You are on page 1of 41

Unit 2


Introduction: FMS definition and classification of
manufacturing systems, Automated production
cycle, Need of flexibility, Concept of flexibility,
Types of flexibilities and its measurement.
FMS Equipment:

Why FMS, Factors responsible

for the growth of FMS. FMS types, its components,



justification for FMS




FMS is the most automated and technologically
sophisticated manufacturing system applied in
group technology cells.
An FMS typically possesses multiple stations and
is capable of variable routing among stations. Its
flexibility allows it to operate in mixed model

What is a flexible manufacturing

A flexible manufacturing system is 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.


Types of FMS
A single Machine Cell
A flexible manufacturing cell
A flexible manufacturing system

Single Machine Cell

Flexible Manufacturing cell

Flexible Manufacturing


A manufacturing system must posses
three capabilities to be flexible:
To identify and distinguish among the
different incoming part or product
styles processed by the system
Quick changeover of Operating
Quick changeover of physical setup.

To qualify as being flexible, a manufacturing system should
satisfy several criteria. The following are four reasonable
tests of flexibility in an automated manufacturing system:
1. Part Variety test: Can the system process different part
styles in a non-batch mode?
2. Schedule change test: can the system readily accept
changes in production schedule, that is changes in part
mix and/or production quantity?
3. Error recovery test: can the system recover gracefully
from malfunctions and breakdowns, so that production is
not completely disrupted?
4. New Part test: Can new part designs can be introduced
into the existing product mix?


Flexibility Criteria Applied to the three

types of manufacturing cell system

Two categories of Flexibility

A dedicated FMS :
Produces a limited variety of part styles,
A Random order FMS:
It is more appropriate when part family is
large, there are substantial variation in part
configurations, new part design will be
introduced into the system and engineering
changes will occur in p[arts currently
produced, and the production schedule is
subject to change from day to day.

FMS Components
1. Workstations
2. Material Handling and storage
3. Computer control system
4. People are required to manage
and operate the system.

1. Workstations
Load Unload Stations:
This is the physical interference between the FMS and
the rest of the factory. It is where the raw work parts
enter the system and finished parts exit the system.
Machining Stations: The most common applications
of flexible manufacturing systems are machining
operations. Most common is the CNC machining
Other processing stations: In addition to machining
other processes are there in FMS. Ex. Sheet metal
fabrication such as punching bending shearing and
forming etc.

1. Workstations
Assembly: Some flexible manufacturing systems
are designed to perform assemble operations.
FMS gradually decreasing manual labor in
assemble of product typically made in batches.
Other Station and equipments: Online inspection
can be incorporated into a flexible manufacturing
system, either by including an operation at a
processing work station or by including a station
specifically designed for inspection.

Material Handling and Storage

Allows random, independent
movements of work parts between
Enables handling of variety of
workpart configuration.
Provide temporary usage.
Provide convenient access for
loading and unloading workparts.
Creates compatibility with computer

Material Handling
A primary handling system:
responsible for moving parts in
between stations in the system.
The secondary handling system: it
consists of transfer devices like
automatic pallet changers, and
similar mechanism available at the
workstation of FMS.

FMS layout in According to Material

Handling system

In line layout
Loop layout
Ladder layout
Open field layout
Robot centered cell

Function performed by FMS

computer control system
1. Workstation control
2. Distribution of control instruction to
3. Production Control
4. Traffic control
5. Shuttle control
6. Work piece monitoring
7. Tool control
8. Performance Monitoring
9. Diagnostics