Flexible Manufacturing
Systems
Antonio Martín Quiñones
Irene Cudeiro Tollar
CONTENTS
A REVIEW ON MANUFACTURING FLEXIBILITY
DESIGN OF FLEXIBLE MANUFACTURING SYSTEMS
THE BENEFITS OF FLEXIBLE MANUFACTURING SYSTEMS
CHALLENGES FOR FUTURE
A REVIEW ON MANUFACTURING FLEXIBILITY
Definition
Manufacturing flexibility is the ability to produce diverse products in customer demand while
maintaining high performance. It refers to an organization's ability to adapt to changing
environmental conditions and customer expectations without excessive costs.
Types:
- Machine level flexibility
- Plant level manufacturing flexibility
How to achieve manufacturing flexibility
To achieve manufacturing flexibility, companies should implement three effective methods:
1. Design for reconfigurability. Using equipment that can be easily reconfigured for other purposes is crucial as
investing in new equipment is expensive and often unnecessary.
2. Use an automated traceability system. A real-time traceability system enhances visibility, minimizes delays,
and maintains high quality on flexible lines by enabling quick identification of finished products and work-
in-progress.
3. Connect the dots with mobile robots. Modular systems constantly change, making conveyors difficult to
move and reconfigure. Mobile robots offer flexible connections without obstruction, intelligently navigating
around human workers and unplanned obstacles without facility modifications, making them an alternative
solution.
DESIGN OF FLEXIBLE MANUFACTURING SYSTEMS
Creation of flexibility manufacturing systems
Shaped by a combination of theoretical research, practical experimentation and real-world implementation
a) Cellular manufacturing systems
c) Adapting to demand changes
Based on group technology, dividing resources
into separated cells and products into families. Anticipates changes in demand and product
variants during the design phase especially for
medium-sized product volumes.
b) Numerically controlled manufacturing
systems
Integrate computer-controlled complexes of
automated material handling devices and
machine tools to process a variety of product
types simultaneously.
How to set up a flexible manufacturing system
1) Definition of objectives and requirements 5) Interconnectivity and Communication
Determine manufacturing system goals, product types, production The system's components should be interconnected and Industrial Internet of
volumes, variety, and customization requirements, and identify key Things devices should be utilized for real-time monitoring and data exchange.
performance indicators like lead time and resource utilization.
6) Adaptive Control Systems
2) Modularization
The manufacturing process should be divided into modular components Implement adaptive control systems that adjust process parameters based
each capable of performing multiple tasks and being easily on real-time feedback to reduce downtime and enhance equipment
performance.
reconfigurable.
3) Flexibility Analysis 7) Human-Machine Interaction
Product flexibility, volume flexibility and process flexibility. The system should be designed with user-friendly interfaces that enable easy
system reconfiguration to ensure operators are proficient in its flexibility.
4) Automation and Robotics
8) Continuous Improvement
For flexible control, make use of computer numerical control systems Implement a culture of continuous improvement to identify
and programmable logic controllers. inefficiencies and gather performance data for informed decisions to
guarantee the system effectiveness.
Types of flexibility in ufacturing systems
a) Basic flexibilities
Material handling flexibility, machine flexibility
and operation flexibility.
b) System flexibilities
Expansion flexibility, process flexibility, volume
flexibility , routing flexibility, product
flexibility.
c) Aggregate flexibilities
Production flexibility, program flexibility,
market flexibility:
THE BENEFITS OF FLEXIBLE
MANUFACTURING SYSTEMS
Flexible manufacturing, developed by Jerome H. Lemelson, is a production method that adapts to changes in
product type and quantity, reducing costs and improving efficiency. It combines job-shopped flow, allowing
quick change over time, customizable products, and low inventories, despite higher up-front costs.
Types of Flexible Manufacturing Systems (FMS)
· Based on operation: Progressive (line), Loop, Ladder, Open field, Robot centered.
· Based on machine numbers: Single machine cell (1), Flexible manufacturing cell (2 or 3), Flexible
manufacturing system (4 or more).
· Based on the level of flexibility: Random, Dedicated, Engineered, Modular
Benefits of Flexible Manufacturing Systems
1. Increased Production Flexibility 5. Cost Reduction
FMS allows manufacturers to quickly adapt to changes in FMS investment can be costly initially, but long-term benefits
product demand, design modifications, or new product like reduced setup times, increased efficiency, and reduced
introductions, enhancing production flexibility without waste lead to cost savings throughout the system's life cycle.
extensive downtime.
6. Adaptability to Market Changes
2. Reduced Setup Time FMS allows manufacturers to adapt quickly to market changes,
FMS automates the reconfiguration process, reducing setup customer preferences, and emerging trends, ensuring
times and enabling quicker and more efficient transitions production remains in line with market demands and promoting
between different products in traditional manufacturing competitiveness.
setups.
7. Resource Optimization
3. Enhanced Efficiency and Productivity FMS enhances resource utilization by automating repetitive
The integration of automated systems and intelligent tasks, reducing human intervention, and optimizing machinery
technologies in FMS enhances efficiency and productivity utilization, leading to improved labor utilization, reduced
by optimizing production processes, minimizing idle time, energy consumption, and better resource management.
and maximizing throughput.
8. Customization and Personalization
4. Improved Quality Control FMS offers manufacturers flexibility in product customization,
FMS uses automated inspection systems and sensors to allowing for efficient production of unique products to meet
monitor product quality at various production stages, customer needs or niche market demands.
ensuring consistency and compliance with predefined
standards, thereby minimizing defects and enhancing
overall product quality.
CHALLENGES FOR FUTURE
Integration of Advanced Technologies Sustainability and Environmental Concerns
This is promising revolution in efficiency, agility, and innovation. However, Flexible Manufacturing Systems (FMS) face challenges in aligning with
challenges include compatibility, interoperability, and scalability. Companies must sustainability and environmental responsibility while maintaining efficiency.
invest in robust data management strategies and transparent implementation of AI in Strategies include optimizing energy efficiency, implementing renewable energy,
manufacturing. and circular economy.
Cybersecurity Risks Cost management
Unauthorized access and malicious exploitation of interconnected systems, are Cost management is crucial for investment decisions FMS technologies and
primary risks. Cybercriminals aim to disrupt operations or steal sensitive infrastructure. Organizations prioritize investments based on long-term value,
information through these vulnerable endpoints. cost optimization and competitiveness.
Skill Gap and Workforce Training
The shift towards automation, robotics, and digital technologies in manufacturing
operations necessitates a shift in traditional skill sets. Organizations must recruit and
train their workforce transforming human operators to optimize the automated
processes.
Thank you
for your
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