Government College of Engineering, Chandrapur

EXPERIMENT NO : 07

AIM : Stucty of Flexible M;rnrifacti-rring Systern.

INTRODUCTION:

A flexible manufacturing syslern (FMS) is a highly automated GT machine cell, consists

of a group of processing '"vorkstations (usually CNC m/c toolsJ, interconnecteci bv an
automated material handling and storage system, and controlled by a distributed computer
system. The reason, the FMS is called flexible is that it is capable of processing a variety of
different part style simultaneously at the various workstation , & 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.
The initials FMS are sonietime used to denote the term flexible manufacturing
system. The machining process is presentlythe largestapplication area for FMS technologv.
However, it seems appropriate to interpret FMS in its broader meaning, allowing, for a rvide
range of possible applications beyond machining.
An FMS relies on the principles of group technology. No manufacturing systern can
be cornpletely flexible. There are limits to the range of parts or products that can be made in
an FMS. Accordingly , an FMS is designed to produce parts I or products) within a defined
range of styles, sizes and processes. In other words, FMS is capable of producing a single part
family or a limited range of part families.

Types Of FMS :

1l Single machine cell

It consists of one CNC machining center combined with a parts storage system for unattended
operation. Completed parts are periodically unloaded from the parts storage unit, and raw
work parts are loaded into it. The cell can be designed to operate either in a batch mode or a
flexible mode or a combination of two.

2J Flexible manufacturing cell

It consists of two or three processing worktations plus a part handling system.
The part handling system is connected to load/unload station.

3) Flexible manufacturing system

It has four or more processing workstations connected mechanically by a common part
handling system and electronically by a distributed computer system. Thus an important
distinction between an FMS and an FMC in the number of machines.

Subject: - Automation In Production D ep a rtm ent of M ech ani cal Eng in e ering Poge 43
 Governrnent College of Engineering, Chandrapur

FMS Layout configuration :

a *maSdrrdigflatdirne 6[etar,, we|,|b&fdndd pmreeri,ng $roefuhtrrrc similar for

configuration fou nd
iiri f1ifd ftyf,Anl
1) In line layout-o
W{Of k f I o].v is, from left to rieht, throueh,Ihe same workstations
I ne tnacnlne an o nanolillg system are arraTlged tn stratgfit line. ln lts strnplest
form on worksta*on$^d%tebftAlbVrytt#ftrypHnBSy*et$ work always moving in one
direction and no back flow.

Fartially completed
Pa rt tta n.:qo o rt s"sterTl

@@ tB Sr €41-+
->&
,Startin.g Cornpleted
workparis parh

' straight line flow, well-defined processing sequence similar for all work units

" Work flow is from left to right through the same workstaiions

" No secondary handling s)rstem

Completed parts
<- @@g@
: Shuttle cart
Fi'rma4, line
--+ @ts6 Work flov,,
.ts---+
Starting
*'oikparts
5lecondarl.'
hancilirrg
sl.'-rtern

" Linear transfer system rvith seconCary pafis handling system at each
workstation to facilitate flow in two directions

Subject: - Automation In Production Department of Mechanical Engineering Page 44

 ,::rc-.'..9o.',"1.nnlenrCollegeofEngineering,Chandrapur

2] Loop iaycu'i -
I'iie workstation are organized in a ioop with rungs by part handling system in the
same shape part usualiy flow in the one direction around the loop with capabilities to stop and ile
translerred to any station.

Camplete,J Pirrls tralsp,:r I

r1.rfd
t^^-

<-$rlflrS Directir:n,:l
:+-@&@@ rvork flor,,,
Starting
workparls

0ne direction flow, but variations in processing sequence possible for different part
types

' Secondary handling system at each workstation

--+Bffigs @S€ ---+

Startirg Con:pleted
workparts parts
turni4g paiiets

! Rectangular layout allows recirculation of pallets back to the first station in the
sequence after unloading at the final station

Subject: - Automation In Production D ep artment of M ec h an i cal E ng in eering Page 45

 Government College of Engineering, Chandrapur

3J L,adcier layout -
It consists of a ioop with rungs betrveen the straight section ot '.he loop on
which workstations are located. The rungs increases the rvays of getting from cne machine to
ihe next and o'bviate neeri of secondary handlirig q,,stem"

@ww& BB@@ -a-

-*- workpaits
Startirrg Coropleted
parts

" Loop w,ith rungs to allorv greater variaiion in processing sequence

Subject: - Automation In Production D e partment of M ech an i cal E ng i n eer ing Page 46

 Government Co llege of En gin eering, (.h a rr d r-ap ur'

.1) Open lield layout -

It consists of multiple loop and ladders and many include slicking as ivell. This
layout is generally appropriate ior processing as large iamily of parts.

Completed
parts
+- &@B
-*-> @@&
Starting
rvorkparts

AGV guidepath

' Multiple loops and ladders, suitable for large part families

Subject: - Autamation In Production D ep artment of Mech ani cal Eng i ne er i ng Page 47

 Government College of Engineering Chandrapur

5J Rob0t cente|ed cell -

It uses one or more robcis as a material handling system. indus,rrial robots can
be equipped with the gripper that makes the nrell suited for the hanciing ol rotational part and
robot centerei FMS layout are ofien usei io process cylindrical and disk shaped parts.

Robot

h,Iachirre wcrktabie h,{at}rirre toi,1

pai|s C;rrclr;,g*l

' Suited to the handling of rotational pafts and turning operations

Subject: - Automation In Production D epqrtment of Mechanical Eng i neer i ng Page 48

 Government College of Engineering, Chanrir apur

Advantages of FMS:
f . increase machine utilization.
2. Ferver machine required.
3. Reduction in factory floor space requirei.
4. Greater responsiveness to change.
5. Red uced inventory requirernents.
6. Lower manufacturing iead times,
7. Reduced direct labour requiremenrs & higher labour productivity.
B. 0pportuniB/ for unattended produciion.

Study of FMS setup in the Lab:

The FIt4S setup in the lab can be classified as a Flexible Manufacturing Celland the layout is an
inline layout. The setup consists of a CNC trainer lathe machine, a CNC trainer milling
machine, a robot arm and an automated storage and retrieval system with a linear shuttle
conveyor. The details of the individual equipment in the setup are covered in the preceding
experiments. The complete setup in this case now operates through a central controller called
the Cell Controller. All the communication with the individual controllers is through the cell
controller. Various G codes and N'l codes are used to synchronize the perforrnance of
individual equipment with the others in the setup.

CONCLUSION:

Subject: - Automation In Production De partment of Mechanicol Engineering Page 49