Module 4

FLEXIBLE MANUFACTURING SYSTEM

Topics Covered:

• Flexibility
• Types of flexibility
• Types of FMS
• FMS components
• Quantitative analysis
• Advantages and disadvantages of FMS.
Definition:
A flexible manufacturing system (FMS) is an arrangement of
machines……….interconnected by a transport system. The
transporter carries work to the machines on pallets or other
interface units so that work-machine registration is accurate,
rapid and automatic. A central computer controls both machines
and transport system.

Or

“FMS consists of a group of processing work stations

interconnected by means of an automated material handling and
storage system and controlled by integrated computer control
system.
Basic components of FMS:

The basic components of FMS are:

1. Workstations
2. Automated Material Handling and Storage system.
3. Computer Control System

1. Workstations:
• In present day application these workstations are typically
computer numerical control (CNC) machine tools that perform
machining operation on families of parts.

• Flexible manufacturing systems are being designed with other

type of processing equipments including inspection stations,
assembly works and sheet metal presses.
The various workstations are
(i) Machining centers
(ii) Load and unload stations
(iii) Assembly work stations
(iv) Inspection stations
(v) Forging stations
(vi) Sheet metal processing, etc.

2. Automated Material Handling and Storage system:

• The various automated material handling systems are used
to transport work parts and subassembly parts between the
processing stations, sometimes incorporating storage into
function.
• The various functions of automated material handling and
storage system are

(i) Random and independent movement of work parts between

workstations

(ii) Handling of a variety of work part configurations

(iii) Temporary storage

(iv) Convenient access for loading and unloading of work parts

(v) Compatible with computer control

3. Computer Control System:

• It is used to coordinate the activities of the processing

stations and the material handling system in the FMS.

• The various functions of computer control system are:

(i) Control of each work station

(ii) Distribution of control instruction to work station

(iii) Production control

(vi) Traffic control

(v) Shuttle control

(vi) Work handling system and monitoring

(vii) System performance monitoring and

reporting
Another classification of FMS is according to the level flexibility designed into the
system. This method of classification can be applied to systems with any number of
workstations, but its application seems most common with FMCs and FMSs.

Two categories are distinguished here:

• Dedicated FMS
• Random-order FMS

Dedicated FMS:
• A dedicated FMS is designed to produce a limited variety of part styles, and
the complete universe of parts to be made on the system is known in
advance.
• The term special manufacturing system has also been used in reference to
this FMS type
• The part family is likely to be based on product commonality rather than
geometric similarity.
• The product design is considered stable, and so the system can be designed
with a certain amount of process specialization to make the operations more
efficient.
Random order FMS:
• A random-order FMS is more appropriate when the part family is large,
there are substantial variations in part configurations, there will be new
part designs introduced into the system and engineering changes in
parts currently produced, and the production schedule is subject to
change from day-to-day.
• 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 the variations
in product and is capable of processing parts in various sequences
(random-order).
• A more sophisticated computer control system is required for this FMS
type.