5

Contents
5.1 Introduction ....................................................................................................................................... 5.2

5.2 Components of FMS ......................................................................................................................... 5.5
5.3 Cellular Manufacturing versus Flexible Manufacturing .................................................................. 5.6
5.4 Types of FMS Systems ..................................................................................................................... 5.8
5.5 Advantages of FMS ......................................................................................................................... 5.10
5.6 Tool Management System ............................................................................................................. 5.10
5.7 Flexibility in FMS.............................................................................................................................. 5.12
5.8 FMS Layouts .................................................................................................................................... 5.13
5.9 Automated Guided Vehicle (AGV) .................................................................................................. 5.15
5.10 Automated Storage and Retrieval System (AS/RS) ...................................................................... 5.21
5.11 Workpiece Handling System .......................................................................................................... 5.24
5.12 Flexible Fixturing ............................................................................................................................. 5.25
5.1 Introduction
The use of CNC machine tools provides flexibility in terms of the low job changing time. However, the full
benefits of automation cannot be achieved simply by the use of the CNC machine tool alone. The complete
job-making process involves the use of machine tools along with all the associated equipment being made
available at the right time.
The associated equipment involves the cutting tool, workpiece blank, part program, tool offsets, and the
like. As a result, effective CNC machine utilization can be achieved if all these are integrated. Some typical
figures for machine utilization based on the general trend in the industries are given in Table 5.1.
Table 5.1 - Machine utilization based on the general trend in the industries
Automation Machine Utilization
Basic CNC: Manual tool and work loading. 40%
Basic CNC with automatic work holding and workpiece storage, manual loading. 60%
Complete machine automation: Automatic work and tool handling, tool 75%
monitoring, workpiece inspection, work and tool storage.
Integration of group machines similar to that shown in the third type. 80%
Flexible Manufacturing System: Automated Workpiece Movement between 90%

machines.
Thus it can be seen that the full utilization (90% with the rest allocated for maintenance) can be achieved
in FMS by properly integrating all the required functions. A large number of definitions have been provided
for FMS as follows:
"A series of automatic tools or items of fabrication equipment linked together with an automatic material
handling system, a common hierarchical digital preprogrammed computer control, and provision for
random fabrication of parts or assemblies that fall within predetermined families."
"An FMS group of NC machine tools that can randomly process a group of parts, having automated
material handling and central computer control to dynamically balance resource utilization so that the
system can adapt automatically to changes in part production, mixes, and levels of output."
"FMS is a randomly loaded automated system based on group technology manufacturing linking
integrated computer control and a group of machines to automatically produce and handle parts for
continuous serial processing."
"FMS combines microelectronics and mechanical engineering to bring the economies of scale to batch
work. A central online computer controls the machine tools, other workstations, and the transfer of
components and tooling. The computer also provides monitoring and information control. This
combination of flexibility and overall control makes possible the production of a wide range of products
in small numbers."
"A process under control to produce varieties of components or products within its stated capability and
to a predetermined schedule."
"A technology which will help achieve leaner factories with better response times, lower unit costs, and
higher quality under an improved level of management and capital control."
Prof. Sunil G. Janiyani, Department of Mechanical Engineering

5.2 Computer Aided Manufacturing (3161917) |
Unit-5 Flexible Manufacturing System
Thus it can be seen that a true FMS can handle a wide variety of dissimilar parts, producing them in small
numbers even one at a time, in any order, as needed by making use of all the computer-controlled
equipment (workstations and material handling) with the help of central computer control of all the
equipment within.
Typical costs associated with various types of manufacturing systems are shown in Table 5.2.
Table 5.2 - Costs associated with various types of manufacturing systems
Costs Small Scale Medium Scale Small Scale

(Standalone Machine Tools) (FMS) (Transfer Lines)
Direct labor 43.7 24.7 19.7
Overhead 13.5 13.9 23.7
Capital 17.8 33.1 29.8
Other Costs 25 28.3 26.8
Total 100 100 100
5.1.1 Need of FMS

The key objective in manufacturing is to get the right raw materials or parts to the right machines at the
right time. Too much or too soon creates backed-up excess in-process inventory. Too little or too late
causes delayed work schedules and idle machines. The result in many cases is a poor use of capital, in
the form of excess in-process inventory and/or underutilization of equipment.
Fig.5.1 - Breakdown of 8760 available hours in a calendar year to manufacturing operation
In any single calendar year, there are 8760 hours available to the manufacturing operation, as can be seen
in Fig.5.1. Statistics have shown that about 44 percent of the total time available is lost due to incomplete
use of second and third shifts.
The skilled, experienced people required to operate and set up machines are either not available or
disinterested in working "unsocial" hours, and the problem is going to get worse.
Computer Aided Manufacturing (3161917) | 5.3
The long-term trend is firmly established that a declining percentage of people entering the workforce will
choose careers in manufacturing.
Thirty-four percent of the total time is lost due to vacations and holidays. Twelve percent is lost while
machines are being set up for the next operation or parts are being loaded or unloaded. About 4 percent
of the time is lost due to process difficulties or unforeseen material, tooling, or quality-control problems.
This leaves only 6 percent of the total time for actual production. The batch manufacturer's capital
investment for equipment and facilities is working, trying to pay for itself, less than one hour in seventeen.
Fig.5.2 - Breakdown of the time spent by an average part in the shop
Similar studies indicate that in a typical manufacturing operation a part moving through a metal-cutting
operation would be on an individual machine tool only 5 percent of its total time in manufacturing, as
depicted in Fig.5.2.
And, when a part is on a particular metal-cutting machine tool, only 1.5 to 2 percent of the part's total
manufacturing time is a cutter in the work, actually performing work and adding value. The other 95
percent of the time the part is either moving through the shop or waiting in queue for the next operation.
These examples indicate the underutilization of equipment and gross inefficiencies existing in a vast
majority of manufacturing industries.
5.1.2 General FMS Considerations

Many manufacturing industries are currently dedicated to manual and conventional production methods
or high-speed fixed automation by their very nature not very flexible or responsive. And many are ill-suited
to accommodate faster product and process changes in an increasingly globalized and competitive
marketplace.
Flexible manufacturing allows users to react quickly to changing product types, mixes, and volumes while
providing increased utilization and predictable control over hard assets.
Although FMS provides users with many benefits, they are not easy to justify. Limitations and alternatives
must be weighed and compared to determine if FMS is the best or even the right approach to productivity
and profitability improvements.

The once traditional accounting and cost justification practices have become outdated and have lost their
applicability to many factory automation programs and projects. The rules for staying competitive have
changed. The measurements must also change.
5.1.3 OBJECTIVES OF FMS

The principal objectives of FMS are:
1. Improve operational control through:
 Reduction in the number of uncontrollable variables
 Providing tools to recognize and react quickly to deviations in the manufacturing plan
 Reducing dependence on human communication
2. Reduce direct labor through:
 Removing operators from the machining site (their responsibilities and activities can be
broadened)
 Eliminating dependence on highly skilled machinists (their manufacturing skills can be better
utilized in manufacturing engineering functions)
 Providing a catalyst to introduce and support unattended or lightly attended machine operation
3. Improve short-run responsiveness consisting of:
 Engineering changes
 Processing changes
 Machine downtime or unavailability
 Cutting tool failure
 Late material delivery
4. Improve long-run accommodations through quicker and easier assimilation of:
 Changing product volumes
 New product additions and introductions
 Different part mixes
5. Increase machine utilization by:
 Eliminating machine setup
 Utilizing automated features to replace manual intervention
 Providing quick transfer devices to keep machines in the cutting cycles
6. Reduce inventory by:
 Reducing lot sizes
 Improving inventory turnovers
 Providing the planning tools for just-in-time manufacturing
5.2 Components of FMS

Various components of FMS are explained below.
5.2.1 Workstations
The workstations vary according to the type of part being produced. In metal cutting systems, the
machines are usually computer numerically controlled (CNC) horizontal spindle machining centers, if
prismatic workpieces are to be produced or turning centers if rotational workpieces.
Some systems consist of both types of machines when workpieces involving both types of operation are
required. Other systems include single-purpose machines, as opposed to machining centers which are
designed to perform a range of processes.

In addition to metalworking machines, there may also be gauging machines or other types of inspection
machines. There are systems for sheet-metal operations, P.C.B manufacture, and assembly operations.
5.2.2 Load and unload stations

Parts have to be introduced into the system at some point and there are usually load-unload stations,
where parts are placed on pallets, usually by human operators.
In some cases, parts may be supplied by an orienting device and loaded by the robot. Unloading is usually
done at the same stations, but there may be separated unload stations.
5.2.3 Workpieces transport equipment

Workpieces must be transported from the load positions to the production equipment and back for
unloading. Three types of equipment are in common use, namely conveyors, vehicles, and robots. There
are loop-lines in conveyor systems for each workstation. Conveyor systems are less popular.
There are several types of vehicles: Railcars and AGVs. There are several types of mobile floor-mounted
robots, which can be used for workpiece transport. Overhead gantry robots are popular for both
workpieces and tool handling.
5.2.4 Pallets
Workpieces are normally held in pallets of some sort for transport and locating on machine tables. Two
types are common: one type of pallet serves just as a carrier for a batch of small parts, to facilitate and
reduce the frequency of movements, perhaps by a robot. This type is common in systems that use
conveyors and gantry robots but are also used in AGV systems.
The other type of pallet is one on which one or more parts are accurately located and which is itself moved
onto the machine table and held in position while machining operations are performed on the parts.
5.2.5 Fixtures
Fixtures are used to locate parts precisely on pallets. They are usually specific to one type of part so that
each part requires a different fixture. In some cases, however, several types of the part may be sufficiently
similar to make use of the same fixture.
The fixtures may be permanently bolted on the pallets, or they may be removed from the pallet when a part
requiring a different fixture is to be produced into the system and placed on the pallet.
5.2.6 Tools
Most operations require some form of tooling specific to the particular operation being performed typically
cutting tools in machining centers.
Machining centers have tool magazines in which a set of tools can be held so that any operation on a
range of workpieces can be performed. Tools have to be changed, because of their tool life or because
the part to be worked on requires tools that are not currently in the tool magazine.
5.3 Cellular Manufacturing versus Flexible Manufacturing

An FMS, even though it is a unique manufacturing system, is sometimes referred to as a cell a highly
sophisticated and automated one among some manufacturers. And, in some cases, a single NC machine
cell or an integrated multimachine cell is referred to as a flexible manufacturing system (FMS); in actuality,
the only "flexibility" that may exist at all is changing to a different part when similar batch requirements
are completed.
Although sometimes described as a cell, an FMS is set apart from any other cell under its central computer
control and highly developed software; complete part, tooling, and material-handling flexibility and control;
and randomness of production scheduling and machining.
Conventional equipment cannot compete with FMS concepts because of the lack of management control,
inherent inefficiencies, and the ever-present setup and retooling requirements.
The primary differences between an automated manufacturing cell and a true flexible manufacturing
system (FMS) are:
1. Cells lack central computer control with real-time routing, load balancing (software), and
production scheduling logic. They are generally controlled by cell controllers or by their own
independent but interfaced machine controllers
An FMS will almost invariably be connected to a higher-level computer within the manufacturing
operation. In many cases, it is tied directly to the corporate computing system, which may also be
running the MRP (material requirements planning) system, the inventory control system, and
sometimes the CAD (computer-aided design) system in design engineering.
2. Cells are typically tool capacity constrained. Both single and multimachine cells are limited by the
total number of unique and redundant cutting tools that occupy available tool pockets. This limits
the part spectrum that could be run through a cell at a given time without stopping the equipment
and manually exchanging tools to accommodate different workpieces.
An FMS with automated tool delivery and tool management can automatically transfer, exchange,
and migrate tools through centralized computer control and software independent of equipment
activity. With a cellular application, the cutting tool count must be minimized to offset the limited
tool buffer storage of the machine. Parts must be closely scrutinized and part prints sometimes
changed to match the part family tool range with the available tool pockets.
3. Cells generally have less flexibility than an FMS and are restricted to a relatively tight family of
parts. As long as the part family remains unchanged and design-stable, the automated cell can
operate very efficiently.
An FMS, on the other hand, has greater depth and breadth of flexibility due to the range of parts in
varying lot sizes that can be accommodated in the system, random machine scheduling, and
automated material flow and movement. In some multimachine cells, parts are passed in sequence
from one machine to another. Whether material handling is automated or not, this type of cell
configuration can present problems when some flexibility of part variation requires certain
machining operations to be omitted, added, or changed.
Table 5.3 - Differences between cell and FMS
Cell FMS
Low Flexibility High Flexibility
Small stored part program inventory and Large stored part program inventory and
accessibility accessibility
Limited online computing power and decision- High online computing power and decision-
making software making software
Low to moderate equipment and resource costs High equipment and resource costs

Limited flexibility and variety of parts produced High flexibility and variety of parts produced
Low to medium preparation and implementation High preparation and implementation

requirements requirements
Benefits narrow but easily identified and Benefits broad but hard to identify and quantify
quantified
Moderate justification complexity and difficulty Difficult and complex justification process with
with mid-management approval required high-level approval required
Moderate level of management commitment A high level of management commitment and

and support required support required
Low staffing and training impact High staffing and training impact
Moderate effect on other internal operations and High effect on other internal operations and
organizations organizations
Low to moderate risk and complexity, minimal High risk and complexity, many facility changes or
facility changes new facility required
Short planning to implementation cycle Long planning to implementation cycle
5.4 Types of FMS Systems

There are various ways to classify flexible manufacturing systems. One classification that is sometimes
made in FMS terminology is the difference between a flexible manufacturing system and a manufacturing
cell.
The term cell can be used to refer to a machine grouping that consists of either manually operated or
automated machines or combinations of the two. The cell may or may not include automated material
handling and it may or may not be computer-controlled.
The term flexible manufacturing system generally means a fully automated system consisting of
automated workstations, automated materials handling, and computer control.
The term manufacturing cell is used largely in connection with group technology but both cells and FMS
rely on a GT approach in their design. A distinction between an FMC and FMS is in the number of machines
in the grouping.
A grouping of four or more machines in a system and three or fewer machines constitute a cell. For
example, a grouping of several machines served by a robot and capable of processing a family of parts is
commonly called a flexible manufacturing cell.
A flexible manufacturing system can be described as being either a dedicated FMS or a random order
FMS. A dedicated FMS is used to produce a much more limited variety of part configurations. The
geometry differences are minor and the product design is considered stable. Therefore, the machine
sequence is identical or identical for all parts processed on the system.
This means that a flow line configuration is generally most appropriate and that the system can be
designed with a certain amount of process specialization to make the operations more efficient. Instead

of using general-purpose machines, the machines can be designed for the specific processes required to
make the limited part family.
The random-order FMS is the more appropriate type under the following conditions:
(a) The part family is large.
(b) There are substantial variations in the part configurations.
(c) There will be new part designs produced on the system and engineering changes in parts currently
made on the system and the production schedule is subject to change from day today.
To accommodate these variations, the random-order FMS must be more flexible than the dedicated FMS.
It is equipped with general-purpose machines to deal with product variations and is capable of processing
parts in various sequences (random order).
A classification in flexible machining systems is based on the part geometry being processed. Machined
parts can usually be divided into two categories: prismatic parts are cube-like and require milling and
related machining operations to shape them. Round parts are cylindrical or disk-shaped and require
turning and related rotational operations.
5.4.1 Flexible manufacturing cells (FMC)

Flexible manufacturing cells consist of one or more CNC machine tools, general-purpose or special design
interfaced with automated material handling and tool changers. FMCs are capable of automatically
machine a wide range of different workpieces.
A turning center fitted with a gantry loading and unloading system and pallets for storing workpieces and
finished parts is a typical flexible turning cell. Automatic tool changers, tool magazines, block tooling,
automatic tool offset measurement, automatic chuck change, and chuck jaw change make the cell more
productive.
One or two horizontal machining centers with modular fixturing, multiple pallets, advanced tool
management systems, robots or other material handling systems to facilitate access of the jobs to the
machine is a flexible machining cell.
5.4.2 Flexible transfer lines (FTL)

Flexible transfer lines are designed for high volume production wherein a part undergoes different types
of operations. As each operation is assigned to and performed on only one machine, there is a fixed route
for each part through the system.
The material handling system is usually a pallet or conveyor. It also consists of SPMs and robots. In FTL,
many different workpieces are manufactured as the scheduling is easier and the resetting procedure is
automatic.
5.4.3 Flexible machining systems

A flexible machining system consists of several flexible automated machine tools of universal or special
type which are flexible interlinked by an automatic workpiece flow system so that the different workpieces
can be machined at the same time.
Different machining times at the individual stations are compensated for by central or decentralized
workpiece buffer stores. Flexibility is applied by the usage of CNC control, flexible transport system, and
by adapting to changes in the volumes in the product mix, machining process, and sequences.

5.5 Advantages of FMS
1. Flexible Manufacturing Systems are regarded as one of the most efficient methods to employ in
reducing or eliminating problems in manufacturing industries.
2. FMS brings flexibility and responsiveness to the manufacturing floor.
3. FMS enables manufacturers to machine a wide variety of workpieces on few machines with low
staffing levels, productively, reliably, and predictably.
4. A true FMS can handle a wide variety of parts, producing them one at a time in random order.
5. Machine tools in many manufacturing industries are woefully under-utilized due to equipment not
being used in the second and third shifts, decreasing availability of skilled personnel, and day-to-
day disturbances.
6. FMS shortens the manufacturing process through improved operational control, round-the-clock
availability of automated equipment, increased machine utilization and responsiveness, and
reduction of human intervention.
7. Better competitive advantage.
8. Lower work in process inventories
9. Reduced throughput time and its variability.
10. Improved manufacturing control.
11. Improved quality and reduced scrap rate.
12. Reduction of floor space used.
13. Better status monitor of machines, tools, and material handling devices.
14. Improves the short-run response time to the problems on the shop floor such as:
 Demand variations,
 Design and process changes that can be easily adjusted by changing the CNC part program,
which is generally developed by a CAD/CAM system as part of the design change,
 Machine unavailability can be taken care of by the FMS control system which can automatically
transfer the part to another available machine, and
 Cutting tool failures can be detected by sensors and stop the machine thereby reducing
catastrophic failures. Then the control system can initiate steps to repair and replace the failed
cutting tool.
15. Improve the long term cost-effectiveness of the system by supporting:
 Changing product volumes,
 Allowing different part mixes, and
 Allowing new parts to be added.
5.6 Tool Management System

Tooling is one of the most important element in a manufacturing system and hence in FMS special
attention need to be given to see that the right tools are made available for machining without any delay.
5.6.1 Tool Supply Systems

In an automated manufacturing system, cutting tools have to be taken out and supplied into the system
at intervals depending upon their utilization. If one considers the stand-alone machining center, the tool

magazine of the automatic tool changer is supplied at the beginning of the shift, all the tools in refurbished
condition.
If any of the tools have to be changed during the operation, then the machine tool may have to be stopped
for changing. This would be expensive in terms of the lost production time on the machine, and hence
alternative better means have to be found for replenishing the tools in the system. The tools need to be
replaced while the machine is cutting.
But with some machine tools, the problem gets compounded further. Also in FMS, whenever the part
spectrum to be manufactured gets changed, the tooling required may have to be altered accordingly.
Hence more and varied solutions have been tried by various machine tool manufacturers.
The basic concept in all the systems is to get a secondary (auxiliary) tool storage from where the required
tools can be transferred to the main tool magazine where and when necessary without much effort and
loss of cutting time.
In the conventional method of tool changing where the machine tool will have to stop for the complete
tool magazine refurbishing with new tools or single tool exchange. Such storage units as drums, chains,
discs, and other forms are used.
There is a limit to the maximum number of tools available at the machine tool in this form. The limit may
be of the order of 120 or so. Refurbishing of the entire tool magazine is normally done during the start of
the shift.
Care has to be taken to see that the tools loaded completely all the machining till the end of the scheduled
period. There is no secondary tool storage system available close to the machine tool.
In the second case, the traditional system is modified slightly. The tool magazine is split into two or smaller
magazines so that the machine tool can be running while one of the tool magazines is being replenished.
Sometimes the second and subsequent tool drums (discs or chains) carry special tooling required less
often for special jobs.
One of the disadvantages is that if a job requires more tools than can be accommodated in the small
capacity of the drum or disc, more frequent disc transfers would be required. This would make the tool
change time small but would increase the cost of tools in the system higher than in the previous case.
Hence this method is not widely practiced.
In the third system, an entire tool magazine is swapped for replenishment so that tool re-sharpening and
replacement into the magazine can be done in the tool crib. An automated guided vehicle carries the tool
magazine from the machine tool to the tool crib.
Though this reduces tool changeover time, the additional cost of a replaceable tool magazine and the
system of transporting it to the tool crib and back makes it a more expensive proposition. However, it is
possible to reduce the total number of tools in the system by making for a tool magazine with fewer tools.
5.6.2 Tool Monitoring Systems

In the case of tool monitoring systems, the tool has to be continuously monitored while it is cutting. This
would allow for continuously looking for tool wear, as well as the times when the tool breaks because of
unforeseen conditions in the machining system. The various methods adopted for these two functions are
slightly different.

5.6.2.1 Tool Wear Monitoring
Tool wear is a phenomenon whose behavior can be explained qualitatively but not quantitatively. An
important process parameter is the tool wear, which may be measured directly or indirectly. The following
principles are generally used for the direct measurement of tool wear.
 Tool wear is measured by relating it to changes in the resistivity of a resistor embedded in the
tooltip. In this method, there is no need to interrupt the process.
 The profile of the tooltip is recorded periodically using optical methods and tool wear is determined
from the variations.
 Opto-electrical methods using TV cameras and photodiodes etc. are employed to record variations
in the cutting edge to measure the width of the worn edge.
All the above methods are complex and are more expensive to implement regularly on the production CNC
machine tools. As a result, tool wear measurement has to be indirect. Some parameters used for
measuring tool wear are:
 Cutting power
 Cutting forces: By measuring cutting force using force measuring sensors. The cutting force
increases with the increasing dullness of the tool and can therefore be related to tool wear.
 Vibrations: By measuring vibrations of the tool edge, i.e., tool chatter wear can also be indirectly
estimated.
 Acoustic Emission
 Tool temperatures: By measuring the tool tip temperature and relating it to the wear of the tool.
Of these variables, mainly the cutting forces and power-based tool monitoring systems are commercially
and widely available, whereas the others are still not proven to be widely used in practice.
5.6.2.2 Tool Breakage Monitoring

Another problem often faced is the breakage of the tool during cutting, which if not detected in time may
lead to various problems associated with spoiled jobs, particularly in unmanned machining shifts. Hence
it is necessary to have systems that can detect the breakage of tools through some means and give an
alarm to the operator, or automatically replace the tool with a sister tool from the secondary tool storage.
In the plate sensor or any other cutting force measuring system, it is possible to detect a drop in cutting
force almost to zero from the peak during a breakage. The force drops since the tool may lose contact
because of tool breakage. Hence the controller can be given the signal for either other tool change, or
stoppage till the operator attends.
Another method used by many machine tool manufacturers is to cheek the tool length or tool offset at the
end or beginning of the cut using the tool probes described earlier. This value is compared with the tool
values stored for the new tool. If the difference is more than a certain value (typically 1 mm), it is
considered a tool breakage. This type of system is simple but can detect tool breakages only after a cut.
Any tool breakage during cutting remains unnoticed. However, this system does reduce the effective
damage caused by broken tools.
5.7 Flexibility in FMS

Flexibility can be defined as the collection of properties of a manufacturing system that support changes
in production activities or capabilities.

Several types of flexibility have been listed as follows:
Machine flexibility:
This defines the capability of the machines to a wide range of products of operations and part cycles that
may require. This may be characterized by having a low setup or change over time, ease of machine
programming, sufficiently large tool storage capacity, and the skill and versatility of machine operators.
Production flexibility:
This aspect refers to the range of part styles that can be produced in the system. This is dependent on the
machine flexibility and the range of machine flexibilities.
Mix flexibility:
This is the ability with which the product mix in a given system can be changed. This depends to a great
extent on the parts in the mix, the relative work content times of parts produced, and the machine flexibility.
Product flexibility:
This is the ease with which changes in product designs can be accommodated in the system. This will
depend on how closely the new part design matches the existing part family, the ability for off-line part
program preparation, and the machine flexibility.
Routing flexibility:
This specifies the capacity to produce parts through alternative workstation sequences in response to
equipment breakdowns, tool failures, and other interruptions. This is facilitated by the similarity of parts
in the mix, the similarity of workstations, duplication of workstations, cross-training of manual operators,
and the availability of common tooling.
Volume flexibility:
This is the ability to produce parts in high and low total quantities of production depending upon the market
demand. This will depend upon the level of manual labor performing production and the amount invested
in capital equipment.
Expansion flexibility:
This is the ease with which the system can be expanded to increase total production quantities, should
the need arise. This can be examined by the expense of adding workstations, the ease with which layout
can be expanded, the type of part handling system used, and the ease with which properly trained workers
can be added.
5.8 FMS Layouts

The broad categories of layouts that have been used are explained below.
5.8.1 In-line Layout

All the machine tools are kept along a straight line as shown in Fig.5.3. This is the simplest form and is
generally used for a smaller number of machines in a system. The parts move in well-defined sequences
and the workflow is generally in both directions.
The part handling at the individual workstations is performed by the transport vehicle, which will have the
necessary pallet changer. Often the machine tools used in such a system are identical so that the part
routing will not be a problem.

Fig.5.3 - In-line FMS Layout
5.8.2 Loop Layout
Fig.5.4 – FMS Loop Layout
In this system, the workstations are arranged in a loop as shown in Fig.5.4.

Parts generally move in a single direction in the loop similar to a conveyor, with the ability to stop at defined
positions for transferring the parts to the workstation. To move parts from the conveyor to the workstation
may have to be carried using a secondary part exchange system such as a pallet changer. An alternative
form of the loop could be rectangular.
5.8.3 Ladder Layout

In this system, the workstations are arranged in a loop with rungs as shown in Fig.5.5 (a). The rungs help
in reducing the congestion and allow for smooth part flow between machines.
5.8.4 Open Field Layout

In this system, there are multiple loops for the appropriate arrangement of all the facilities as shown in
Fig.5.5 (b). This type of system is generally suitable for a large group of parts to be machined. The facilities
may consist of some workstations with different varieties. The material handling is provided with AGVs
along the guide path.
Fig.5.5 – (a) FMS Ladder Layout (b) Open Field FMS Layout
5.9 Automated Guided Vehicle (AGV)

An Automated Guided Vehicle (AGV) is a programmable mobile vehicle without human intervention. The
Material Handling Institute defines it as "An AGV is a vehicle equipped with automatic guidance equipment,
either electromagnetic or optical. Such a vehicle is capable of following prescribed guide paths and may
be equipped for vehicle programming and stop selection, blocking and any other special functions required
by the system."
Fig.5.6 - Automated Guided Vehicle (AGV) System with a Work Piece

A typical Automated Guided Vehicle System AGVS with a pallet and workpiece mounted is shown in Fig.5.6.
These are driverless vehicles and work generally in fixed routes that are laid on the factory floor. The AGVS
are used for workpiece distribution and transferring from stores to shop/assembly lines. They are
sometimes also called robocars. The main components of an AGV based material handling system are:
 Structure
 Drive system
 Steering mechanism
 Power source, battery
 An onboard computer for control
5.9.1 AGV Types

Several AGV types are available to cater to a variety of functions. They are:
 AGVS Towing vehicles
 AGVS Unit load vehicles
 AGVS Pallet trucks
 AGVS Fork trucks
 Light load vehicles
 AGVS Assembly line vehicles
Fig.5.7 - Various Types of Automated Guided Vehicle (AGV) Systems
Schematic representation of these vehicles is shown in Fig.5.7. Over the years, the developments in AGVS
have made them very versatile because of the very large applications for which these are used.
5.9.1.1 AGVS Towing Vehicles

These are the first types introduced and are still very popular. These are used for very large load
applications. The towing vehicle can have a variety of trailers. These are generally used for bulk transport
applications.
5.9.1.2 AGVS Unit Load Vehicles

These have a deck that permits unit load transport operation and are suitable for the automatic transfer
of load. The decks can be either lift and lower type, which is most common, powered or non-powered roller,

chain, or custom design. The unit load carrier is used for moving high volumes over moderate distances,
and can easily integrate other subsystems such as conveyors and storage systems.
Typical speeds are 50 meters per minute. They are used in warehousing and distribution systems. The
typical path of a unit load vehicle is shown in Fig.5.8. These systems have bi-directional mobility and
operate independently. As a result, they allow for good system versatility for product movement.
Fig.5.8 - Typical Application Path of a Unit Load Type AGVS
5.9.1.3 AGVS Pallet Trucks

Pallet trucks are used to transport palletized loads from floor level and eliminate the need for fixed load
stands. These are used in distribution functions.
5.9.1.4 AGVS Fork Trucks

Fork trucks can service palletized loads both at floor level as well as on stands. They may also be able to
stack the loads when required. These are generally used where the heights of load transfer vary.
The vehicle has the capability of positioning to any height so that conveyors or all load stands of varying
height in a given system can be serviced. These are some of the most expensive AGVS and can only be
justified where total automation is required.
5.9.1.5 Light Load Vehicles

Light load AGVs are vehicles with small capacities of the order of 200 kg and therefore used to transport
small parts through a light manufacturing environment.
5.9.1.6 AGVS Assembly Line Vehicles

These are the adoption of light load vehicles for serial assembly processes. For light assembly
applications, these vehicles carry the subassemblies such as motors or transmissions, to which parts are
added in a serial assembly operation. Before the assembly operation, the vehicle reaches the parts staging
area where the necessary parts are placed on a tray on-board the vehicle.
The vehicle then moves to the assembly area where the assembler completes the assembly operation
taking the parts on-board. When the assembly is completed, the vehicle is released and proceeds to the
next parts staging area.

Fig.5.9 - Typical Application Path of an Assembly Line AGVS
The same process may be repeated many times, before the completion of the assembly. The typical layout
is shown in Fig.5.9. AGVS assembly systems allow flexibility in assembling operations by providing for
parallel operations. It is possible to track individual parts and measure work rates.
5.9.2 Guidance
AGV is operated with onboard batteries and moves generally in a fixed path. One of the important elements
in the AGV is guidance control. The various guiding principles used in AGV control are given in Table 5.4.
The actual use of a particular guidance method mainly dependent upon application, environment, and
need. Wire guidance is the most commonly used method in manufacturing shops.
Table 5.4 - Guidance Principles Used for Guiding AGVs
Guidance Type Description
Wire guided The vehicle's antenna senses and follows an energized wire embedded in the
floor
Infrared Infrared light is transmitted and reflected from reflectors in the roof of a facility;
radar-like detectors relay signals to the computer and calculations and
measurements taken to determine the position and direction of travel
Laser Laser scans wall-mounted, barcoded reflectors; Through known distances and
measurement of the distance, the vehicle's front wheel has traversed, the AGV
can be accurately maneuvered and located
The principle of wire guidance is given in Fig.5.10. The control wire is embedded in the factory floor along
which the AGV is to traverse. For this purpose, a rectangular slot is cut into the concrete floor and the wire
is placed in position with the rest of the slot being filled with epoxy.
The wire is actually in segments depending upon the actual path to be taken. The transfer of AGV from
one loop to the other is done with the help of the circular transfer elements present in the path.
Fig.5.10 - The Principle of Wire Guidance used in AGV
Each of the travel is identified by a particular frequency, and the wire that forms the part will be energized
to that frequency. The onboard controller of the AGV will be adjusted for this frequency. The sensor coils
present in the AGV sense the presence of the magnetic field and accordingly steer the AGV along the path.
The two coils placed at equidistance on either side of the coil helps in maintaining the movement of the
vehicle along the wire. If the AGV has to follow a different path, then its frequency needs to be adjusted
for that frequency.
Fig.5.11 - Typical Path of a Wire Guided AGV
There are situations when the floor wired system might not be feasible for guiding the AGV movement.
Some of the situations are:
 The floor is uneven and not suitable for embedding wire
 There are frequent changes in the path
 There are some metal encumbrances inside the floor
In such cases, free-ranging AGVS with no fixed path using laser ranging are also available but less used in
manufacturing plants. AGVS locates its position by reading the bar code targets and by sensing steer
wheel angle and rotation as shown in Fig.5.12. The onboard computer communicates the information
processed through a radio link to a stationary control computer.
Fig.5.12 - Wireless Guidance of AGVS using Laser Guidance
Another form of the AGV is a rail-guided vehicle or RGV, which travels on fixed rails laid out as shown in
Fig.5.13. This type of vehicle is used for short travel distances and heavy workpieces.
They are not as flexible as the wire-guided and therefore are used exclusively in flexible manufacturing
systems involving a smaller number of machine tools. Whereas wire-guided AGVs are used in all most all
types of applications including assembly and storage.
Fig.5.13 - Typical Path of a Rail Guided Vehicle
5.9.3 Advantages of AGVs

The main advantages derived from the use of AGVs in a manufacturing environment are:

1) Dispatching, tracking, and monitoring under real-time computer control. This helps in planned
delivery, a line interface to production and inventory control systems, and management information
on vehicle and workstation production.
2) Better resource utilization. Most AGVs can be justified economically in three years or less.
3) Increased control over material flow and movement
4) Reduced product damage and less material movement noise
5) Routing consistency with flexibility
6) Operational reliability can be achieved in a hazardous and special environment
7) Ability to interface with various peripheral systems such as machine tools, robots, and conveyor
systems
8) Increased throughput because of dependable on-time delivery
9) High location and positional accuracy
10) Improved cost savings through reduction in floor space, WIP, and direct labor.
5.10 Automated Storage and Retrieval System (AS/RS)

In large manufacturing establishments, the volume of items to be stored and retrieved becomes so large
that the manual means of doing so becomes extremely unreliable and time-consuming. The large volumes
also call for proper information management procedures to reduce duplication and reduction of inventory
costs.
Automated Storage and Retrieval System (AS/RS) play a central role in the automated factory. The AS/RS
not only controls inventories but also keeps track of parts and materials in process or transit. In other
words, the AS/RS can know where everything is, on a real-time basis, even as the material moves within
the factory.
The importance of it for management to make manufacturing decisions based on accurate real-time
information can be understood from the fact that in-process materials rarely spend more than 5% of their
time being worked on, and that the remaining 95% is spent in transit or storage. Thus, it becomes easier
to visualize the role of materials handling and storage systems within an automated factory.
Fig.5.14 - Typical AS/RS with its Component Parts

An AS/RS sometimes also referred to as an automated warehouse, is a combination of equipment and
controls, which handles the stores and retrieves material faster and with greater safety and efficiency than
conventional material handling and storage systems. It contains several rows of storage racks and storage
and retrieval devices (stacker cranes).
The system can be linked to other external devices such or Automated Guided Vehicles (AGV) for
transferring material (in trays or pallets) to the shop floor or palletizing stations. Typical AS/RS is shown
in Fig.5.14.
The incoming items are first sorted and assigned to pallets. The pallet loads are then routed through
weighing and sizing stations to ensure that they are within the load and size limits. The accepted ones are
transported to the pick-up and delivery (P and D) stations, with the details of the pallet contents
communicated to the central computer. This computer assigns the pallet a storage location in the rack
and stores the location in its memory.
The pallet is moved from P and D station to storage by storage and retrieval machines (S/R machines), or
stacker crane. Upon receipt of a request for an item, the computer will search its memory for storage
location and direct the stacker crane to retrieve the pallet. The supporting transportation will transport the
pallets from P and D stations to their destination.
The major components of an AS/RS are:
 Storage and Retrieval Machine (shuttle crane or stacker crane),
 Storage structures,
 Transport devices (AGV, Conveyor, etc.), and
 Controls
a) Storage and Retrieval Machine (S/R machine)
Fig.5.15 - Physical Arrangement of the Aisle and Storage Structures in an Automatic and Retrieval Systems
The S/R machine is characterized by its ability to operate accurately and safely at high speeds, reach
heights of 30 m or beyond, and operate in aisles only a few cm wider than the load it carries.
The modern S/R machine runs on a floor-mounted rail and is guided at the top. It comes in a wide variety
of sizes and configurations because its design is a function of the load it carries and the task performs.

Speed is generally determined by the system's throughput requirements (i.e., how many loads need to be
stored and retrieved in an hour). Traveling speeds sometimes exceed 150 m/min while hoisting speeds
can be as high as 50 m/min.
b) Storage Structure
The storage structure (racking) is a critical part of the AS/RS. It differs considerably from conventional
pallet racking in that AS/RS storage racks are normally much higher and interface directly with the S/R
machines, thus making manufacturing and installation tolerances more critical. AS/RS rack design must
provide for integration with S/R machine guide rails.
The most common storage structures are free-standing and installed inside a building. Specifications
differ, depending on the type of load to be stored and system configuration. Today an increasing number
of systems are rack supported: that is, the rack storage structure supports the building itself. This type of
system can be over 30 meters tall and is popular because it reduces construction time and cost.
c) Transport Devices
Fig.5.16 - Physical Layout of Automatic Storage and Retrieval System Linked with AGV for Further Movement
The transport (system) device moves the loads beyond the limit of the S/R machine. Some systems need
only a conveyor, while larger and more complex installations require elaborate transport devices
connecting the S/R with other factory operations.
Many types of transport devices can be used with an AS/RS: forklifts, roller or chain conveyors, overhead
power and free conveyors, in-floor tow-lines, shuttle trolleys and automated guided vehicles.
The choice depends on the throughput requirements, type of load to be handled, and degree of interaction
with shipping, receiving, manufacturing, assembly, and other plant operations. An example system that
links with a conveyor and AGV is shown in Fig.5.16.
d) System Controls
The system controls encompass two functions, the control of equipment and the control of data. This
computer control system may also perform tasks like inventory control, data automation, networking
control and is frequently linked to an even larger corporate management information system computer.

5.10.1 Advantages of AS/RS
Absolute inventory accountability is one of the most important benefits of an AS/RS. By knowing exactly
how much of what materials are located at any given moment, inventory reductions are quite common
and higher reductions are frequently realized.
Also, these systems discourage pilferage and generate very little product or equipment damage. The
systems can also improve customer service and working conditions, and thus results in less indirect cost
associated with supervision, administration, facilities, and security.
The following are the benefits of using an AS/RS:
 Better space utilization
 Less direct and indirect labor
 Reduced inventories
 Less energy consumption
 Reduced pilferage
 Less product damage
 Improved working conditions
 Easier housekeeping
 Less equipment damage
 Improved customer service
 Better management control
5.11 Workpiece Handling System

This system has the function of timely supply of unmachined workpiece from the storage to the machining
centers and transporting the machined parts from the centers to the locations. This block generally
consists of the following modules:
 Workpiece setup or loading and unloading station
 Workpiece store and
 Workpiece transport
5.11.1 Workpiece setup or loading and unloading station

Prismatic components meant for machining centers are generally set up on pallets. The pallets are
nowadays standardized to have a compatible mechanical interface with the storage locations, transport
systems, pallet changer, and machining centers. The palletization may be done manually or with the help
of a robot.
Fixtures are used to locate the parts precisely on the pallets. The fixtures should be able to accommodate
several parts belonging to a family. The principle of group technology (GT) is generally employed in this
connection. The fixtures may even be permanently fixed to the pallets which in turn may also have the
provision for automatic clamping actuated hydraulically or pneumatically. Several setup stations may be
combined to constitute a central clamping and unclamping station.
When the workpieces have relatively low weight and size, they may be directly loaded onto the machine by
a robot or a manipulator. In such cases, the workpieces may be loaded manually or automatically on tray-
like pallets. A transport pallet of this type may be used to accommodate several workpieces in the proper
position. Rotational workpieces may also be loaded into similarly turning centers.

5.11.2 Workpiece store
Pallets with workpieces on them may be stored in expandable workpiece stores. The storage position for
each of the pallets may be fixed or alternately identified as explained in pallet workpiece identification.
Such stores may be used as buffer storage points for an unmanned shift.
Workpiece storage and retrieval can also be automated in FMS. An FMS is generally a small lot but great-
variety manufacturing system involving frequent modifications of parts and workpiece changeovers on
the pallets.
At the same time minimization of setup time is one of the prime objectives in FMS. In this respect, AS/RS
is gaining wider acceptance for becoming a centrally controlled pallet/workpiece store working unmanned
around the clock. The number of pallets which can be stored may vary between 400 to 10,000 for small-
scale to large-scale AS/RS. The system essentially consists of storage racks, a PLC-based or computer-
controlled stacker crane, the location and accuracy of which is comparable to that of a robot.
The employment of servomotors in the cranes helps achieve positioning accuracy and reliability. Elevating
speeds of the stacker could be as high as 180 m/min. The AS/RS computer is also networked in the LAN
of the FMS for necessary data processing and integrated operations.
Several software modules continue to be developed to enhance AS/RS functioning to include sorting of
several types of workpieces, setting up rearrangements and real-time changes and positioning and
allocation of cranes, and optimum utilization of the AS/RS.
5.11.3 Workpiece transport

The following devices are used for transporting the workpieces from the store to the machine.
 Rail-mounted transport vehicles (RTV)
 Automatically guided vehicles (AGV)
 Gantry robots (GR)
An RTV can carry workpieces from the store or set up stations to all those machines which can be
interlinked with rails. This may sometimes impair access to the machines but offers reliable transport
traveling at high speed on linear routes.
AGVs, on the other hand, do not require any rails and transport even over non-linear routes
and are widely employed. Most of these unmanned industrial trucks are inductively controlled and
consequently move at lower speeds than RTVs. Several AGVs may be used in an FMS to cover all the
routes.
Gantry robots which are essentially mobile may be used to load the workpieces directly onto the machines
from the pallets which store workpieces. This, of course, requires robot grippers that suit the workpiece
geometry. Further, the components should not have large dimensions and their weight should be small.
It may be noted that, in this case, several of the expensive fixtures, which would otherwise be used to
mount the workpieces on the pallets, are not required. Alternatively, a gantry robot moving along a linear
overhead gantry may be used to transport work piece-set pallets from the store or set up stations to the
machines.
5.12 Flexible Fixturing

A flexible (adaptable) fixture has been defined as a single device that holds parts of various shapes and
sizes that are subjected to the wide variety of external force fields and torques associated with

conventional manufacturing operations. Flexibility is a property of the fixturing device that makes it
conform to the workpiece geometry. Flexible fixtures offer the following advantages
 Reduction in lead time and effort required for designing special fixtures;
 The lower overhead cost of storing a multiplicity of fixtures required to effect a rapid changeover
between different manufacturing operations; and
 Simpler programming requirements.
Designs of various "resettable" fixtures for use in an FMS have been proposed. These fixtures have a
common location scheme for a group of the workpiece, and just resetting the clamping element is required
when a new workpiece is introduced.
Many individuals have surveyed flexible-fixturing methodologies. Broadly, there are two major groups of
flexible fixtures: discrete contact and continuous contact. In the discrete-contact type, there are a finite
number of contact points that can be arranged in space to give different configurations.
A continuous-contact fixture is a fixture in which the number of contact points is infinite, such as a line or
area contact. A point contact would completely constrain the motion in a direction normal to the workpiece
surface only. Motions parallel to the workpiece surface would not be completely constrained, because of
the limited friction in point contact. Surface contact would not only constrain the motion of the workpiece
along the three axes but also would constrain the applied moments.
References:
1. P. N. Rao “CAD/CAM Principles and Applications”, Tata McGraw Hill.
2. Lalit Narayan “CAD/CAM”, Prentice Hall.
3. William W. Luggen “Flexible Manufacturing Cells and Systems”, Prentice Hall.


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Contents

5.1 Introduction ....................................................................................................................................... 5.2

Automation Machine Utilization

Basic CNC: Manual tool and work loading. 40%

Flexible Manufacturing System: Automated Workpiece Movement between 90%

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

Table 5.2 - Costs associated with various types of manufacturing systems

Costs Small Scale Medium Scale Small Scale

Direct labor 43.7 24.7 19.7

Overhead 13.5 13.9 23.7

Capital 17.8 33.1 29.8

Other Costs 25 28.3 26.8

Total 100 100 100

5.1.1 Need of FMS

Fig.5.1 - Breakdown of 8760 available hours in a calendar year to manufacturing operation

Fig.5.2 - Breakdown of the time spent by an average part in the shop

5.1.2 General FMS Considerations

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

5.1.3 OBJECTIVES OF FMS

5.2 Components of FMS

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

5.2.2 Load and unload stations

5.2.3 Workpieces transport equipment

5.3 Cellular Manufacturing versus Flexible Manufacturing

Table 5.3 - Differences between cell and FMS

Low Flexibility High Flexibility

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

Low to medium preparation and implementation High preparation and implementation

Moderate level of management commitment A high level of management commitment and

Short planning to implementation cycle Long planning to implementation cycle

5.4 Types of FMS Systems

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

5.4.1 Flexible manufacturing cells (FMC)

5.4.2 Flexible transfer lines (FTL)

5.4.3 Flexible machining systems

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

5.6 Tool Management System

5.6.1 Tool Supply Systems

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

5.6.2 Tool Monitoring Systems

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

5.6.2.2 Tool Breakage Monitoring

5.7 Flexibility in FMS

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

5.8 FMS Layouts

5.8.1 In-line Layout

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

5.8.2 Loop Layout

Fig.5.4 – FMS Loop Layout

In this system, the workstations are arranged in a loop as shown in Fig.5.4.

5.8.3 Ladder Layout

5.8.4 Open Field Layout

5.9 Automated Guided Vehicle (AGV)

Fig.5.6 - Automated Guided Vehicle (AGV) System with a Work Piece

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

5.9.1 AGV Types

Fig.5.7 - Various Types of Automated Guided Vehicle (AGV) Systems

5.9.1.1 AGVS Towing Vehicles

5.9.1.2 AGVS Unit Load Vehicles

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

Fig.5.8 - Typical Application Path of a Unit Load Type AGVS

5.9.1.3 AGVS Pallet Trucks

5.9.1.4 AGVS Fork Trucks

5.9.1.5 Light Load Vehicles