVE
PHASE2. MODEL BUIULDING AND DATA
COLLECTION
PHASE3. RUNNING A MODEL
PHASE4. IMPLEMENTATION
PHASE1. PROBLEM FORMULATION
AND SETTING OF OBJECTIVE
 FORMULATON :-
IT BEGINS WITH THE STATEMENT OF
PROBLEMS.THESE STATEMENTS ARE PROVIDE BY
THE POLICY MAKERS, THE ANLYST MUST ENSURE
THAT THE PROBABILITY DESCRIBED IS CLEARLY
UNDERSTOOD.
 SETTING OF OBJECTIVES :-
THE OBJECTIVES INDICATES THE QUESTION TO BE
ANSWERED BY THE SIMULATION AND WHAT
MEASUREMENTS TO BE TAKEN IN ORDER TO
ANSWER THOSE QUESTION.
PHASE2. MODEL BUIULDING AND
DATA COLLECTION
 MODEL CONCEPTUALIZATION :-
THE MODEL USER IS INVLOVED IN MODEL
CONCEPTUALIZATION FOR ENHANCE THE
QUALITY OF THE RESULTING MODEL AND
INCREASE THE CONFIDENCE OF THE MODEL USER
IN THE APPLICATION OF THE MODEL.
 DATA COLLECTION :-
DATA COLLECTION IS ONE OF THE BIGGEST TASK
IN SOLVING A REAL PROBLEM.IT IS ONE OF THE
MOST IMPORTANT AND DIFFICULT PROBLEM IN
SIMULATION.
PHASE2. MODEL BUIULDING AND DATA
COLLECTION

 MODEL TRANSLATION :-
THE MODEL MUST BE ENTERED INTO A COMPUTER
RECOGNIZABLE FORMAT.
 VERIFIED :-
IT CONCRENED WITH BUILDING THE MODEL RIGHT
.
 VALIDATED :-
VALIDATION IS ACHIVED THROUGH THE
CALIBRATION OF THE MODEL .THE PROCESS IS
REPEATED UNTIL MODEL ACCURACY IS ACHIEVED.
PHASE3. RUNNING A MODEL
 EXPERIMENTAL DESIGN :-
THE ALTERNATIVES THAT ARE TO BE
STIMULATED MUST BE DETERMINED.
 PRODUCTION RUNS :-
ESTIMATE MEASURES OF PERFORMANCE
FOR THE SYSTEM DESIGNS THAT ARE
BEING STIMULATED.
PHASE4. IMPLEMENTATION
 DOCUMENATATION :-
FROM VERY FIRST STEP TO THE FINAL STEP
THE IMPORTANT FACTORS WILL BE
DOCUMENTED AND WILL BE PRESERVED
AS REPORT FOR FURTHER PERSUAL.
 IMPLEMENTATION
HOST COMPUTER
 IT IS A COMPUTER CONNECTED TO ALL THE FMS
EQUIPMENT THROUGH VARIOUS NETWORK. IT CAN HOST
INFORMATION RESOURCES AS WELL AS APPLICATION
SOFTWARE FOR PROVIDING SERVICES.
 FUNCTION OF HOST COMPUTER :-
THE AREA CONTROLLER PLANS THE WORK TO GO INTO A
MANUFACTURING AREAS AVAILABLE CAPACITY AND MAY
EVEN PROVIDE THE TRANSPORT ORGANIZATION TO
PHYSICALLY ARRANGE THAT THE AREAS PRODUCTION
FACILITIES ARE PROVIDED WITH WORK.
THE DATA EXCHANGE CARRIED OUT IS TO UPDATE THE
FMS HOSTS WITH NEW DATABASE OR TO INFORM THE
CORPORATE COMPUTER OF THE STATUS OF THE FMS.
HOST COMPUTER
 THE DATA EXCHANGES ARE :-
* NC PROGRAM
* PRODUCTION ORDERS
* MASTER DATA
* SYATEM STATUS DATA
* WORK CALENDAR
* PROCESS ROUTINGS
QUESTION???