BOHR International Journal of Engineering

2022, Vol. 1, No. 1, pp. 37–41

DOI: 10.54646/bije.2022.08
www.bohrpub.com

ORIGINAL ARTICLE

Optimization of flexible manufacturing systems using IoT

V. Kandavel * , V. Preethi and Johnpeter Soosairaj
Department of Mechanical Engineering, SSM Institute of Engineering and Technology, Dindigul, India

*Correspondence:
V. Kandavel,
[email protected]

Received: 11 September 2022; Accepted: 20 September 2022; Published: 28 September 2022

A flexible manufacturing system (FMS) is an automated material handling and integrated workstation that is
computer-controlled and used for the automatic random processing of palletized parts. To assess the effectiveness
of the FMS design before deployments, computer simulation is a cost-effective method. It is crucial to test this
simulation software before usage since they have such a clear influence on the FMS decision-making process.
A FMS is a complicated, integrated system that includes a central computer numerical control machining center
and an automated material management system. The sole drawback of FMS is its greater initial cost and
replacement cost if it does not function properly. Therefore, it is important to analyze FMS before installing it. The
use of Industry 4.0 technologies has expanded the flexibility of the entire manufacturing system. The development
of these technologies, which include the Internet of Things (IoT), big data, artificial intelligence (AI), additive
manufacturing (AM), sophisticated robotics, virtual reality, cloud computing, simulation, and others, has increased
the industrial system’s adaptability.
Keywords: flexible transfer lines, flexible manufacturing cells (FMC), internet of Things (IoT), flexible manufacturing
system

1. Introduction assistance of a central computer to satisfy the daily changes

in consumer expectations. Such a production system has the
The availability of several workstations at which generic benefit of being very flexible in terms of the little effort and
processes are carried out defines flexible manufacturing rapid turnaround time needed to make a new product; for
systems (FMS). This system’s flexibility is realized through this reason, it is referred to as a FMS.
a network of programmable transportation that connects
the workstations and an advanced control system that
coordinates the operations of the workstations and transport 2. The FMS concept
systems while keeping track of the status of the ongoing
jobs. In general, innovations fascinate people, especially if the The FMS offers batch production with the efficiency of mass
results can benefit them. The global marketplace is impatient manufacturing. When components are produced in lots of
and price-sensitive. few to more than 50, with a total yearly demand of less
Due to daily fluctuations in client demand for a wide than, say, 100,000 units, it is referred to as batch production.
range of goods with eight pre-specified quality at lower When greater yearly production rates are needed, mass
prices, Indian business requires flexible production facilities manufacturing is used, and thus, the usage of specialized
to compete in today’s global market incorporating innovative machinery might be justified. It may cost 100 times as
production technologies like FMS, JIT, CAD, and CAM, much to create a single unit using general-purpose machine
which have enormous potential. The many independent tools as it does to produce the identical item using the
manufacturing systems that were discussed throughout this most effective mass production techniques. It should be
article may be combined in India to create a single, large-scale able to lower the cost of creating components in small and
system in which the production of parts is managed with the medium quantities by utilizing FMS technology. Advanced

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38 Kandavel et al.

FIGURE 1 | Value-wise contents of mechanical and electronic software and hardware in different manufacturing facilities.

FMS will contain a high-power laser station incorporated tools to system-oriented manufacturing. This resulted in the
into the production line; the laser will be used mainly for introduction of flexible manufacturing cell (FMC), FMS, and
heat treatment, sheet metal cutting, drilling, and welding. computer-integrated manufacturing.
At present, laser treatment of materials with a CO2 laser Thus, the emphasis has shifted from mechanical hardware
in the 5–15 kW range is becoming more popular in the in the case of conventional manufacturing to a combination
industry. The central computer of an advanced FMS will of mechanical and electronic software and hardware,
contain machining data to provide the recommended cutting which now accounts for 30–50% of the value of modern
parameters to the machine tools in the plant, based on a manufacturing systems.
selected tool, workpiece material, and upon maximization of An FMC/FMS is typically a manufacturing cell or system
the production rate in the entire plant. made up of one or more CNC machines connected by
Different manufacturing equipment with sensing, an automated material handling system, all of which are
identification, processing, communication, actuation, and controlled by a central computer. There may also be
networking capabilities can be connected through the additional auxiliary subsystems, like component loading
Internet of Things (IoT). The IoT can be utilized for and unloading stations, automatic tool handling systems,
industrial applications and smart manufacturing through wash stations, component measuring apparatuses, and tool
network control and management of manufacturing pre-setters. Figure 2 shows the major constituents of
equipment, asset and situation management, or an FMS, and Figure 3 gives the integration of various
manufacturing process control. Intelligent IoT solutions constituents of an FMS.
allow for quick product development, product optimization, Factory managers may automatically gather and evaluate
and quick reaction to market demands. data using smart manufacturing to make better decisions and
The IoT includes digital control systems that automate maximize production. IoT connectivity solutions installed at
process controls, operator tools, and service information the factory level transmit data from sensors and machines to
systems that improve plant safety and security. Utilizing the cloud. These data are examined, merged with relevant
measurements, statistical analysis, and predictive information, and then disseminated to relevant parties
maintenance, IoT can also be used in asset management with authorization.
to increase reliability. Energy optimization is made
possible through the integration of industrial management
systems with smart grids. Networked sensors are used for
measurements, automated controls, plant optimization,
health and safety management, and other purposes. IoT is
employed for procedures in the industrialization of buildings
in addition to normal manufacturing.

2.1. Advanced manufacturing systems

While the various evolutionary stages in the development

of computer numerical control (CNC) machines provided
a means for effective part production, over time and with
rapid developments in electronics, machine tool technology
has graduated from the concept of standalone machine FIGURE 2 | Major constituents of an FMS.
10.54646/bije.2022.08 39

FIGURE 3 | Integration of various constituents of an FMS.

2.2. Benefits of an FMS to choose from depending on part variety and production
volume. The production of a limited variety of parts in high
• Balanced output volume, which is typical of automobile industries, is served by
• Better control over production transfer lines. When the volume is large, but a variety of parts
• Easier to expand are inserted, the transfer line is designed with some built-
• Fewer rejections in flexibility to handle the production requirement. FMS
• Flexibility to change part variety are ideal for the production of large part tools, industrial
• High product quality machinery, and general engineering.
• Higher machine utilization Industries manufacturing items such as tractors,
• Higher productivity earthmoving equipment, agriculture machinery, and
• Just-in-time manufacturing defense-related components have production requirements
• Minimally manned operation of a fairly large volume and a wider variety of parts. This need
• Reduced cycle time is being met by what may be termed as designed FMS/FMC,
• Reduced work in process and inventory. where the basic production equipment is flexible, but the
volume is high enough to dedicate individual machines
to specific parts.
3. Trends in the adoption of FMS Industries see an increase in productivity during product
production when this technology is used properly.
FMS was adopted in the USA way back in 1967, but its Manufacturing is done more cheaply and with fewer
widespread application has been rather slow. In 1981, the mistakes. To fully benefit humanity, there is still much work
world population of FMS was estimated to be only 115, with to be done. It has numerous uses for monitoring production
25 FMS installations each in the USA, Western Europe, and systems in the manufacturing and service industries.
40 in Japan. But by 1986, the population had grown to over By enabling increased performance, this technology
200; an industry-wise application of FMS is given in Figure 4. expands manufacturing’s potential for innovation and new
Thus, with development over time, the manufacturing possibilities. The main elements of this technology are
industry now has a spectrum of production alternatives software, hardware, and network connectivity for data
collection and alteration. IoT fosters innovative disruption
in the manufacturing sector.

3.1. Stepwise approach to FMS

A leading machine tool manufacturer abroad has outlined

a stepwise adoption of an FMS for prismatic production,
as detailed below.
Step 1: The user can gain expertise in palletizing
work and processing a mixed batch of components
on a standalone machine with nameless operation
capabilities.
Step 2: Performance in 2 days is improved by the addition
FIGURE 4 | Industry-wise application of FMS. of a rail-guided vehicle and up to 15 pallet stands. The
40 Kandavel et al.

variety of components that can be handled without operator 3.3. Flexible transfer lines
assistance expands, and the duration of unnamed operation
can be increased. High-volume productions are suited for flexible transfer
Step 3: It is possible to add machines with up to 15 lines (FTLs). In a high-volume manufacturing setting,
pallet stands apiece. Pallets are dedicated to certain machines a part could need to go through numerous operations,
at this level. Each machine has a designated load/unload each of which is assigned to be completed on a single
station where these operations are performed. In response machine. As a result, each component travels along a set
to commands from the various machine control systems, the path through the system. Typically, the material handling
rail-guided vehicle moves. system consists of a conveyor, carousel, or pallet. Along
Step 4: The same system hardware specifications as in with general-purpose machines, it may also include robots,
step 3 plus control over separate transports. Now, any special-purpose machines, and some specialized equipment.
machine may be loaded with any pallet. Rather than It is simpler to plan for balancing machine loads. Unlike
responding to machine requests in a queue for the next conventional transfer lines, the FTL allows for the fabrication
component, the transporter operates following the priorities of a variety of work parts. The process of resetting is
set by the operator. mostly automatic.
Step 5: The cell may be extended to accommodate Multiple universal or specialized flexible automated
more machines and support operations like inspection machine tools are combined into a flexible machining
and washing with the installation of a host computer. system called a flexible machining system. This allows for
To fully utilize automated manufacturing technologies, the simultaneous machining of multiple work components.
encompassing all business and engineering operations The defining characteristic is the machine interlinkage,
leading to computer-integrated production, a host computer which is unrestricted by cycle concerns. It is possible to
upgrades the system. compensate for varied machining times at the various
Step 6: The IoT is to collect and share data via Internet- stations by employing centralized or decentralized workpiece
connected machines and gadgets. It is connected to particular buffer storage. Flexibility is applied to machines through
identification numbers or codes that can be managed by CNC control and product flow from one machine to
everyday gadgets like cell phones, which is very much useful another, which is made possible by adaptable transport
for the beneficiaries of the human concern working in that systems. Flexibility is the capacity of a system to adapt
industrial environment. to changes in the volumes of the product mix as well as
the machining procedures and sequences. As a result, an
FMS will be able to react quickly to shifting consumer
3.2. Flexible manufacturing cells and market demands.

An FMC is the most fundamental type of FMS and is

therefore the most adaptable. It is made up of a few general-
purpose or specialized CNC machine tools connected
4. Major elements of FMS
to automatic tool and material changes. Centers are
Each major subsystem in an FMS carries out a variety of tasks,
frequently the starting point for FMS, but they can be
and each one depends on the others for the system to operate
automatically machined by FMCs. A turning center with
as a whole. The tasks vary according to the machinery and
a gantry, an unloading system, and pallets for storing
manufacturing processes that are used.
workpieces and finished components is commonly
known as a flexible turning cell. The productivity of
the cell can be increased if the turning center contains • Production equipment
post-process metrology tools like Renishaw probes or • FMS for sheet metal work
inductive measuring tools, automatic tool changes, • FMS for machining
tool magazines, block tooling, automatic tool offset • Support systems.
measurement, and automatic chuck changes. One or
more horizontal machining centers with modular fixtures, Automated machine tools frequently require many
numerous pallets, an advanced tool management system, systems to function. At each machine or in the center
an automobile tool changer, an automobile head changer, tool storage, the required tools for machining centers or
an automatic magazine change, robots or other material turning centers’ numerous operations may be housed in
handling systems to aid in job access to the machine, magazines. Local publications provide quick access and
and one or more flexible machining cells make up a backup capacity, but in a large FMS, a central tool facility
flexible machining cell. might be more efficient.
10.54646/bije.2022.08 41

4.1. Material handling system FMS to the defense sector under a joint working agreement
with an overseas manufacturer. Although the FMS requires
To maintain an FMS, several material-handling systems a higher initial investment, its benefits are substantial in the
are often required. long run. Hence, the adoption of FMS in the Indian industry
is likely to grow in the future as the demand for flexibility and
• A mechanism for moving goods in and out of productivity increases.
the FMS, such as RVs, gantry systems, AGVs, and With thermal and video sensors gathering comprehensive
overhead conveyors. product data across various stages of a product cycle,
• A transfer system to load and unload the machines. the IoT makes this procedure proactive. At each stage
• A buffer storage system for machine workpiece queues of the manufacturing process, the goods can also be
(e.g., pallets). checked to see if their characteristics meet the requirements.
• These systems must be coordinated with machine Instrumentation and monitoring of production equipment
operations to function properly. also assist quality control staff in determining whether and
where equipment calibration deviates from standard settings.
Such inaccuracies must be stopped in advance to prevent
5. Optimization of FMS misalignment of products.

The following strategies should be taken into account to

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