Flexible 

Manufacturing System

Dr. Umesh Khandeyy
Department of Manufacturing Engg. 
NIFFT, Hatia, Ranchi
 What Is A Flexible Manufacturing 
System?
Flexible Manufacturing System:

A flexible manufacturing system (FMS) is a highly automated

Groupp Technology
gy ((GT)) machine cell,, consistingg of a ggroup
p of
processing workstations (usually CNC machine tools),
interconnected by an automated material handling and
storage system, and controlled by a distributed computer
system.
t

An FMS relies on the principles of group technology.

‐ “A system that consists of numerous programmable machine

tools connected byy an automated material handlingg system”
y

Dr. Umesh Khandey
 G
Group Technology or GT 
T h l GT
• Group Technology or GT is a manufacturing philosophy
in which the parts having similarities (Geometry,
manufacturing process and/or function) are grouped
t th to
together t achieve
hi hi h level
higher l l off integration
i t ti between
b t
the design and manufacturing functions of a firm.
• The group of similar parts is known as part family and
the group of machineries used to process an individual
part family is known as machine cell.
• Group technology emphasizes on part families based
on similarities in design attributes and manufacturing,
therefore GT contributes to the integration of CAD
(Computer Aided Design) and CAM (Computer Aided
Manufacturing). Dr. Umesh Khandey
 History of FMS
• FMS first proposed in England in 1960’s
• The concept is credited to David Williamson.a British
engineer employed by Molins during the mid‐l96Os. Molins
patented the invention (granted in 1965).
• “System
System 24
24” operates 24 hours a day
• Automation is main purpose in beginning.
• First FMS to be installed in the United States was a machiningg
system at Ingersoll‐ Rand Company in Roanoke, Virginia. in the
late 1960s by Sundstrand
• The
Th original
i i l conceptt included
i l d d computert control
t l off the
th NC
machines, a variety of parts being produced and tool
magazines holds the variety of tolls for different machining
operations
Dr. Umesh Khandey
 FMS is called flexible 
• The reason the FMS is called flexible is that it is capable of
processing a variety of different part styles simultaneously
at the various workstations,
workstations and the mix of part styles and
quantities of production can be adjusted in response to
changing demand patterns.

• The FMS is most suited for the mid‐variety, mid‐volume

production range.

Three capabilities that a manufacturing system must possess to

be flexible:
(I) The ability to identify and distinguish among the different
part or product styles processed by the system,
((II)) Quick changeover
g of operating
p g instructions,, and
(III) Quick changeover of physical setup.
Dr. Umesh Khandey
To qualify as being flexible, a manufacturing 
q y g , g
system should satisfy several criteria:
1. Part variety
i test. Can the
h system process different
d ff part
styles in a non‐batch mode?
2 Schedule change test.
2. test Can the system readily accept
changes in production schedule, and changes in either part
mix or production quantities?
3. Error recovery test. Can the system recover gracefully
from equipment malfunctions and breakdowns, so that
production is not completely disrupted?
4. New part test. Can new part designs be introduced into
the existing product mix with relative ease?

Dr. Umesh Khandey
Automated manufacturing cell with Two 
machine tools and robot Is it a flexible
machine tools and robot. Is it a flexible 
cell? Is the Robotic Work Cell Flexible?

Dr. Umesh Khandey
 Types of FMS
Types of FMS
FMS is designed
g for a specific
p application,
pp , that is a specific
p
family of parts and processes. Therefore each FMS is custom
engineered, each FMS is unique.

FMS can be distinguished according to the kind of

manufacturing operations they perform
1. Processing
P i operations
i
2. Assembly operations

FMS can also be classified by

1. Number of machines.
2 Level of Flexibility
2.
Dr. Umesh Khandey
 Types of FMS according to number of 
machines (workstations):
machines (workstations):
FMS can be distinguished according to the number of machines
in the system.
y The following
g are the typical
yp categories:
g

Single machine cell (SMC) consists of one CNC machining

center combined with a p
parts storage
g system
y for unattended
operation.

Flexible
lexible machine cell ((FMC)
C) co
consists
s sts o
of ttwo
ooor tthree
ee p
processing
ocess g
workstations (typically CNC machining or turning centers) plus
a part handling system. The part handling system is connected
to a load/unload station.
station

Flexible manufacturing system (FMS) has four or more

processing workstation
orkstation connection mechanically
mechanicall by
b a common
part handling systems and electronically by a distributed
computer system.
Dr. Umesh Khandey
• Single
Single‐Machine
Machine Manufacturing Cell(n = 1)
Manufacturing Cell(n = 1)

Dr. Umesh Khandey
• A single
A single‐machine
machine CNC machining cell
CNC machining cell

Dr. Umesh Khandey
• Flexible Manufacturing Cell (n = 2 or 3)
Flexible Manufacturing Cell (n = 2 or 3)

Dr. Umesh Khandey
• A two‐machine flexible manufacturing cell for 
machining (n = 2 or 3)
machining  (n = 2 or 3)

Dr. Umesh Khandey
• A five‐machine flexible manufacturing system 
for machining (n = 4 or more)
for machining (n  4 or more)

Dr. Umesh Khandey
Features of the Three Categories
Features of the Three Categories

Dr. Umesh Khandey
 FMS Types according to
Level of Flexibility
Level of Flexibility
1. Dedicated FMS

–Designed to produce a limited variety of part styles

–The
The complete universe of parts to be made on the system is known in advance
complete universe of parts to be made on the system is known in advance

–Part family likely based on product commonality rather than geometric similarity

2. Random‐order FMS

–Appropriate
Appropriate for large part families
for large part families

–New part designs will be introduced

–Production schedule is subject to daily changes
Dr. Umesh Khandey
 Dedicated vs. Random‐Order FMSs
There is a trade-off b/w the flexibility and productivity in the two types of system.

The dedicated FMS is less flexible but more capable of higher

production rates.
rates

The random order FMS is more flexible but at the proce of lower production rates.

Dr. Umesh Khandey
 Types of flexibility in Manufacturing
Types of flexibility in Manufacturing
1. Machine Flexibility. It is the capability to adapt a given machine in the system to
a wide range g of p production operations
p and p
part styles.
y The ggreater the range
g of
operations and part styles the greater will be the machine flexibility
2. Production Flexibility. It is the range of part styles that can be produced on the
systems.
3. Mix Flexibility. It is defined as the ability to change the product mix while
maintaining the same total production quantity that is, producing the same parts only
in different proportions. It is also known as process flexibility.
4 Product
4. Fle ibilit It refers
Prod ct Flexibility. f t ability
to bilit to
t change
h over tot a new sett off products
d t
economically and quickly in response to the changing market requirements.
5. Routing Flexibility. It can define as capacity to produce parts on alternative
workstation in case of equipment breakdowns, tool failure, and other interruptions at
any particular station.
6. Volume Flexibility. It is the ability of the system to vary the production volumes
of different products to accommodate changes in demand while remaining profitable.
7. Expansion Flexibility. It is defined as the ease with which the system can be
expanded to foster total production volume.
Dr. Umesh Khandey
 Five basic types of FMS layouts
Five basic types of FMS layouts
1.In‐line

2.Loop

3.Ladder

4.Open field

5.Robot‐centered cell

Dr. Umesh Khandey
 1.In line
1.In‐line
• Straight line flow, well-defined processing sequence
similar for all work units

• Work flow is from left to right

g through
g the same
workstations

• No secondary handling system

• Linear transfer system

y with secondary y pparts handling
g
system at each workstation to facilitate flow in two
directions

Dr. Umesh Khandey
 Figure: In‐line
Dr. Umesh Khandey
2.FMS Loop Layout
2.FMS Loop Layout

Dr. Umesh Khandey
 3.FMS Ladder Layout
Ladder Layout

Loop with rungs to allow

greater variation in
processingg sequence
p q

Dr. Umesh Khandey
 4.FMS Open 
p
Field Layout

Multiple loops and

ladders, suitable
for large part
families

Dr. Umesh Khandey
5.Robot‐Centered
5.Robot Centered Cell
Cell

Suited to the
handling of
rotational parts
and turning
operations

Dr. Umesh Khandey
 FMS Components can be categorized as:
FMS Components can be categorized as: 
1.Workstations

2 Material handling and storage system

2.Material handling and storage system

3.Computer control system
l

4.Human labor

Dr. Umesh Khandey
Following are the types of workstation typically found in
an FMS

¾ Load/Unload stations
¾ Machining
h Stations
¾ Other Processing Stations
¾ Assembly
¾ Other Stations and Equipment

Dr. Umesh Khandey
The second major component of an FMS is its material
handing and storage system.
system Function of the material
handling system are:
¾ Random, independent movement of work parts b/w

stations.
¾ Handle a variety of work part configurations

¾ Temporary
T storage
t
¾ Compatible with computer control

Dr. Umesh Khandey
Functions p
performed byy the FMS computer
p control system:
y
¾ Workstation control
¾ Distribution of control instruction to workstations
¾ Production control
¾ Traffic control
¾ Work piece monitoring
¾ Tool control - (a) Tool location (b) Tool life monitoring
¾ P f
Performance monitoring
i i and d reporting
i
¾ Diagnostics

Dr. Umesh Khandey
One additional components in the FMS is human labour.
labour
Humans are needed to manage the operations of the FMS.
Functions typically performed by humans include:
¾ Loading raw work parts into the system.
¾ Unloading finished parts (or assemblies) from the system.
¾ Changing and setting tools.
¾ Equipment maintenance and repair.
¾ NC partt programming
i ini a machining
hi i system.
t
¾ Programming and operating the computer system.
¾ Overall management of the system.
system

Dr. Umesh Khandey
 Components of Flexible 
Manufacturing Systems

• NC (Numerical control)
• Automated Inspection
• CNC (Computer
p numerical control)
• Cells and Centers
• DNC ‐(Direct numerical control)
• Robotics
• AGV‐ (automatic guided vehicles)
• ASRS (automated storage and retrieval systems)
(automated storage and retrieval systems)

Dr. Umesh Khandey
 Flexible Automation
• Ability to adapt to • Ability to accommodate
engineering changes in routing changes
parts
• Ability to rapidly change
• Increase in number of production set up
similar parts produced on
the system

Dr. Umesh Khandey
 Integration of FMS
Integration of FMS

FMS

Manufacturing 
CIM Robotics
Technology

Dr. Umesh Khandey
 Making FMS Work
– By implementing the components of robotics,
manufacturingg technology
gy and computer
p
integrated manufacturing in a correct order one
can achieve a successful System of Flexible
Manufacturing‐

Dr. Umesh Khandey
 Flexible Manufacturing Systems (FMS)

• Using automated Auto Tool

machines (DNC) & Chg.
materials handling Machine 1
equipment together
Robot
• Often
f connectedd to or AGV
centralized computer Computer
• Also
Al called
ll d automated
t t d
work cell Auto Tool
Chg.
Machine 2
Dr. Umesh Khandey
Dr. Umesh Khandey
 General
purpose
1000
Work cells
CIM
Products

Flexible
100 Manufacturing
System
FFocused
d
10 automation

Dedicated
automation
i
1
1 10 100 1000 10000 100000 1000000

Volume
l
Dr. Umesh Khandey
 FMS ‐ Pros & Cons
FMS  Pros & Cons
• Advantages
– Faster,
F t lower-cost
l t changes
h from
f one partt to
t another
th
– Lower direct labor costs
– Reduced inventory
– Consistent,
i andd perhaps
h better
b quality
li
• Disadvantages
– Limited abilityy to adapt
p to product
p or product
p mix changes
g
– Requires substantial preplanning and capital
expenditures
– Technological problems of exact component positioning and
precise timing
– Tooling and fixture requirements

Dr. Umesh Khandey
The benefits that can be expected from 
FMS include 
• Increased machine utilization
Increased machine utilization
• Fewer machines required
• Reduction in factory floor space required
• Reduction in factory floor space required
• Greater responsiveness to change
• Reduced inventory requirements
R d di t i t
• Lower manufacturing lead times
• Reduced direct labor requirements and higher 
labor productivity
• Opportunity for unattended production
Dr. Umesh Khandey
 Assignment ‐II
Assignment  II
Write about following issues and discuss:
Write about following issues and discuss:
• FMS planning and design issues.
• FMS operational issues.
S i li

Dr. Umesh Khandey
Thank You!
h k !

Dr. Umesh Khandey