Flexible Manufacturing Systems

Definition
A flexible manufacturing system (FMS) is
consists of group of processing stations,
interconnected by means of an automated
material handling and storage system, and
controlled by an integrated computer system.

The key idea in FMS is that the

coordination of the flow of work which is
carried out by a central control computer.  

2
Components of FMS
1) Processing stations.
2) Material handling and storage systems.
3) Computer control system.
4) Human resources
Processing stations
• Machining stations (CNC machine tools)
• Sheet metal presses (CNC presses)
• Other processing stations
• Assembly
• Inspection stations
Components of FMS (cont.)
Material Handling and Storage
• Various automated material handling equipment
AGVS, Conveyors, Robots
• Buffer as a temporary storage
Computer Control System
coordinate the activities of
• Processing station
• Material handling system

5
Elements of FMS (cont.)
Human Resources
• Loading raw materials to the system
• Unloading finished parts from the system
• Changing and setting tools
• Equipment management and repair
• NC part programming
• Programming and operating the computer system
• Overall management of the system

6
Number of machines
Typical categories are
• Single machine cell
• Flexible Manufacturing Cell (FMC)
• Flexible Manufacturing System (FMS)
In single machine cell, there is only one processing
machine.
In flexible manufacturing cell there are 3 or less
machines.
In flexible manufacturing system there are more than 4
machines.
There is more difference between FMC and FMS
7
Difference between FMC and FMS

Other than the number of the machines, there are

more differences between FMC and FMS
• FMS generally includes non-processing work
stations that supports the production as;
coordinate measuring stations, automated storage
etc.
• The computer control of FMS generally larger and
more sophisticated.
 Part Geometry
• Prismatic parts
- cube like shape, require milling and related
machining operations
• Round parts
- cylindrical or disk-shaped, require turing and
related rotational operations

Production systems are classified according to whether

they make one of the two part geometry types or
the other.
 Level of flexibility
Typical categories are
• Dedicated FMS
• Random order FMS
Dedicated FMS is designed
- to produce a limited variety of parts.
- Geometrical differences are minor and product design is stable.
- Flow line configuration is applied
- specific purpose machines used.
- More production rate.
Random order FMS is designed
- to produce wide range of part family
- Huge geometrical differences
- Accommodates design changes easily
- New part designs can be produced
- Production schedule changes on daily basis
- More flexible than dedicated FMS,
- General purpose machines used.
 FMS Workstations
• Machining centers
CNC machines as they include automatic tool changing and storage,
CNC/DNC control, use of palletized workparts.

12 post turret
80 – tool chain magazine
• lathes and milling centers, CNC EDM, CNC grinding machines,
CNC cutting machines (laser, plasma, electron, or flame),
CNC welding machines

CNC milling centers

CNC Wire cut EDM
• Head changers
- special m/c tool, changes the tool heads
- tool heads are stored on a rack or drum located on or near the
machine.
- performs simultaneous multiple drilling and related operations
- high production rates
- High cost: used for justifying production volume
• Head indexers
- Are similar to head changers
- tool heads are larger
- Heads are attached semi permanently to a indexing
mechanism
- simultaneous operations
- 8 or more heads can be mounted
- simplex (single indexing table) or duplex style – specially used
in FMS for processing of specific part families.
• Milling modules
- Vertical, horizontal, multi – spindle
- High rate of production

• Turning modules
- Workpiece is held in pallet and single point cutting tool is
rotated around the work.

• Assembly workstations
- Industrial robots
as they can be programmed to perform tasks with
variations in sequence and motion pattern to accommodate
different product variety
• Inspection stations
- included either at a workstation or a specific
station for inspection

- Coordinate measuring machines

dimensional measuring device, designed to move the measuring
probe to determine the coordinates along the surface of the work
piece. Apart from dimensional measurement, these machines are
also used for profile measurement, angularity, digitizing or imaging.

- special inspection probes

- Machine vision

- to ensure that the components are properly

added to workstation
• Sheet metal processing machines
- CNC presses to perform operations such as punching,
shearing, bending, forming

• Forging stations
- consists of heating furnace, forging press, and a trimming
station.
 Material Handling and Storage
Functions
• Random, independent movement of workparts between
workstations
- parts can be moved form one machine to any toher machine
- achieves various processing sequences on the different
machine in a cells
- substitution for a busy machine can be done
• Handle a variety of workpart configurations
- For prismatic parts: pallet fixtures. Fixture located on the top
face of the pallet is designed to accommodate different parts
configurations by means of common components, quick
change features and other devices that permit rapid build up.
The base of the pallet is designed for the material handling
system.
 - For rotational parts, industrial robots are employed to
transfer between workstations. Load and Unload the machine
tools

• Temporary storage
- stores the WIP between workstations

• Convenient access for loading and unloading workparts

- A separate manual loading/unloading station is provided.
- Wherein pallet fixtures are built, parts are loaded/unloaded.

• Compatible with computer control

- controlled by the computer to direct it to various
workstations like machining, load/unload, etc.
 FMS Layout Configurations

The types of commonly found FMS layout

configurations:

1. In-line layout

2. Loop layout

3. Ladder layout

4. Open field layout

5. Robot-centered cell
In-line layout
• Well defined sequence
• No Back flow
• Similar to Transfer line
flow

• Back flow is permitted

• Secondary work
handling system
Loop layout
• Uni-direction flow
• Parts can be stoppped at
any station
• Single station for
loading/unloading –located
at the end of the loop
• Secondary work handling
system to permit the
movement of parts without
obstruction
Ladder layout
• Adaptation of loop
configuration
• The workstations are
located on rungs
• This increases the possible
ways of getting from one
station to other
• Reduces average distance
travelled and hence the
time
 Open-field Layout
• Adaptation of loop configuration
• Consists of loops, ladders, and sidings to achieve the
desired processing requirements
• Large part families
Robot-centered cell
• One or more robots are used in
material handling
• Robot is located at the center
and the equipments are
arranged around it.
• A single robot services one or
more production machines
• Industrial robots with grippers
like – vaccum cups, Mechanical
fingers, magnetized devices
• Rotational parts – cylindrical or
disk-shaped
Material Handling Equipment
The material handling function in a FMS is shared between
two systems:
1. Primary handling system - establishes the basic layout of the FMS
and is responsible for moving workparts between stations in the
system.
- includes: roller conveyors, cart-on-track conveyors, AGVS, in-floor
towline carts.
- Supported by Automated Storage/Retrieval Systemlong with S/R
machine
- Includes positioning and registration to individual stations, in the
absence of secondary system
2. Secondary handling system – is located at each workstation and is
used to transfer work from primary to the processing station.
- positions and locates the parts with accuracy and repeatability.
- Buffer storage of parts
- consists of transfer devices, automatic pallet changers, and similar
mechanisms located at the workstations in the FMS.
Equipment used as primary handling system
Layout configuration Typical material handling system

In-line layout Conveyor system

Shuttle system
Rail guided vehicle system

Loop layout Conveyor system

In-floor towline carts

Ladder layout Conveyor system

Automated guided vehicle system
Rail guided vehicle system

Open field layout Automated guided vehicle system

In‑floor towline carts
 FMS FEATURES
• MANY PART TYPES CAN BE LOADED
• PARTS CAN ARRIVE AT MACHINES IN ANY
SEQUENCE
• PARTS IDENTIFIED BY CODES
• MANY MACHINES CAN BE INCLUDED
• SMALL FMS LEAD TO FLEXIBLE CELLS