FMS

A flexible manufacturing system (FMS)

is a highly automated machine cell consisting
of a group of processing work stations,
interconnecmanagementutomated material
handling and storage system and controlled by
a 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.  

IE 262 Class Notes by Figen Eren 1

 FMS (cont.)
FMS technology can be applied if
•Presently, the plant is either produces in
batches or uses group technology cells and the
management wants FMS
•It must be possible to categorize the products
as a part of a family. Parts belong to common
product or part possess similar geometries etc.
•Production facility should work mid-volume
and mid-production size.

IE 262 Class Notes by Figen Eren 2

 What makes it flexible
• Ability to identify and distinguish among
the different part or product styles
processed by the system.
• Quick changeover of operation
instructions.
• Quick changeover of physical setup.
To qualify as being flexible a manufacturing
system should satisfy several criterias.
1)Part variety 2) Schedule change
3)Error recovery 4)New part
IE 262 Class Notes by Figen Eren 3
Elements of FMS
1) Workstations.
2) Material handling and storage systems.
3) Computer control system.
4) Human resources
Workstations
• Load-unload stations
• Machining stations
• Other processing stations
• Assembly
• Other stations and Equipments

IE 262 Class Notes by Figen Eren 4

Elements of FMS (cont.)
Material Handling and Storage
• Random independent movement of work parts
between stations
• Handle a variety of work part configuration palettes
and robots etc.
• Buffer as a temporary storage
Computer Control System
• Workstation control
• Distribution of control instructions
• Production control
• Traffic control
• Tool control IE 262 Class Notes by Figen Eren 5
Elements of FMS (cont.)
Human Resources
• Loading raw materials to the system
• Unloading from the system
• Changing and setting tools
• Equipment management and repair
• NC part programming
• Operating system programming
• Overall management of the system

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Types of FMS
Flexible manufacturing can be distinguished according
to the kind of operation
• Processing operation
• Assembly operation
FMS designed to perform either one, rarely both, almost
none!Other ways to distinguished the systems
• By the number of the machines in the system
• By the level of flexibility

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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 2-3 machines.
In flexible manufacturing system there are more than 3
machines.
There is more difference between FMC and FMS

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Difference between FMC and FMS
Other than the number of the machines,there are more
difference 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.

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Level of flexibility
Typical categories are
• Dedicated FMS
• Random order FMS
Dedicated FMS is designed to produce a limited
variety of parts. Another name is Special Manufacturing
System, specific purpose machines used. More
production rate.
Random order FMS is designed to produce wide range
of part family. Production schedule changes sometimes
from day to day.More flexible than dedicated FMS,
more general purpose machines used.
IE 262 Class Notes by Figen Eren 10
Types of flexibility
Machine Flexibility
Capability to adapt a given machine in the system to a
wide variety of production operations and part styles.
The greater the range of operations and part styles, the
greater the machine flexibility. This flexibility depends
on the factors such as
1)Setup or changeover time
2)Ease of machine reprogramming
3)Tool storage capacity
4)Skill and versatility of workers in the system

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Types of flexibility (cont. 1)
Production Flexibility
The range or universe of part styles that can be
produced on the system is called production flexibility.
It totally depends on machine flexibility of the
individual stations in the system.
Mix Flexibility
Ability to change the product mix, while maintaining
the same total production quantity, for example
producing the same products in different quantities.
Depends on the factors like similarity of the parts in the
mix, machine flexibility and the relative work content
times of the parts produced.
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Types of flexibility (cont. 2)
Product Flexibility
Ease with which design changes can be accommodated
and ease with which new products can be introduced.
Depends on machine flexibility and the similarity of the
existing part family and off line part program
preparation.
Routing Flexibility
Capacity to produce parts through alternative work stations
of individual work stations in response to equipment
malfunctions of individual work stations. Depends on the
factors like similarity of work stations, duplication of work
stations, cross training of manual workers, common tooling
and similarity of parts.
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Types of flexibility (cont. 3)
Volume Flexibility
Ability to economically produce parts in high and low
quantities.
Expansion Flexibility
Ease with which the system can be expanded to increase
total production quantities. Expense of adding work stations.
Ease with which layoıt can be expanded. Type of part
ahndling system used are the factors.

IE 262 Class Notes by Figen Eren 14

Necessary codes to program FMS
Turning machine controls
lathe2 chuckoff: closes the chuck
lathe2 chuckon: opens the chuck
lathe2 dooron: opens the door
lathe2 dooroff: closes the door
load paletten lathe2: stops the palette n in front of the
turning machine for loading
unload paletten lathe2: stops the palette n in front of the
turning machine for unloading
lathe2 programname: starts the cutting program
“programname.fab”
lathe2=0: non-availability of the machine
lathe2=1: machine available to take commands
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Necessary codes to program FMS(cont.1)
Milling machine controls
mill2 tableoff: closes the vise
mill2 tableon: opens the vise
mill2 dooron: opens the door
mill2 dooroff: closes the door
load paletten mill2: stops the palette n in front of the milling
machine, and push arm performs loading
unload paletten mill2: stops the palette n in front of the
milling machine, and push arm pulls the ready part.
mill2 programname: starts the cutting program
“programname.fab”
mill2=0:non-availability of the machine
mill2=1: machine is available
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Necessary codes to program FMS(cont.2)
Ports readings
There are 2 ports: a and b
port a: output port that sends “0” or “1”
bit 1: autorization bit for milling machine (porta 1=1)
bit 2: autorization bit for turning machine
(porta 2=0:can stop, porta 2=1:release palette)
port b: input port that sends “0” or “1”
bit 1: controls the palettes in front of the milling machine
(portb 1=0:palette is not in front of the milling machine)
(portb 1=1:palette is in front of the milling machine)
bit 2: controls the palettes in front of the turning machine
(portb 2=0:palette is not in front of the turning machine)
(portb 2=1:palette is in front of the turning machine)
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Necessary codes to program FMS(cont.3)
Variable names
set var1: var1 will be used as a variable by the program
or
set var1 var2 var3 ....: multiple variable setting in the same
line
var1=init value: sets the var1 to the given value
Initilizations
init robot: brings robot to the home position
init transfert: initialize the transfer machine
var1=init value: sets the var1 to the given value
Line names
label name: represents the name of the line for loops

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Necessary codes to program FMS(cont.4)
Subroutines (functions, methods...)
label subroutinename
.
.
return
Subroutine call
gosub subroutinename: takes the program flow to the label
“subroutinename”, when hits to return goes to the following
line of the subroutine call.
goto labelname: unconditional jump to the line represented
by “labelname”, not related to the subroutines.
Program end
end: last line of the program, subroutines should be out of
the loop. IE 262 Class Notes by Figen Eren 19
Necessary codes to program FMS(cont.5)
Condition check
if condition result
Ex: label repeat
if lathe2=0 goto repeat
(will loop until lathe2=1)
Ex: set var1
:
if var1=10 goto bir label error
if var1<>10 goto iki var1=0
if var>10 goto error
label iki
var1=var1+1
label bir
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:
Necessary codes to program FMS(cont.6)
Palette condition for milling
read paletten pn: reads the palette n’s condition into fixed
variable name p”n”(ex:read palette3 p3). Changes the
condition of execom”n”
execom”n” can be, 0: unload operation is in progress
255:unload operation is complete
1:ERROR
3:robot arm is not ready
ex:
label xxx
read palette5 p5
if execom5<>255 goto xxx (<>:not equal)

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