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Background On Flexible Manufacturing System

Flexible manufacturing systems (FMS) aim to solve the production problems of mid-volume and mid-variety parts. An FMS consists of computer-controlled machine tools and material handling systems that can simultaneously process different part types with minimal setup times. It provides both machine flexibility through versatile machine tools and routing flexibility to continue production even if breakdowns occur. While improving productivity and reducing costs, FMS also require large initial investments and have high maintenance costs.

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70 views4 pages

Background On Flexible Manufacturing System

Flexible manufacturing systems (FMS) aim to solve the production problems of mid-volume and mid-variety parts. An FMS consists of computer-controlled machine tools and material handling systems that can simultaneously process different part types with minimal setup times. It provides both machine flexibility through versatile machine tools and routing flexibility to continue production even if breakdowns occur. While improving productivity and reducing costs, FMS also require large initial investments and have high maintenance costs.

Uploaded by

Rahaprad
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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BACKGROUND ON FLEXIBLE MANUFACTURING SYSTEM:

Batch manufacturing has always had inherent limitations on account of the mid-
volume, mid-variety nature of manufacturing. Work in process levels are generally high
and machine utilization tends to be low. This leads to loss of time which was generally
spend waiting for a machine to be setup, waiting to be moved or waiting for other jobs on
the machines to be completed. Batch production often requires an army of expeditors’
progress chasers to keep jobs flowing through the manufacturing facilities.

Advancements in the field of manufacturing technology have had an impact on


process design. Versatile machines that are capable of handling the work of several
traditional machines have provided some relief in simplifying process flow. These
machines also provide considerable flexibility to address some of the issues pertaining to
mid-volume, mid-variety manufacturing systems. Of the several developments, Flexible
Manufacturing Systems have been most prominent.

DEFINITION:

A flexible manufacturing system (FMS) is a manufacturing system in which


there is some amount of flexibility that allows the system to react in the case of changes,
whether predicted or unpredicted. It involves substituting machines capable of
performing a wide variety of tasks for machines dedicated to the performance of specific
tasks. FMS can also be programmed to handle new products, thus extending the
machines' life cycles. Thus they represent a change from "standardized goods produced
by customized machines" to "customized goods produced by standardized machines".
This volume contains new and updated material in this field, and will be of great interest
to researchers, managers and students concerned with problems related to flexible
manufacturing systems.

This flexibility is generally considered to fall into two categories, which both contain
numerous subcategories. This are listed below:

1. Machine Flexibility: This is related to the ease of making changes required to


produce a given set of part types. Measurement of these changes includes, for
example, time to change tools in a tool magazine to produce a different part
family, time to assemble new fixtures and so on. Technological progress, proper
operation assignment and technological capability of bringing part and tool
together etc. will improve this flexibility.

• Process flexibility and Mix flexibility: This is the ability to produce a given
set of part types, each possibly using different materials in several ways. This,
in essence, relates to the mix of jobs, which the system can process
simultaneously. Process flexibility increases as the machine setup cost
decreases, and by having multipurpose adaptable CNC machines.
• Product flexibility: It is the ability to produce a new set of products
economically and quickly. Product flexibility can be measured from the time
required to switch from one part mix to another.

2. Routing flexibility: This is the ability to handle breakdowns and to continue


processing the given set of part types. This ability exists if either a part type can
be processed via several routes or each operation can be performed by more than
one machine.

• Volume flexibility: This is a measure of the ability to operate an FMS


profitably at different production volumes. This flexibility can be measured by
how small the volumes can be for all part types with the system still being run
profitably.

• Expansion flexibility: It is the capability to build a system and expand it as the


need arises, easily and in a modular fashion.

FEATURES OF FLEXIBLE MANUFACTURING SYSTEM:

• Attempts to solve the production problem of mid-volume and mid-variety parts


for which neither high production rate transfer lines nor highly flexible stand-
alone NC machines are suitable.
• Designed to process, simultaneously, several types of parts in the given mix.
• Equipped with sophisticated flexible machine tools that are capable of processing
a sequence of different parts with negligible tool change over time.
• Parts are transferred from machine to machine by a computer controlled Material
Handling System (MHS).
• It consists of three sub-systems: the machining system, the material handling
system and the control system.
A schematic representation of the structure of FMS is given below:

System Controller

Load Primary Secondary


Unload MHS MHS

Machine Auxiliary
Tools Equipment

Information flow Material flow


Machine tools are the main machines used in manufacturing while auxiliary
equipments are those used for other purpose such as measuring quality using coordinate
measuring machine and automatic washing machine. The primary MHS transports the
work pieces from one location to another in an FMS. On the other hand, MHS transports
work pieces from the machine table to the storage point in front of the machine tool.

ADVANTAGES:

• Productivity increment due to automation


• Preparation time for new products is shorter due to flexibility
• Saved labor cost, due to automation
• Improved production quality, due to automation

DISADVANTAGES:

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