Table of Contents

List of Figures ............................................................................................................................. ii

1.1 Introduction ........................................................................................................................... 1

1.2 Definition .............................................................................................................................. 1

1.3 How Does Flexible Manufacturing System Work? .............................................................. 2

1.4 Basic Components of FMS ................................................................................................... 4

1.5 Different Types of FMS ........................................................................................................ 7

1.6 The Principle Objectives of FMS .......................................................................................... 7

1.7 Advantages of Flexible Manufacturing System .................................................................... 9

1.7 Application of Flexible Manufacturing System FMS ......................................................... 11

1.8 Conclusion ........................................................................................................................... 13

References ................................................................................................................................. 15

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List of Figures
Figure 1: Types of flexibilities ........................................................................................................ 1
Figure 2: flexible manufacturing system operation ........................................................................ 2
Figure 3: Application characteristics of FMS ................................................................................. 6
Figure 4: Flexible manufacturing system ....................................................................................... 6

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1.1 Introduction
In the middle of 1960s, market competition became more intense. During 1960 to 1970 cost was
the primary concern. Later quality became the priority. As the market became more and more
complex, speed of delivery became something customer also needed.

A new strategy was formulated (Customizability). The companies have to adapt to the environment
in which they operate, to be more flexible in their operations and to satisfy different market
segments. Thus the innovation of FMS became related to the effort of gaining competitive
advantage.

First of all, FMS is a manufacturing technology. Secondly, FMS is a philosophy. “System” is the
key word. Philosophically, FMS incorporates a system view of manufacturing. The buzzword for
today’s manufacturer is “agility”. An agile manufacturer is one who is the fastest to the market,
operates with the lowest total cost and has the greatest ability to “delight” its customers. FMS is
simply one way that manufacturers are able to achieve this agility.

Figure 1: Types of flexibilities

1.2 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

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so that work-machine registration is accurate, rapid and automatic. A central computer controls
both machines and transport system.

“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.” FMS
is called flexible due to the reason that it is capable of processing a variety of different part styles
simultaneously at the workstation and quantities of production can be adjusted in response to
changing demand patterns.

1.3 How Does Flexible Manufacturing System Work?

A flexible manufacturing system could be machine flexible, material handling flexible, or
operationally flexible.

The world is becoming closer than ever with advancements in technology and trade. This generates
stress on companies engaged in international trade or otherwise. The demand for certain products
has skyrocketed as companies now have to face the challenge with innovative, high-quality
solutions produced in large numbers, some of them with a heavy scope for customization.
This has led businesses to look for new solutions to ramp up production while remaining flexible
enough to change the output when needed. One such solution is the flexible manufacturing system
capable of automating production without sacrificing the ability to change output when required.

Figure 2: flexible manufacturing system operation

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Flexible manufacturing systems can work in several different ways depending on the production
needs of an individual business. However, these systems will typically consist of three main
functions that allow the system to remain operational. These include:

i. Central Control Computer

ii. Production Machines
iii. Material Handling Systems

These three functions will work together to allow a smooth transition of information and
functionality from one component to another. Understanding how the flexible manufacturing
system works is like comparing the different functions of human body parts – the brain, muscles,
and blood.

i. Central Control Computer

The central control computer will be the brains of the operation. It will be in control of the
transition between producing different parts and changing the amount of production. The transition
to making different parts must be a smooth and rapid process.

The central control computer should also overcome malfunctions to allow for uninterrupted
manufacturing, although this function can change from system to system. This function is vital to
tell the other systems how to transition from one another.

ii. Production Machine

The production machines are the muscle of the operation. They will be the computer numerical
control (CNC) machinery or robots that take orders from the central control computer. These
highly automated machines can change tasks rapidly when needed. This process assures
production is each part as per the requirements.

The production machines connect to the material handling systems to receive the required
materials to produce a specific part. At this stage, 3D printing machines are becoming more
popular for their ease of use and added functionality.

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 iii. Material Handling Systems

The material handling systems are similar to the nutrients in the blood sent to the muscles to keep
them moving and functioning properly. They will be moving the materials to the production
machines to keep making the products.

This part of the system is critical in getting the right materials to the right places.

1.4 Basic Components of FMS

The basic components of FMS are:

i. Workstations
ii. Automated Material Handling and Storage system.
iii. Computer Control System

i. 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

a. Machining centers
b. Load and unload stations
c. Assembly work stations
d. Inspection stations
e. Forging stations
f. Sheet metal processing, etc.

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 ii. 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

a. Random and independent movement of work parts between workstations

b. Handling of a variety of work part configurations
c. Temporary storage
d. Convenient access for loading and unloading of work parts
e. Compatible with computer control
iii. 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:

a. Control of each work station

b. Distribution of control instruction to work station
c. Production control
d. Traffic control
e. Shuttle control
f. Work handling system and monitoring
g. System performance monitoring and reporting

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Figure 3: Application characteristics of FMS

Figure 4: Flexible manufacturing system

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1.5 Different Types of FMS
The different types of FMS are

i. Sequential FMS
ii. Random FMS
iii. Dedicated FMS
iv. Engineered FMS
v. Modular FMS

i. Sequential FMS:

It manufactures one-piece part batch type and then planning and preparation is carried out for the
next piece part batch type to be manufactured. It operates like a small batch flexible transfer line.

ii. Random FMS:

It manufactures any random mix of piece part types at any one time. Dedicated FMS: It continually
manufactures, for extended periods, the same but limited mix of piece part batch types.

iii. Engineered FMS:

It manufactures the same mix of part types throughout its lifetime.

iv. Modular FMS:

A modular FMS, with a sophisticated FMS host, enables and FMS user to expand their FMS
capabilities in a stepwise fashion into any of the previous four types of FMS.

1.6 The Principle Objectives of FMS

The principle objectives of FMS are

i.To improve operational control through:

 Reduction in the number of uncontrollable variables.

 Providing tools to recognize and react quickly to deviations in the manufacturing plan
 Reducing the dependence of human communication.

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ii. To reduce direct labor:

 Removing operators from the machining site (their responsibilities activities can be
broadened).
 Eliminating dependence on highly skilled machines (their manufacturing skills can be
better
 Utilized in manufacturing engineering functions).
 Providing a catalyst to introduce and support unattended or lightly attended machining
operation.

iii. To improve short run responsiveness consisting of:

 Engineering changes
 Processing changes
 Machining downtime or unavailability
 Cutting tool failure
 Late material delivery

iv. To improve long-run accommodations through quicker and easier assimilation of:

 Changing product volumes

 New product additions and introductions
 Differentiation part mixes
 Increase Machine Utilization by:
 Eliminating machine setup
 Utilizing automated features to replace manual intervention
 Providing quick transfer devices to keep machines in the cutting cycle
 Reduce inventors by:
 Reducing lot sizes
 Improving inventors turn-over
 Providing the planning tools for JIT manufacturing

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1.7 Advantages of Flexible Manufacturing System
The benefits or advantages of flexible manufacturing system are listed below:

i. Increase efficiency
ii. Cost reduction
iii. Enhanced flexibility
iv. Improved quality
v. Faster time to market
vi. Stability
vii. Reduce setup time
viii. Faster time to market
ix. Increase equipment utilization
x. Improved workplace safety
xi. Competitive advantage
xii. Real time monitoring and control

i. Increased Efficiency: FMS allows for efficient and streamlined production processes. It
integrates various machines, equipment, and computer systems, enabling automated and
synchronized operations. This reduces manual intervention, minimizes errors, and
optimizes production cycles, leading to higher efficiency and productivity.
ii. Cost Reduction: FMS helps in reducing production costs through various means. By
automating processes and eliminating the need for excessive labor, businesses can reduce
labor costs. FMS also enables better resource utilization, minimizes material waste, and
optimizes inventory management, resulting in cost savings. Additionally, FMS allows for
quick changeovers between different products, reducing downtime and improving overall
operational efficiency.
iii. Enhanced Flexibility: As the name suggests, FMS provides a high degree of flexibility in
manufacturing operations. It enables rapid changes in production processes, allowing
businesses to adapt to market demands and customer requirements quickly. FMS supports
the production of a wide range of products without significant reconfiguration, making it
suitable for businesses with diverse product portfolios or those operating in dynamic
market conditions.

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 iv. Improved Quality: FMS incorporates automation, advanced control systems, and real-
time monitoring capabilities, which contribute to improved product quality. The automated
processes ensure consistency and precision, minimizing human errors. Real-time
monitoring allows for timely identification and rectification of any issues, ensuring
adherence to quality standards. Overall, FMS helps in producing high-quality products with
reduced defects and rework.
v. Faster Time-to-Market: FMS enables faster product development and shorter production
cycles. It supports rapid prototyping and quick customization, allowing businesses to
respond swiftly to market trends and customer demands. The ability to switch between
different products efficiently and quickly reduces the time required to introduce new
products, giving businesses a competitive edge in the market.
vi. Scalability: FMS provides scalability options, allowing businesses to adjust their
production capacity based on market demand. It enables easy integration of additional
machines or equipment to accommodate increased production requirements. This
scalability helps businesses optimize their resources and respond effectively to fluctuations
in demand, preventing overcapacity or underutilization of manufacturing capabilities.
vii. Reduced Setup Time: FMS minimize setup and changeover times between different
product runs, enabling manufacturers to switch between products quickly and efficiently.
viii. Faster Time-to-Market: FMS enable faster production cycles, shorter lead times, and
quicker response to market demands, allowing companies to bring products to market more
rapidly.
ix. Increased Equipment Utilization: FMS maximize the utilization of manufacturing
equipment by minimizing idle time and optimizing machine usage, resulting in improved
return on investment.
x. Improved Workplace Safety: FMS automate hazardous or physically demanding tasks,
reducing the risk of accidents and creating a safer working environment for employees.
xi. Competitive Advantage: By embracing FMS, companies gain a competitive edge by
increasing productivity, improving product quality, reducing costs, and enhancing
responsiveness to customer demands.

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xii. Real-time Monitoring and Control: FMS incorporate advanced monitoring and control
systems that provide real-time visibility into production processes, allowing for prompt
decision-making and proactive adjustments.

1.7 Application of Flexible Manufacturing System FMS

The followings are the Application of Flexible Manufacturing System FMS

i. Metal-cutting machining
ii. Metal forming -forging, plastic injection molding
iii. Assembly of parts and/or equipments (Auto )
iv. Joining-welding (arc , spot)
v. Sheet metal – press working
vi. Surface treatment
vii. Inspection and testing
viii. Automotive industry
ix. Electronics industry
x. Aerospace industry
xi. Medical equipment
xii. Consumer goods
xiii. Pharmaceutical industry

i. Metal-cutting machining: FMS can automate metal-cutting processes such as milling,

turning, drilling, and grinding. It allows for increased precision, faster production rates,
and the ability to handle complex machining operations.
ii. Metal forming - forging, plastic injection molding: FMS can be utilized in metal forming
processes like forging, where it can automate the loading and unloading of raw materials,
control the forging process, and handle post-processing operations. In plastic injection
molding, FMS can automate mold changes, material handling, and quality inspection.
iii. Assembly of parts and/or equipment (Auto): FMS can streamline the assembly process
by automating the handling and assembly of parts and components. In the automotive

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 industry, FMS can automate tasks such as part feeding, component assembly, and quality
control inspections, leading to increased productivity and consistency.
iv. Joining - welding (arc, spot): FMS can automate welding processes, including arc
welding and spot welding. It can handle tasks such as part positioning, welding parameter
control, and quality inspection. FMS allows for precise and consistent welds, reduces
human error, and improves overall efficiency.
v. Sheet metal - press working: FMS can automate press working operations in sheet metal
manufacturing, such as stamping, bending, and punching. It can handle tasks like material
feeding, die changes, part ejection, and quality control. FMS improves productivity,
reduces setup times, and enhances the flexibility of sheet metal production.
vi. Surface treatment: FMS can automate various surface treatment processes, including
painting, coating, and finishing. It can control the application of surface treatments, drying
or curing processes, and inspection of the treated surfaces. FMS improves the consistency
and quality of surface treatments while reducing manual labor and production time.
vii. Inspection: FMS can incorporate automated inspection systems such as vision systems,
coordinate measuring machines (CMMs), and non-destructive testing equipment. It allows
for real-time quality control and inspection during the manufacturing process, ensuring that
products meet the required specifications.
viii. Testing: FMS can automate testing procedures, including functional testing, performance
testing, and reliability testing. It can integrate testing equipment, collect data, and perform
analysis. FMS enables efficient and consistent testing, reducing human error and ensuring
the reliability of the manufactured products.
ix. Automotive Industry: FMS is extensively used in the automotive sector for the production
of vehicles and their components. It enables automated assembly lines, efficient material
handling, and quick changeover between different vehicle models. FMS helps
manufacturers meet the demands of customization, reduce production lead times, and
achieve high-quality standards.
x. Electronics Industry: FMS plays a crucial role in the electronics industry, where there is
a need for fast-paced production and frequent product variations. FMS facilitates the
production of electronic devices, such as smartphones, laptops, and consumer electronics,

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 by automating assembly processes, handling delicate components, and supporting rapid
prototyping
xi. Aerospace Industry: The aerospace industry relies on FMS for the manufacturing of
aircraft components, engines, and related equipment. FMS allows for precision machining,
integration of complex assembly systems, and efficient management of composite
materials. The aerospace industry benefits from FMS in terms of improved productivity,
cost-effectiveness, and adherence to strict quality standards.
xii. Medical Equipment: FMS finds application in the production of medical devices and
equipment, including instruments, implants, and diagnostic systems. FMS enables the
efficient manufacturing of customized medical products, reduces lead times for production,
and ensures high levels of quality and reliability. It supports the industry’s requirements
for flexibility, traceability, and adherence to regulatory standards.
xiii. Consumer Goods: FMS is utilized in the production of consumer goods, such as
appliances, furniture, and household products. FMS helps manufacturers meet the demands
of rapidly changing consumer preferences, shorter product life cycles, and increased
product variations. It enables efficient and flexible production processes, reduces costs, and
ensures timely delivery of products to the market.
xiv. Pharmaceutical Industry: FMS plays a role in pharmaceutical manufacturing by
automating processes such as packaging, labeling, and filling. FMS enables precise dosage
control, ensures compliance with regulatory requirements, and enhances production
efficiency. It allows pharmaceutical companies to optimize their manufacturing operations,
reduce errors, and meet the increasing demand for personalized medicines

1.8 Conclusion
In conclusion, Flexible Manufacturing Systems (FMS) offer numerous benefits and find
application across various manufacturing sectors. The key benefits of FMS include increased
production efficiency, improved product quality, enhanced flexibility, reduced setup time, cost
reduction, faster time-to-market, increased equipment utilization, real-time monitoring and
control, improved workplace safety, and a competitive advantage.

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The application of FMS spans across various manufacturing sectors, including metal-cutting
machining, metal forming, assembly of parts and equipment, joining and welding, sheet metal
press working, surface treatment, inspection, and testing. FMS revolutionize these manufacturing
processes by automating tasks, enhancing precision, improving quality control, and streamlining
production workflows.

Overall, FMS offer a wide range of benefits that enable manufacturers to achieve higher efficiency,
productivity, quality, and competitiveness. Embracing FMS technology has become increasingly
important for companies aiming to thrive in a dynamic and demanding manufacturing landscape.

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