ANSWER KEY

K.S.RANGASAMYCOLLEGE OF TECHNOLOGY, TIRUCHENGODE – 637 215

MECH
(An Autonomous Institution, Affiliated to Anna University, Chennai)

PROGRAMME / BRANCH BE / MECHANICAL ENGINEERING VII SEMESTER 100 MARKS

40 ME E21 & FLEXIBLE MANUFACTURING
COURSE CODE & NAME DURATION 3 HOURS
SYSTEM
1. a) Identify any four functions of the material handling systems in FMS. 4
(i) Random and independent movement of work parts between workstations
(ii) Handling of a variety of work part configurations
(iii) Temporary storage
(iv) Convenient access for loading and unloading of work parts
(v) Compatible with computer control
b) Differentiate between primary and secondary material handling systems. 4
A. The primary work handling system - used to move parts between machine tools in the CIMS.
It should meet the following requirements.
i). Compatibility with computer control
ii). Provide random, independent movement of palletized work parts between machine tools.
iii). Permit temporary storage or banking of work parts.
iv). Allow access to the machine tools for maintenance tool changing & so on.
v). Interface with the secondary work handling system
B. The secondary work handling system - used to present parts to the individual machine tools
in the CIMS.
i). Same as A (i).
ii). Same as A (iii)
iii). Interface with the primary work handling system
iv). Provide for parts orientation & location at each workstation for processing.
c) Explain different types of flexibility in manufacturing in FMS concept. 12
There are three levels of manufacturing flexibility.
(a) Basic flexibilities
Machine flexibility: The ease with which a machine can process various operations
Material handling flexibility: A measure of the ease with which different part types can be transported
and properly positioned at the various machine tools in a system
Operation flexibility: A measure of the ease with which alternative operation sequences can be used for
processing a part type
(b) System flexibilities
Volume flexibility: A measure of a system’s capability to be operated profitably at different volumes of
the existing part types
Expansion flexibility: The ability to build a system and expand it incrementally
Routing flexibility: A measure of the alternative paths that a part can effectively follow through a
system for a given process plan
Process flexibility: A measure of the volume of the set of part types that a system can produce without
incurring any setup
Product flexibility: The volume of the set of part types that can be manufactured in a system with minor
setup
(c) Aggregate flexibilities
Program flexibility: The ability of a system to run for reasonably long periods without external
intervention
Production flexibility: The volume of the set of part types that a system can produce without major
investment in capital equipment
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 Market flexibility: The ability of a system to efficiently adapt to changing market conditions
a) What are the capabilities of computer control? 2
(i) Control of each work station
(ii) Distribution of control instruction to work station
(iii) Production control
(vi) Traffic control
(v) Shuttle control
(vi) Work handling system and monitoring
(vii) System performance monitoring and reporting
b) What are the steps involved in computer aided process planning? 6
Approaches to Process planning
1. Manual approach
2. Variant or retrieval type CAPP system
3. Generative CAPP system

2.

c) What are the characteristics of networks for communication in manufacturing 12

environments?
 Management of resources
 Storage, preparation and transport of raw workpieces and finished components
 Acquisition, processing and evaluation of production data
 Inspection of workpieces and continuously monitoring the performance of production
equipment
 Testing of products
 Developing software to control all the above operations.
In such a process of integrated automation it is necessary to combine a number of
machines, both mechanically and in terms of data processing into a closely linked
manufacturing unit. In this way, highly automated manufacturing units (cells) are created which
are capable of handling a number of different workpieces without interruptions due to
operations like setting up workpieces, tool change, inspection etc.
Monitoring and process correction facilities through appropriate sensors are also part of
the system so that operator intervention is kept to a bare minimum. Manufacturing cells
normally contain 1 to 4 production machines. In addition to various “service machines” such as
measuring machines and washing machines) and transport systems like automated guided
vehicles, rail guided vehicles and conveyors for the workpieces and for the tools. The cell
computer simultaneously controls the manufacturing operations within the manufacturing cell.
a) What is the importance of databases in FMS? 2
 Data management system is needed for data access within the company
3.
 It is needed to maintain strong relationships between data
 This system allows newer and better updates
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  It helps brand managers to search data in better manner
b) Describe the mathematical programming formulation for GT in FMS. 4

c) Discuss the languages for the simulation of FMS and the selection of simulation software. 14

Some popular software used in the manufacturing industry includes:

 AnyLogic: Its main feature is that it supports system dynamics, discrete event and agent
based methodologies. It is used in manufacturing, supply chain and logistics among other areas.
 Arena (software): a popular discrete event simulator used by many large companies.
 Flexsim: a discrete event manufacturing simulation software. It is used in fields such as
production assembly lines, logistics and transportation.
 Plant Simulation: computer application especially design for production systems and
logistic operations.
 Simio: a user-friendly, object orientated discrete event simulation software that allows
to rapidly build 3D animated models.
 Visual Components: is a family of 5 products used to efficiently design factories. Among
these products is 3D Simulate, which allows collecting and analysing data about a
production line's performance.
Selection Components
 State
 Clock
 Events list
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  Ending condition
a) What is machine tool in FMS system? 2
A Design of a general system to handle and control tools for a FMS is presented. The system
involves a broad spectrum of functions including:
 Selection of suppliers
 Tool- crib management
 Control of the tool delivery system
 Tool wear
b) How FMS classified does based on level of flexibility? 6
a. Dedicated FMS.
It is made to produce a certain variety of part styles. The product design is considered
fixed. So, the system can be designed with a certain amount of process specialization to make
the operation more efficient.”
b. Random order FMS.
It is able to handle the substantial variations in part configurations. To accommodate
these variations, a random order FMS must be more flexible than the dedicated FMS.
c) Define group technology. Explain Optiz coding system generally used in group technology. 12
Group Technology Defined
 An approach to manufacturing in which similar parts are identified and grouped
together in order to take advantage of their similarities in design and production
 Similarities among parts permit them to be classified into part families
 In each part family, processing steps are similar
 The improvement is typically achieved by organizing the production facilities into
manufacturing cells that specialize in production of certain part families
The Optiz coding is most likely the best-known coding system. It was developed by H.
4. optiz of the Aachen Tech University in West Germany. The code uses a hybrid structure.
However, except the first digit, it resembles a chain structure more closely. It has following
advantages over the existing system
 It is non-proprietary.
 It is widely used.
 It provides a basic framework for understanding the classification and coding process.
 It can be applied to machined parts, non-machined parts, and purchased parts.
 It considers both design and manufacturing information.

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 a) What is the scope for FMS in manufacturing today? 2
 Reliable FMS protocol
 FMS Communications
b) Explain how expert system enhances the performance of FMS. 4
An expert system is a computer program which contains the expertise required to solve a
specific, domain-related problem. The expertise to solve a problem depends on the available
knowledge. Hayes-Roth et al. (1983) define knowledge as "public" and "private," which
indicate, respectively, published literature or individual expertise. The ability of an individual
expert lies in the capacity to analyze problems both in the exact and inexact realms. Expert
systems try to capture the essence of the expertise, both public and private, related to a problem
domain and use it for problem solving and explanation.

5.

c) What is the design philosophy for the FMS of the future? Discuss in detail. 14
General System Design and Specifications
Guidelines for system design and specifications are described for the purpose of simulation
model development.
 Size of FMS
 Job Arrival
 Size of the batch
 Number of part types
 Transportation/Material Handling Systems
 Buffer Limitations/Storage Capacity
 Number of Operations and Processing Time
 Scheduling Period
 Measure of System Performance
 Other Factors
a) Define scheduling. 2
Scheduling is a method of totalling start and finish time data to the job sequencing
dictated in the sequencing process. Sequencing process in turn, is defined as getting the order in
which jobs are processed on a machine.
b) Distinguish between infinite and finite scheduling. 6
Infinite - assumes infinite capacity
6.
– Loads without regard to capacity, levels the load and sequence jobs
– Job shop/batch production
Finite - assumes finite (limited) capacity
– Sequences jobs as part of the loading decision, resources are never loaded beyond
capacity
– Flow shop/continuous production
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c) Explain with sketch of FMS layout configurations 12
(i) Inline Layout

(ii) Loop Layout

(iii) Ladder Layout

Ladder type layout consists of rungs on which workstations are located. This reduces the
average travel distance thereby reducing the transfer time between workstations.

(iv) Open Field Layout

The open field layout is also an adoption of the loop configuration. The open field layout
consists of loops and ladders organized to achieve the desired processing requirements. This is
used for the processing of a large family of parts. The number of different machines may be
limited.

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PREPARED BY HOD/MECH
(RAMESH C)

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