FMS 2011

INDEX

Sr. No. Subject Page No.

1. Introduction 03

2. Flexibility and its Type 04

3. FMS and its Rule 06

4. Machine loading 08

5. Problem Description 09

6. Solution Methodology 10

7. Exact Heuristic by Reallocation paradigm 11

8. Scheduling 12

9. Definition 14

10. Dispatching rules 15

11. Methods and practical applications 16

12. Control of FMS system 18

13. Recent trends 19

14. References 20

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ABSTRACT

Determining the production capacity of flexible manufacturing system is a very

important issue in the design of such system. We propose an approach for determining
the production capacity (i.e., the maximum production rate) of a flexible manufacturing
system with several part types, dedicated pallets, and fixed production ratios among the
different part types. We show that the problem reduces to the determination of a single
parameter, for which we propose an iterative procedure. Simulation or approximate
analytical techniques can be used as the building block performance evaluation
technique in the iterative procedure.

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INTRODUCTION
A flexible manufacturing system 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. A flexible manufacturing system is a highly automated system
that manufactures parts,. In general, an flexible manufacturing system consists of
numerically controlled machine groups with a single machine or several identical
parallel machines, load-unload stations, an automated material handling system, buffer
spaces, a tool store, and a set of pallets. At the load-unload station, each part is clamped
on a fixture which is mounted on a pallet. The part is then processed on the machines
while loaded on the pallet and it is unloaded at the load-unload station when all
operations have been completed. The flexible manufacturing system usually has
intelligent control.
Two categories of flexibility:

 Machine flexibility, covers the system's ability to be changed to produce new

product types, and ability to change the order of operations executed on a part.
 Routing flexibility, which consists of the ability to use multiple machines to
perform the same operation on a part, as well as the system’s ability to absorb
large-scale changes, such as in volume.
If a company was machining earthmover axle components or valve housings in small
batches then high inventory, unpredictable, long lead times and quality problems were
very common. This led to an important problem.

Fig.1 Graph of annual production vs no. of parts per system.

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The key idea in FMS is that the co-ordination of the flow of work is carried out by a
central control computer. This computer performs functions such as:

 Scheduling jobs onto the machine tools

 Downloading part-programs (giving detailed instructions on how to produce a
part) to the machines.
 Sending instructions to the automated vehicle system for transportation

Fig.2 Flexible manufacturing system.

Products to be produced are manually loaded onto pallets at a load station, and the
computer system takes over, moving the product to the various processing stations
using automatic vehicles, which may be rail-guided, guided by wires embedded in the
floor or free-roving. After having visited all necessary stations, usually only two or
three, the job is taken back to the load station, where it is removed from the pallet and
passed to the next process.

A flexible manufacturing system is a highly automated system that manufactures parts,.

In general, an FMS consists of numerically controlled machine groups with a single
machine or several identical parallel machines, load-unload stations, an automated
material handling system, buffer spaces, a tool store, and a set of pallets. At the load-
unload station, each part is clamped on a fixture which is mounted on a pallet. The part
is then processed on the machines while loaded on the pallet and it is unloaded at the
load-unload station when all operations have been completed. The flexible
manufacturing system usually has intelligent control. The control mechanism, for
example, specifies which part to process next at a machine upon the completion of
another. We refer to the combination of the physical components and the control of the
flexibility as its configuration.

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METHODOLOGY

Based on the methodology followed, FMS operations literature could be

classified in the following ways:

1. Mathematical programming approach

2. Multi-criteria decision making approach
3. Control theoretic approach
4. Simulation based approach
5. Artificial intelligence (AI) based approach

2.1. Mathematical programming approach

In this approach, the researchers have cast the problem into an optimization
model.Buzacott and Yao (1986) present a comprehensive review of the analytical
models developed for the design and control of flexible manufacturing system up until
1984.They strongly advocate the analytical methods as giving better insight into the
system performance than the simulation models.

2.2. Multiple-criteria decision making approach

Operating a flexible manufacturing system is an activity with multiple criteria. Some

authors have brought in these criteria in their modelling. Selection and allocation
problem using goal programming. Their model considers the goals of:

 Meeting production requirements.

 Balancing of machine utilisation.

 Minimization of throughout time of parts.

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The goal programming model of Lee and Jung can provide the decision maker with a
satisfacting solution for given goals and their prioritization. But even with restrictive
assumptions, the model is computationally expensive for practical use.

2.3. Control theoretic approach

Gerswin(1986) present a control theoretic perspective on the production control aspects

of flexible manufacturing system. Kimemia(1983) presented a closed loop hierarchical
formulation of flexible manufacturing system scheduling problem. He also described
the performance of a stimulated model of an actual facility using this hierarchical
policy. A flexible manufacturing system is considered where parts are manufactured to
meet a certain demand which could be varying over time.

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FLEXIBILITY AND ITS TYPES

Flexibility is an attribute that allows a mixed model manufacturing system to cope up

with a certain level of variations in part or product style, without having any interruption
in production due to changeovers between models. Flexibility measures the ability to
adapt “to a wide range of possible environment”. To be flexible, a manufacturing
system must posses the following capabilities:

 Identification of the different production units to perform the correct

operation

 Quick changeover of operating instructions to the computer controlled

production machines

 Quick changeover of physical setups of fixtures, tools and other working

units.

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THE DIFFERENT TYPES OF FLEXIBILITY

MACHINE FLEXIBILITY:
It is the capability to adapt a given machine in the system to a wide range of production
operations and part styles. The greater the range of operations and part styles the greater
will be the machine flexibility. The various factors on which machine flexibility
depends are:
 Setup or changeover time.

 Ease with which part-programs can be downloaded to machines.

PRODUCTION FLEXIBILITY:
It is the range of part styles that can be produced on the systems. The range of part
styles that can be produced by a manufacturing system at moderate cost and time is
determined by the process envelope. It depends on following factors:
 Machine flexibility of individual stations.
 Range of machine flexibilities of all stations in the system.

MIX FLEXIBILITY:
It is defined as the ability to change the product mix while maintaining the same total
production quantity that is, producing the same parts only in different proportions. It is
also known as process flexibility. Mix flexibility provides protection against market
variability by accommodating changes in product mix due to the use of shared
resources.Mixed flexibility depends on factors such as:
 Similarity of parts in the mix.

 Machine flexibility.

 Relative work content times of parts produced.

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PRODUCT FLEXIBILITY:
It refers to ability to change over to a new set of products economically and quickly in
response to the changing market requirements. The change over time includes the time
for designing, planning, tooling, and fixturing of new products introduced in the
manufacturing line-up. It depends upon following factors:
 Relatedness of new part design with the existing part family.

 Off-line part program preparation.

 Machine flexibility.

ROUTING FLEXIBILITY:
It can define as capacity to produce parts on alternative workstation in case of
equipment breakdowns, tool failure, and other interruptions at any particular station. It
helps in increasing throughput, in the presence of external changes such as product mix,
engineering changes, or new product introductions. Following are the factors which
decides routing flexibility:
 Similarity of parts in the mix.

 Similarity of workstations.

 Common tooling.

VOLUME FLEXIBILITY:
It is the ability of the system to vary the production volumes of different products to
accommodate changes in demand while remaining profitable. It can also be termed as
capacity flexibility. Factors affecting the volume flexibility are:
 Level of manual labour performing production.

 Amount invested in capital equipment.

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EXPANSION FLEXIBILITY:
It is defined as the ease with which the system can be expanded to foster total production
volume. Expansion flexibility depends on following factors:
 Cost incurred in adding new workstations and trained workers.
 Easiness in expansion of layout.
 Type of part handling system used.

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FLEXIBLE MANUFACTURING AND ITS ENVIRONMENTAL

RULE
A flexible manufacturing system has four or more processing workstations connected
mechanically by a common part handling system and electronically by a distributed
computer system. It covers a wide spectrum of manufacturing activities such as
machining, sheet metal working, welding, fabricating, scheduling and assembly.
Advantages of processes involved in flexible manufacturing system over the
convectional methods are:

Item Flexible Conventional

Set-up. Defined. Varies.

Volume. Low-Medium. Medium-High.
Work-in-process. Low. High.
Flexibility. High. Low.
Scrap. Low. Unpredictable.
Labour. Low. High.
Equipment cost. High (short term). Low (short term).
Automation. High level. Low level.
Future. Lead to integration. Dead end.
Quality. Controlled. Varies.
Inspection. Automatic tie-in. Doesn’t flow.
Tooling and fixturing. Flexible. Rigid.
Market changes. Flexible. Rigid.
Equipment utilization. Optimized. Low.
Production control. Predictable. Unpredictable.
Lead time Low. High.

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COMPARISION BETWEEN FLEXIBLE MANUFACTURING

SYSTEM AND CONVENTIONAL SYSTEM
Another strategic advantage of FMS is that it is able to handle the risk caused by
uncertainty about the future. It can be done through planning in a way that maintains
flexibility of the environment. Although it is impossible to predict the future, one can
make estimates of probabilities and proceed in ways to accord with the future.

As a conclusion, FMS technology can be termed as an evolutionary step beyond transfer

lines that enables the industries to accommodate the growing costumer demand and
maintain the quick delivery of customized products. It is the newest wave in attaining
greater productivity with instant positive response to both adversities and new
opportunities.

ANNUAL PRODUCTION, FLEXIBILITY, COST INCURED:As indicated in our

definition, there are several basic components of an Flexible manufacturing system. In
the following segment, a framework for understanding the components of an FMS is
presented. A flexible manufacturing system consists of two subsystems:

 Physical subsystem

 Control subsystem

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PHYSICAL SYSTEM INCLUDES

1. Workstations. It consists of Numerical Control machines, machine-tools, inspection

equipments, loading and unloading operation, and machining area.

2. Storage-retrieval systems. It acts as a buffer during work-in-processes and holds

devices such as carousels used to store parts temporarily between work stations or
operations.

3. Material handling systems. It consists of power vehicles, conveyers, automated

guided vehicles, and other systems to carry parts between workstations.

CONTROL SUBSYSTEM INCLUDES

1. Control hardware. It consists of mini and micro computers, programmable logic

controllers, communication networks, switching devices and others peripheral devices
such as printers and mass storage memory equipments to enhance the working
capability of the FMS systems.

2. Control software. It is a set of files and programs that are used to control the physical
subsystems. The efficiency of FMS totally depends upon the compatibility of control
hardware and control software.

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MACHINE LOADING

Operation management in an FMS is more intricate than that of the conventional

manufacturing systems e.g. transfer line or job shop production system and depends
largely upon how the decision problems is being tackled. This is primarily due to
versatile machines, which are capable of performing a wide range manufacturing
operations with quick tooling and instruction changeovers that result in many
alternative routes for processing of part types.

In most Flexible manufacturing systems, the part to be machined has to be loaded on

a pallet of some kind and after required operations; it is needed to be taken-off from the
pallets. In other words, we can say that loading involves, taking a component delivered
to the systems and preparing it for processing. After processing the component is
brought back from its pallet to the load/unload area and it is placed on the floor to wait
its disposal to assembly department or a storehouse. These actions come under
unloading process.

Machine loading problem of a flexible manufacturing system is known for its

complexity, which encompasses various types of flexibility aspects pertaining to part
selection and operation assignments along with constraints ranging from simple
algebraic to potentially complex and conditional one. Decision pertaining to machine
loading problems has been considered as tactical level planning decision that acts as a
tie between strategic and operating level decision in manufacturing.

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SCHEDULING

Scheduling is a process of adding start and finish time information to the job order
dictated in the sequencing process. Sequencing process in turn, is defined as getting the
order in which jobs are to be run on a machine. The sequence thus obtained determines
the schedule, since we assume each job is started on the machine as soon as the job has
finished all predecessor operations and the machine has completed all earlier jobs in
the sequences.

This is referred to as semi-active schedule and acts as an optimal policy for minimizing
the completion time, flow time, lateness, tardiness, and other measures of performance.
Scheduling problems are often denoted by N/ M/ F/ P, where N is the number of jobs
to be scheduled, M is the number of machines, F refers to the job flow pattern, and P is
performance measures that are to be appropriately minimized or maximized. The
solution of scheduling problems are generally presented in the form of gannt-chart
which is a chart plotted between different work centers and total processing time on
that work center. Following is given an example problem to illustrate the formation of
Gantt-chart.

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CONTROL OF FMS SYSTEM

The flexible manufacturing system includes a distributed computer system that is linked
to the work stations, material handling system and other hardware components. A
typical flexible manufacturing computer system consists of a central computer and
micro computers controlling the individual machines and other components.

The control system in FMS causes the process to accomplish its defined function. The
control can be either closed loop or open loop. A closed loop control system is one in
which the output variable is compared with an input parameter and any difference
between the two is used to drive the output into agreement with the input. It is also
known as feedback control system.

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RECENT TRENDS

Depending upon the problem environment, many new trends have been accommodated
with FMS to accord with the requirements of highly customized production, high
flexibility, low production cost, and low lead time. Some of these recent developments
in the field of manufacturing sector made in order to stack up against the competitive
market scenario are given below:

 Production planning and control (PPC). It is concerned with the logistic

problems that are encountered in manufacturing processes. It includes the
details of what and how many products to produce and when to obtain the raw
materials, parts and resources to produce those products

 Master production schedule (MPS). It is a list of the product to be manufactured,

when they should be completed and delivered, and in what quantities. The
master schedule must be based on an accurate of demand and realistic
assessment of the company’s production capacity.

 Material requirements planning (MRP). It is a planning technique, usually

implemented by computer, that translates the MPS of end products into a
detailed scheduled for the raw materials and parts used in those end products.
MRP is often thought of as a method of inventory control. However its
implementation is complicated due to the sheer magnitude of data to be
processed. For example several component may be made out of the same gauge
sheet metal the component are assembled into simple sub assemblies, and these
sub assemblies are put together into more complex sub assemblies, and so on,
until the final products are assembled. Each step in the manufacturing and
assembly sequence takes time. All of these factors must be incorporated into the
MRP calculations which make it a complicated one.

 Just in time (JIT). It refers to a scheduling discipline in which materials and

parts are delivered to the next production line station just prior to their being

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used. In this type of discipline tends to reduce inventory and other kinds of waste
manufacturing. The ideal JIT production system produces and delivers exactly
the required number of each component to the down stream operation in the
manufacturing sequence just at the time when that component is needed.

 Manufacturing resource planning (MRP II). It is defined as a computer based

system for planning, scheduling, and controlling the materials, resources, and
supporting activities needed to meet the MPS. The recent generations of MRP
II such as enterprise resource planning (ERP), manufacturing execution system
(MES), customer oriented manufacturing management systems (COMMS) etc
have found great applications in the areas of quality control, maintenance
management, customer field service, supply chain management, and product
data management.

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SUMMARY

The flexible manufacturing system is a manufacturing concept for mid-volume, mid-

variety part production. There could be a number of FMS’s configurations possible
depending upon its feature such as number of machines, kinds of operation, and level
of flexibility designed into the system. Further more, the degree of automation of the
machine tools, material handling systems and central computer system, depends on the
objectives of an organization.

An FMS is capable of accommodating engineering and process changes that are liable
to occur during manufacturing. In this chapter, various aspects of FMS such as physical
and control components, its types, and some analytical treatments of machine loading
problems, scheduling problems is illustrated to characterize its supremacy over the
other conventional manufacturing system.

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REFERENCES

 ASKIN R. G., and STANDRIDGE C. R., 1993 “Modeling and Analysis of

Manufacturing Systems”. John Wiley and Sons, Inc.

 GROOVER, M. P., 2001. “Automation, Production Systems, and Computer-

Integrated Manufacturing, 2nd Ed”. Pearson education, Singapore.

 KIM, Y. D., and YANO, C. A., 1997, Impact of throughput based objectives
and machine grouping decisions on the short-term performance of flexible
manufacturing system, International Journal of Production Research, 35 (2),
3303-3322.

 SHANKAR, K., and SRINIVASULU, A., 1989, Some solution methodologies

for loading problems in flexible manufacturing system, International Journal of
Production Research, 27 (6), 1019-1034.

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