ME8691 Notes 006 6 Edubuzz360

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com
UNIT-5
 Types of Flexibility - FMS – FMS Components – FMS Application

& Benefits – FMS Planning and Control– Quantitative analysis in
FMS
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FMS
 FMS may be defined as “a highly automated GT machine cell,

consisting of a group of processing workstations (usually CNC
machine tools), interconnected by an automated material
handling and storage system, and controlled by a distributed
computer system.”
 FMS employs a fully integrated handling system with automated
processing stations.
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Flexibility and its Types
 Flexibility is an attribute that allows a manufacturing system to

cope up with a certain level of variations in part or product type,
without having any interruption in production due to
changeovers between models.
 Flexibility measures the ability to adopt “to a wide range of
possible environment”
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Tests of Flexibility
 Part variety test

 Schedule change test
 Error recovery test
 New part test
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Types of Flexibility
 Machine flexibility
 Production flexibility
 Mix (or Process) flexibility
 Product flexibility
 Routing flexibility
 Volume (or capacity) flexibility
 Expansion flexibility
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Machine flexibility
 Definition: Machine flexibility is the capability to adapt a given

machine in the system to a wide range of production operations
and part types.
 Influencing factors:
 Setup or change over time
 Ease with which part-programs can be downloaded to machines
 Tool storage capacity of machine
 Skill and versatility of workers in the systems
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Production flexibility
 Definition: Production flexibility is the range of part types that

can be produced by a manufacturing system.
 Machine flexibility of individual stations
 Range of machine flexibilities of all stations in the system
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Mix (or Process) flexibility
 Definition: Mix flexibility, also known as process flexibility, is

the ability to change the product mix while maintaining the
same production quantity. i.e., producing the same parts only in
different proportions
 Similarity of parts in the mix
 Relative work content times of parts produced
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Product flexibility
 Definition: Product flexibility is the ability to change over to a

new set of products economically and quickly in response to the
changing market requirements.
 Relatedness of new part design with the existing part family
 Off-line part program preparation
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Routing flexibility
 Definition: Routing flexibility is the capacity to produce parts on

alternative workstation in case of equipment breakdowns, tool
failure, and other interruptions at any particular station.
 Similarity of parts in the mix
 Similarity of workstations
 Common testing
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Volume (or capacity) flexibility
 Definition: Volume flexibility, also known as capacity flexibility,

is the ability of the system to vary the production volumes of
different products to accommodate changes in demand while
remaining profitable.
 Level of manual labour performing production
 Amount invested in capital equipment
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Expansion flexibility
 Definition: Expansion flexibility is the ease with which the

system can be expanded to foster total production volume.
 Cost incurred in adding new workstations and trained workers
 Easiness in expansion of layout
 Type of part handling system
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Four Tests of Flexibility Vs Seven Types of Flexibility
Sl No Flexibility Test Type of Flexibility
1 Part Variety  Machine

 Production
2 Schedule Change  Mix
 Volume
 Expansion
3 Error recovery  Routing
4 New part  Product
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Types of FMS
 Classification based on the kinds of operations they perform
Processing operation
Assembly operation
 Classification based on the number of machines in the system
Single machine cell (SMC)
Flexible machine cell (FMC)
Flexible manufacturing system (FMS)
 Classification based on the level of flexibility associated with the system
Dedicated FMS
 Random order FMS
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Classification based on the kinds of

operations they perform
 Processing operation
 Processing operation transforms a work material from one state to another
moving towards the final desired part or product.
 It adds value by changing the geometry, properties or appearance of the
starting materials.
 Assembly operation
 Assembly operation involves joining of two or more components to create a
new entity which is called an assembly.
 Permanent joining processes include welding, brazing, soldering, adhesive
banding, rivets, press fitting and expansion fits.
Classification based on the number
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of machines in the system

 Single Machine Cell (SMC)
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Flexible machine cell (FMC)
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Flexible manufacturing system (FMS)
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Classification based on the level of

flexibility associated with the system
Dedicated FMS
A dedicated FMS is designed to produce a limited variety of part
configurations.
Thus the dedicated FMS usually consists of special purpose machines
rather than general purpose machines.
Random order FMS
The random order FMS is equipped with general purpose machines so as
to meet the product variations. Also FMS type requires a more
sophisticated computer control system.
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Components/Elements of FMS
 Workstations
 Material handling and storage system
 Computer control system
 Human resources
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FMS Workstations
 The workstations/processing stations used in FMS depends upon the

type of product manufactured by the system.
 The types of workstations that are usually found in a FMS are:
 Load/unload stations
 Machining stations
 Assembly workstations
 Inspection station
 Other processing stations
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Material handling and storage system
 FMS material handling and storage system include part

transportation, raw material and final product transportation
and storage of workpieces, empty pallets, auxiliary materials,
wastes, fixtures and tools.
 Functions of the material handling system

 Types of FMS layout
 Types of handling equipment used in FMS
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Functions of the material handling

system
 Material handling may be defined as the functions and systems
associated with the transportation, storage, and physical control
to work-in-process material in manufacturing.
 The general purpose of material handling in a factory is to move
raw materials, work-in-process, finished parts, tools, and
supplies from one location to another to facilitate the overall
operations of manufacturing.
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Types of FMS layout Configurations
 In-line layout
 Loop layout
 Ladder layout
 Open-field layout
 Robot-centered cell
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In-line layout
 As the name suggests, the materials and handling systems are

arranged in a straight line in the in-line layout.
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Loop layout
 In the loop layout, the workstations are arranged in a loop, as

shown in figure.
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Ladder layout
 The ladder layout, an adaptation of the loop layout, consists of a

loop with rungs on which workstations are located.
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Open-field layout
 The open field layout, also an adaptation of the loop

configuration, consists of multiple loops, ladders and sliding
organized to achieve the desired processing requirements.
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Robot-centered cell
 In the robot-centered cell, one or more robots are used as the

material handling system.
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Types of handling equipment used in

FMS
 Primary Handling System
 Secondary Handling System
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Primary Handling System
 The primary handling system establishes the basic layout of the

FMS and is responsible for moving work parts between work
stations in the system.
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Secondary Handling System
 The secondary handling system consists of transfer devices,

automatic pallet changers, and similar mechanisms located at
the workstations in the FMS.
 The functions of the secondary handling systems are:
 To transfer work parts from the primary system to the machine
tool or other processing stations.
 To position the work parts with sufficient accuracy and
repeatability at the workstation for processing.
 To provide buffer storage of work parts at each workstation.
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Types of Material Handling

Equipment
 The material handling equipment commonly used to move parts
between stations can be grouped under six categories,
 Conveyors
 Cranes and hoists
 Industrial trucks
 Monorails and other rail guided vehicles
 Automated guided vehicles (AGVs) and
 Industrial robots.
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Computer control system
 In flexible manufacturing systems, computers are required to

control the automated and semi-automated equipment and to
participate in the over all coordination and management of the
manufacturing system.
 A typical FMS computer control system consists of a central
computer and micro computers controlling the individual
machines and other components.
Functions of a FMS computer control
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system
 Workstation/processing station control
 Distribution of control instructions to workstations
 Production control
 Material handling system control
 Workpiece monitoring
 Tool control
 Quality control
 Failure diagnosis
 Safety monitoring
 Performance monitoring and reporting
Structure of FMS Application software systems www.edubuzz360.com
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Types of FMS Data Files
 Part program file

 Routing file
 Part production file
 Pallet reference file
 Station tool file
 Tool life file
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Human Resources
 In FMS, human labours are needed to perform the following functions

 To load raw work parts into the system
 To unload finished work parts from the system
 For tool changing and tool setting
 For equipment maintenance and repair
 To program and operate the computer system
 To accomplish overall management of the system
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Example of Flexible
Manufacturing System
 FMS installed at Vought Aerospace in Dallas
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FMS Applications
 Machining
 Assembly
 Sheet-metal press working
 Forging
 Plastic injection moulding
 Welding
 Textile machinery manufacture
 Semiconductor component manufacture
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Economics of FMS
 5-20% reduction in personnel

 15-30% reduction in engineering design cost
 30-60% reduction in overall lead time
 30-60% reduction in work-in-process
 40-70% gain in overall production
 200-300% gain in capital equipment operating time
 200-500% gain in product quality
 300-500% gain in engineering productivity
Advantages of FMS
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(Benefits of FMS)
 Increased machine utilization
 Reduced inventory
 Reduced manufacturing lead time
 Greater flexibility in production scheduling
 Reduced direct labour cost
 Increased labour productivity
 Shorter response time
 Consistent quality
 Reduced factory floor space
 Reduced number of tools and machines required
 Improved product quality
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Disadvantages of FMS
 Very high capital investment is required to implement a FMS

 Acquiring, training and maintaining the knowledgeable labour
pool requires heavy investment
 Fixtures can sometimes cost much more with FMS, and software
development costs could be as much as 12-20% of the total
expense
 Tool performance and condition monitoring can also be
expensive since tool variety could undermine efficiency
 Complex design estimating methodology requires optimizing
the degree of flexibility and finding a trade off between
flexibility and specialization
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FMS Planning and Control

(FMS Planning and Implementation
issues)
 FMS planning and design issues
 FMS control (or operational) issues
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FMS Planning issues
 Part family considerations

 Processing requirements
 Physical characteristics of the work parts
 Production volume
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FMS design issues
 Type of work stations

 Variations in process routings and FMS layout
 Material handling system
 Work-in-process and storage capacity
 Tooling
 Pallet fixtures
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FMS operational issues
 Scheduling and dispatching

 Machine loading
 Part routing
 Part grouping
 Tool management
 Pallet and fixture allocation
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Quantitative analysis of Flexible

Manufacturing System
 Flexible manufacturing system can be analysed using different
models. The four different categories of FMS analysis models
are:
 Deterministic models- Complex models,Bottleneck model
 Queuing models - Mathematics theory ,Simple system
 Discrete event simulation -Simulation Model
 Other techniques – OR Techniques
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Bottleneck model
 The bottleneck model is a simple and intuitive approach to

determine the starting estimates of FMS design parameters such
as production rate, capacity and utilization.
Terminology and symbols
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FMS operational Parameters
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System Performance Measures
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ME8691 Notes 006 6 Edubuzz360

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ME8691 Notes 006 6 Edubuzz360

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www.edubuzz360.

 Types of Flexibility - FMS – FMS Components – FMS Application

 FMS may be defined as “a highly automated GT machine cell,

Flexibility and its Types

 Flexibility is an attribute that allows a manufacturing system to

 Part variety test

 Definition: Machine flexibility is the capability to adapt a given

 Definition: Production flexibility is the range of part types that

Mix (or Process) flexibility

 Definition: Mix flexibility, also known as process flexibility, is

 Definition: Product flexibility is the ability to change over to a

 Definition: Routing flexibility is the capacity to produce parts on

Volume (or capacity) flexibility

 Definition: Volume flexibility, also known as capacity flexibility,

 Definition: Expansion flexibility is the ease with which the

Sl No Flexibility Test Type of Flexibility

1 Part Variety  Machine

4 New part  Product

Classification based on the kinds of

of machines in the system

Flexible machine cell (FMC)

Classification based on the level of

 The workstations/processing stations used in FMS depends upon the

Material handling and storage system

 FMS material handling and storage system include part

 Functions of the material handling system

Functions of the material handling

Types of FMS layout Configurations

 As the name suggests, the materials and handling systems are

 In the loop layout, the workstations are arranged in a loop, as

 The ladder layout, an adaptation of the loop layout, consists of a

 The open field layout, also an adaptation of the loop

 In the robot-centered cell, one or more robots are used as the

Types of handling equipment used in

Primary Handling System

 The primary handling system establishes the basic layout of the

Secondary Handling System

 The secondary handling system consists of transfer devices,

Types of Material Handling

Computer control system

 In flexible manufacturing systems, computers are required to

Types of FMS Data Files

 Part program file

 In FMS, human labours are needed to perform the following functions

 FMS installed at Vought Aerospace in Dallas

 5-20% reduction in personnel

 Very high capital investment is required to implement a FMS

FMS Planning and Control

FMS Planning issues

 Part family considerations

FMS design issues

 Type of work stations

FMS operational issues

 Scheduling and dispatching

Quantitative analysis of Flexible

 The bottleneck model is a simple and intuitive approach to

FMS operational Parameters

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