Non-Traditional Machining and

Automation
(MET 255)
B.Tech. (4th Sem) Spring 2021
Department of Mechanical Engineering
NIT Srinagar

Course Incharge
Dr. Noor Zaman Khan
Course Outcomes
At the end of the course, a student should be able to:

• CO1: Analyze and access the importance of automation and industrial automated systems.

• CO2: Identify and Analyze functions and functioning of CNC machines.

• CO3: Recognize the need of non-traditional machining processes and understand the working of high energy
beam machining.

• CO4: Illustrate underlying mechanisms in non-traditional machining processes along with their applications
Syllabus of Unit 1
• Introduction to automation

• Types of automation

• Introduction to Flexible manufacturing systems (FMS)

• Elements, types and advantages of FMS

• Cellular manufacturing

• Types of flexibilities in FMS

• Test of flexibility

• Product processing strategies

• Introduction to robotics

• Elements of Robotic Systems

 Tests of flexibility in an automated manufacturing system

1. Part variety test: Process different part styles in a nonbatch mode

2. Schedule change test: Accept changes in production schedule, and changes in either part
mix or production quantities
3. Error recovery test: Respond gracefully to equipment malfunctions and breakdowns in the
system.
4. New part test: Accommodate the introduction of new part designs

❑If the automated system does not meet at least the three tests, it should not be classified as an
FMS.
Types of Flexibility
• Machine flexibility: Capability to adapt a given machine (workstation) in the system to a wide
range of production operations and part styles.

• Production flexibility: The range of part styles that can be produced.

• Mix flexibility: Ability to change the product mix while maintaining the same total production
quantity.

• Product flexibility: Ease with which new products can be introduced.

• Routing flexibility: Capacity to produce parts through alternative workstation sequences in

response to equipment breakdowns.

• Volume flexibility: Ability to economically produce parts in high and low quantities.

• Expansion flexibility: Ease with which the system can be expanded to increase total production
Comparison of Four Criteria of Flexibility and types of flexibility

S. No. Flexibility Tests or Criteria Type of Flexibility

1 Part variety test Machine Flexibility
Production Flexibility

2 Schedule change test Mix Flexibility

Volume Flexibility
Expansion Flexibility

3 Error recovery test Routing Flexibility

4 New part test Product Flexibility

 Types of FMS
Number of machines
• Single machine cell
• Flexible manufacturing cell
• Flexible manufacturing system
Level of flexibility
• Dedicated FMS
• Random-order FMS
Single machine cell
• A single machine cell (SMC) consists of one CNC machining centre combined
with a parts storage system for unattended operation.

• When operated in a flexible mode, the system satisfies three of the four f1exibili1y
tests.

• It is capable of

(1) Processing different part styles,

(2) Responding to changes in production schedule,

(4) Accepting new part introductions.

Criterion (3), Error recovery, cannot be satisfied because if the single machine
breaks down, production stops.
 A flexible manufacturing cell (FMC)
• FMC consists of two or three processing workstations (typically CNC machining centers or
turning centers) and a part handling system.

• A flexible manufacturing cell satisfies the four flexibility tests.

• It is capable of

(1) Processing different part styles,

(2) Responding to changes in production schedule,

(3) Responding gracefully on breakdown

(4) Accepting new part introductions.

 A flexible manufacturing system (FMS)
• It has four or more processing workstations connected mechanically by a common part
handling system and electronically by a distributed computer system.
• Difference between FMC and FMS
• Number of machines: a FMC has two or three machines, while an FMS has four or
more.
• FMS generally includes non-processing workstations that support production but do not
directly participate in it.
• The computer control system of FMS is generally larger, often including functions not
always found in a cell.
• These additional functions are needed more in an FMS than in an FMC because the
FMS is more complex.
 Difference between CMS, FMC and FMS

Investment, FMS
Production
rate,
Annual FMC
volume

SMC

1 2 or 3 4 or more
Number of machines
Comparison of the SMC, FMC and FMS in terms of the four flexibility tests

Flexibility Criteria
System Part variety Schedule Error recovery New part
Type change
SMC Yes, sequential Yes Limited recovery due to only one Yes
processing machine
FMC Yes, Simultaneous Yes Error recovery limited by fewer Yes
production of machines than FMS
different parts
FMS do Yes Machine redundancy minimizes Yes
effect of machine breakdowns
Level of Flexibility: Dedicated FMS and Random-order FMS

Dedicated FMS
• A dedicated FMS is designed to produce a limited variety of part
styles, and the complete universe of parts to be made on the system is
known in advance.
• Instead of using general purpose machines, the machines can be
designed for the specific processes required to make the limited part
family, thus increasing the production rate of the system
Random-order FMS

• A random-order FMS is more appropriate when the part family is large, there are
substantial variations in part configurations, there will be new part designs
introduced into the system and engineering changes in parts currently produced,
and the production schedule is subject to change from day-to-day.

• The random order FMS is more flexible than the dedicated FMS.

• It is equipped with general-purpose machines to deal with the variations in product

and is capable of processing parts in various sequences (random-order).

• A more sophisticated computer control system is required for this FMS type.
 Difference between Dedicated and Random-order FMS
• In these two system types the trade-off
between flexibility and productivity.
Random
• The dedicated FMS is less flexible but more order
Flexibi
capable of higher production rates.
lity, FMS
• The random- order FMS is more flexible but Part Dedicated
at the price of lower production rates. variety
FMS
• A comparison of the features of these two
FMS types is presented in Figure.

Production rate, annual volume

Comparison of the dedicated FMS and random-order FMS in terms of the four
flexibility tests

Flexibility Criteria

System Type Part variety Schedule change Error recovery New part

Dedicated Limited, All parts Limited changes Limited by sequential No, new part
known in advance can be tolerated processes. introduction is
difficult
Random Yes, Simultaneous Frequent and Machine redundancy Yes, system
order production of significant changes minimizes effect of designed for new
different parts can be possible machine breakdowns part intriductions.
FMS COMPONENTS
• There are several basic components of an FMS:

(1)workstations,
• CNC machine tools, Assembly equipment, Inspection equipment, Washing stations
(1)material handling and storage system
• (Primary handling system, secondary system), Load/Unload stations, AGVS, AS/RS
(1)Control systems
• (workstation control, production control, Traffic control (primary), shuttle control
(secondary)
• Monitoring equipment, Networks
(1)Tool systems
• Tool setting stations, Tool transport systems
Benefits that can be expected from an FMS
• Increased machine utilization
• Fewer machines required (Because of higher machine utilization. fewer machines
are required)
• Reduction in factory floor space required
• Greater responsiveness to change
• Reduced inventory requirements
• Lower manufacturing lead times
• Reduced direct labor requirements and higher labor productivity
• Opportunity for unattended production
Thank You