Unit-5

Cellular Manufacturing and Flexible

Manufacturing System (FMS)
Illustration of the Part Family Concept
Methods for Part Family Formation
• Visual inspection
• Part classification ad coding system
• Production flow analysis
Visual Inspection Method
Parts Classification and Coding Method
• Coding is a systematic process of establishing an alphanumeric value
for parts based on selected part features. Classification is the
grouping of parts based on code values.
• Parts classification and coding method is the most sophisticated, most
difficult, most time-consuming and widely used of the three methods.
Design and Manufacturing Attributes
Any parts classification systems fall into one of the following three
categories:
• Systems based on part design attributes
• Systems based on part manufacturing attributes
• Systems based on both design and manufacturing attributes
Common design and manufacturing attributes
Coding System Structure
• A GT code is a string of characters capturing information about an
item

There are three basic structures used in group technology application.

They are:
• Hierarchical codes (or monocodes or tree structure)
• Attribute codes (or polycodes or chain type structure)
• Decision tree codes (or hybrid codes or mixed codes)
Hierarchical Code
(or Monocode)
• In hierarchical structure, the
interpretation of each successive
symbol depends on the value of
the preceding symbols.
Attribute Code
(or Polycode)

• In this structure, the

interpretation of ach symbol in
the sequence does not
depend on the value of
preceding symbols.
Decision-Tree
(or Hybrid) Code

• A hybrid code captures the

best features of the
hierarchical and polycode
structures. This system is also
know as decision-tree coding.
Reasons for Using a Coding
Scheme
• Design retrieval
• Automated process planning
• Machine cell design
Coding Systems

• Opitz classification system

• MICLASS system
• DCLASS system
• KK-3 system
• CODE system
• CUTPLAN system
• RNC system
• Part Analog system
• COFORM
Basic structure of the
Opitz system of parts
classification
Form code (digits 1-5)
for rotational parts in
the Opitz coding
system
Opitz Classification System
Opitz Classification System
Opitz Classification System
DCLASS
Coding System
• DCLASS stands for
Design and
Classification
Information System
The MICLASS
System
• MICLASS stands for
Metal Institute
Classification System
The structure of a KK-3
system for rotational
components

The KK-3
System
 • Production flow analysis (PFA) is a
method for identifying part families
Production and associated groupings that uses
the information contained on
Flow production route sheets rather on
Analysis part drawings

(PFA)
 • Data collection
Steps • Sortation of process routings
involves in • Preparation of PFA chart
PFA • Cluster analysis
PFA chart
Facility Design using Group
Technology
• Once parts have been grouped into part families by parts
classification and coding or production flow analysis, the
next problem would be determining how to arrange the
machines in the shop.
• Facility layout, also know as plant layout, refers to the
physical arrangement of production facilities. It is the
configuration of departments, work centres, and
equipment in the conversion process.
The objective of facility
layout is to design a
physical arrangement that
most economically meets
the required output
quantity and quality
There are three ways to arrange machines in a shop. They are:

• Line (or product) layout

• Functional (or process) layout
• Group (or combination) layout
Line (or
Product Layout)
• In a line layout, the
machines are
arranged in the
sequence as required
by the product
Line (or Product
Layout)
Functional (or
Process) Layout
• The functional layout is
characterized by keeping
similar machines /
operations at one location
 Functional (or
Process) Layout
Group (or
Combination)
Layout
• A group layout is a
combination of the
product layout and
process layout
• In a group layout,
machines are
arranged into cells.
 Group (or
Combination)
Layout
Benefits of Group Technology

Product design Tooling and Materials Production and Process planning Management
setups handling inventory control and employees
Cellular Manufacturing

Cellular manufacturing (CM) is

Don’t get confused with GT and
an application of group
CM. The central issue in GT is
technology in which dissimilar
‘formulation of part-families’
machines have been
while CM forms the ‘machine
aggregated into, each of which
cells’ to manufacture the
is dedicated to the production
family of parts.
of a part family.
Benefits of Cellular
Manufacturing
 Design
Considerations
Guiding the Cell
Formulation
 • A composite part is a hypothetical part which
includes all of the design and manufacturing
attributes of a family. The composite is a single
Composite hypothetical part that can be completely
processed in a manufacturing cell.
Part Concept • The composite part concept is useful for the
design of GT machine cells, since it facilitates
the identification of the manufacturing
operations required and also their sequence.
Composite Part Concept
Flexible
Manufacturing
Systems
• A flexible manufacturing system
is one manufacturing machine,
or multiple machines that are
integrated by an automated
material handling system, whose
operation is managed by a
computerized control system. An
FMS can be reconfigured by
computer control to
manufacture various products
Flexible
Manufacturing
Systems

• A highly automated GT machine cell,

consisting of a group of processing
workstations (usually CNC machine
tools), interconnected by an
automated material handling and
storage system, and controlled by a
distributed computer system
Schematic view
of a flexible
manufacturing
system / cell
FMS vs Other
Manufacturing
Systems
Flexibility

• Flexibility is an attribute that

allows a manufacturing system
to cope up with a certain level of
variations in part or product
type, without having any
interruption. in production due
to changeovers between
models.
• Flexibility measures the ability to
adopt `to a wide range of
possible environment'.
Types of Flexibility

Expansion
Volume Machine
Production
(or flexibility
flexibility
Mix (orcapacity)
Routing
process)
Product
flexibility
flexibility
flexibility
flexibility
flexibility
Machine • Machine flexibility is the capability
to adapt a given machine in the
Flexibilit system to a wide range of
production operations and part
y types.
Production • Production flexibility is the range
of part types that can be produced
Flexibility by a manufacturing system.
 Mix • Mix flexibility, also known as
process flexibility, is the ability to
Flexibility change the product mix while
maintaining the same
(or Process production quantity. i.e.,
producing the same parts only in

Flexibility) different proportions.

 • Product flexibility is the ability to
Product change over to a new set of
products economically and quickly
Flexibility in response to the changing
market requirements.
 • Routing flexibility is capacity to
Routing produce parts on alternative
workstation in case of equipment

Flexibility breakdowns, tool failure, and

other interruptions at any
particular station.
 Volume
Flexibility • Volume flexibility, also known as
capacity flexibility, is the ability of

(or the system to vary the production

volumes different products to
accommodate changes in demand
Capacity while remaining profitable.

Flexibility)
Expansion • Expansion flexibility is the ease
with which the system can be

Flexibility expanded to foster total

production volume.
Types of
FMS
Single Machine Cell (SMC)

• SMC consists of a fully

automated machine tool
capable of unattended
operations for a time period
longer than one machine cycle
Flexible Manufacturing Cell (FMC)

• FMC consists of two or three

processing workstations
(usually CNC machining centres
or turning centres), a load /
unload station, and a part
handling system
Flexible Manufacturing System
(FMS)

• A flexible manufacturing
system (FMS) consists of four
or more processing
workstations (typically CNC
machining centres) connected
mechanically by a common
part handling system and
controlled automatically by a
distributed computer system
FMC vs FMS
 Features of the
three categories of
flexible cells and
systems
 Types of
FMS vs
Types of
tests of
flexibility
FMS
Workstations
The types of workstations that are
usually found in a FMS are:
• Load/unload stations
• Machining stations
• Assemble stations
• Inspection stations
• Other processing stations
FMS Layout
Configurations
• In-line layout
• Loop layout
• Ladder layout
• Open-field layout
• Robot-centered cell
 In-line
Layout
The materials and handling
systems are arranged in a straight
line in thein-line layout
 Loop Layout
In the loop layout, the workstations are arranged in a loop
Ladder
Layout
• The ladder layout, an
adaptation of the loop
layout, consists of a loop
with rungs on which
workstations are located
Open-Field
Layout
• The open field layout, also
an adaptation of the loop
configuration, consists of
multiple loops, ladders, and
slidings organized to achieve
the desired processing
requirements
 Robot-
Centered
Cell
In the robot-centered cell,
one or more robots are used
as the material handling
system
 Types of
material
handling
systems for
different FMS
layout
Structure of
FMS
application
software
system
Example of
FMS
Advantages of FMS

• Increased machine utilization

• Reduced inventory
• Reduced manufacturing lead time
• Greater flexibility in production scheduling
• Reduced direct labour cost
• Increased labour productivity
• Shorter response time
• Consistent quality
University
Question