COMPUTER INTEGRATED MANUFACTURING

(CIM)
YEAR / SEMESTER : III/ VI

UNIT V SHOP FLOOR CONTROL AND

INTRODUCTION TO FMS

Dr.M.Prabhahar
Professor
Department of Mechanical Engineering
Aarupadai Veedu Institute of Technology
Vinayaka Mission’s Research Foundation
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UNIT V SHOP FLOOR CONTROL AND
INTRODUCTION TO FMS

Shop floor control – phases – factory data collection

system – automatic identification methods – Bar code
technology – automated data collection system. FMS –
components of FMS – types – FMS workstation –
material handling and storage system –FMS layout-
computer control systems – applications and benefits.

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 SHOP FLOOR CONTROL

Shop floor control is responsible for the detailed

management of activities and the flow of materials
inside the plant, including employees, materials,
machines, and production time

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 Function of
SFC
 Scheduling
 Dispatching
 Follow-up
 Providing output
data
 Providing efficiency

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 Phases of
1. Order release SFC
phase provides the documentation needed to process a production
order through the factory.
The collection of document is called as shop packet.
Route sheet
Material requisitions
Job cards
Move tickets
Part list

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 Phases of
2. Order scheduling
SFC
order scheduling executes the dispatching function in production planning and
control. Two elements of order scheduling
• Machine loading
• Job sequencing
Priority sequencing rules (or)Dispatching rules
 SOT (shortest operating time)
 Earliest due date
STR (slack time remaining) = time remaining before due date-remaining process
time
 STR/OP = STR/No.of. Remaining operations
 Critical ratio (CR) = Due date – Current date/No.of remaining working days
Queue ratio (QR) = slack time remaining in the schedule/planned
remaining queue time
 First – come, first served
1/25/ 201
Last – come, last 6
 Phases of
SFC
3. Order progress
The order progress phase monitors the status of the various
orders in the plant, work-in-progress and other characteristics
that indicate the progress and performance of production.
Three forms of order progress report as follow as
 Work order status report
 Progress report
 Exception report
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 Factory data collection
system
Several data collection techniques used to collect data from the shop
floor. These techniques require the employees to gather the data
and later the data are gathered on a fully automated systems that
requires no human participation.
Types of data collected by FDC
– List number of parts that are scraped
– List number of parts requiring rework
– Equipment downtime
– Time clock by employees for punch in and out.
– Time taken at each work Centre
– Labor time in each work order
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 Types of data collection
system
1. On-line data collection system
The data are entered directly into the plant computer
system and are immediately available to the order progress
2. Off-line data collection system
the data are collected temporarily in a storage device
to be entered and processed by plant computer in a
batch mode

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 Automatic identification
method
It refers to various technologies used in automatic (or) semi-
automatic acquisition of product data entry into a computer
system.
Basic components
• Encoded data
• Machine reader (or) scanner
• Decoder

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 Types of Automated Identification
Technology
 Bar codes

 Radio frequency systems

 Magnetic stripe

 Optical character
recognition
 Machine vision
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 Applicatio
1. Material handling n
– Shipping and receiving and Storage
– Sortation
– Order picking
– Parts for assembly
2. Manufacturing
– Order processing
– Work-in-process
– Machine utilization and Worker
attendance
3. Retails sales and inventory
4. Ware housing and distribution center
operations
1/25 5. Mail and parcel handling
7/2.016Cheque processing in banks 12
 BAR CODE TECHNOLOGY
• It is most the most popular method of automatic
identification in factory data collection.
• Bar code technology was invented in 1949 by Norman
J. Woodland and Bernard silver of USA.

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BAR CODES TECHNOLOGY

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 Bar codes
technology
Commonly used bar codes
are: Code 39 interleaved two-of-
Universal product five(ITF) code 93
code Code 128 Codabar

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Radio frequency
identification

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 AUTOMATED DATA COLLECTION
SYSTEM
Computer process monitoring involves the use of the computer
to observe the process and associated equipment and to collect
and record data from the operation.
• Data acquisition system
• Data collection system
• Multi level scanning

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 Flexible manufacturing
system
DEFINITION

• FMS is highly automated GT Machine cell, consisting of group of

processing stations interconnected by automated material handling
system and controlled by computer system.
• or
• A flexible manufacturing system (FMS) is a form of flexible automation
in which several machine tools are linked together by a material-
handling system, and all aspects of the system are controlled by a central
computer.
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TYPES OF
FLEXIBILITY
There are three levels of manufacturing flexibility.

a) Basic flexibilities
1.Machine flexibility: The ease with which a machine can process various
operations
2.Material handling flexibility: A measure of the ease with which different part
types can be transported and properly positioned at the various machine tools in
a system
3.Operation flexibility: A measure of the ease with which alternative
operation sequences can be used for processing a part type

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b) System flexibilities
1.Volume flexibility
2.Expansion flexibility
3.Routing flexibility
4.Process flexibility
5.Product flexibility

c) Aggregate
flexibilities
1.Program Flexibility
2.Production Flexibility
3.Market Flexibility
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TESTS OF
FLEXIBILITY
The following are four reasonable tests of flexibility in
an automated manufacturing system :

 Part variety test. Can the system process different part

styles in a non batch mode?.
 Schedule change test. Can the system readily accept
changes in production schedule, and changes in either part
mix or production quantity.
 Error recovery test. Can the system recover quickly from
equipment breakdowns, so that the production is not
completely disrupted.
 New part test. Can new part designs be introduced into the
existing product mix with relative ease.

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COMPONENTS OF FMS

FMS has the following components.

 Workstation
 Material Handling and Storage System
 Computer Control System
 Human Resources

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WORKSTATIO
N
Following are the types of workstations typically found in an FMS

1. Load/Unload Stations.
2. Machining Stations.
3. Other processing Stations. (punching, shearing,
welding, etc.)
4. Assembly Station.
5. Inspection station.
6. Other Stations and Equipment. (Inspection, Vision, etc)

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MATERIAL HANDLING SYSTEM
The various automated material handling systems are used
to transport work parts and subassembly parts between the
processing stations.
Functions:
1. Random, Independent movement of work piece
between
stations.
2. Handle variety of Parts
3. Temporary storage
4. Convenient access for loading and unloading
5. Compatible with computer control.
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COMPUTER CONTROL SYSTEM

1. Production Control
2. Workstation Control
3. Quality Control
4. Failure diagnosis
5. Safety Monitoring
6. Work piece Monitoring
7. Performance Monitoring and Reporting

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HUMAN RESOURCES

Human are needed to manage the operations of the FMS.

Functions typically performed by human includes:
1. Loading raw work parts into the system,
2. Unloading finished parts (or assemblies) from
the system,
3. Changing and setting tools,
4. Equipment maintenance and repair,
5. NC part programming in a machining system,
and
6. Programming and operation the computer 26
FMS LAYOUT CONFIGURATION

These are different types of layout:

1. Inline or progressive layout

2. Loop Layout
3. Ladder Layout
4. Open-field Layout
5. Robot Centered Layout

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INLINE LAYOUT

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Loop
Layout

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LADDER LAYOUT

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 TYPES OF MATERIAL HANDLING SYSTEM

1. Conveyor
2. Cranes and Hoists
3. Industrial Trucks
4. Monorails
5. AGV’s
6. Industrial Robots

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Conveyo
r

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Crane
s

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Hoist
s

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Truck
s

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RGV and
AGV

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FMS APPLICATION
1. Machining
2. Sheet metal working
3. Plastic Injection Moulding
4. Forging
5. Welding
6. Textile Machinery manufacture
7. Semiconductor Manufacture

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ADVANTAGE OF FMS

1. Increased machine utilization

2. Reduced Inventory
3. Reduced Lead times
4. Greater Flexibility in production scheduling
5. Reduced direct labor cost
6. Increased Labor productivity
7. Consistent quality

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DISADVANTAGES OF FMS

1. High Capital Investment is required

2. Training and Maintaining knowledge labor is difficult
3. Cost of Fixture
4. Conditioning Monitoring is expensive
5. Sophisticated manufacturing systems
6. Limited ability to adapt to changes in product or product mix.

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THANK YOU!!

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