5.

Flexible Manufacturing System

1. Manufacturing System defined and Classified
1. Components of a Manufacturing System
2. Manufacturing Systems Classification
3. Overview of the Classification System
2. FMS Components
3. FMS Applications
4. FMS Benefits
5. FMS Planning and Implementation Issues
6. Quantitative Analysis of FMS

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5.1 Manufacturing System
Manufacturing System Defined
• A collection of integrated equipment and human
resources, whose function is to perform one or more
processing and/or assembly operations on a starting
raw material, part or set of parts
• Equipment includes
– Production machines and tools
– Material handling and work positioning devices
– Computer systems
• Human resources are required either full-time or
periodically to keep the system running
Examples of Manufacturing Systems
• Single-station cells
• Machine clusters
• Manual assembly lines
• Automated transfer lines
• Automated assembly systems
• Machine cells (cellular manufacturing)
• Flexible manufacturing systems
5.1.1 Components of a Manufacturing System
a) Production machines
b) Material handling system
c) Computer system to coordinate and/or
control the preceding components
d) Human workers to operate and manage the
system
a) Production Machines
• In virtually all modern manufacturing systems,
most of the actual processing or assembly work
is accomplished by machines or aid of tools
• Classification of production machines:
1. Manually operated machines are controlled or
supervised by a human worker
2. Semi-automated machines perform a portion of the
work cycle under some form of program control,
and a worker tends the machine the rest of the cycle
3. Fully automated machines operate for extended
periods of time with no human attention
b) Material handling system
Work Transport Between Stations
• Two general categories of work transport in
multi-station manufacturing systems:
1. Fixed routing
• Work units always flow through the same
sequence of workstations
• Most production lines exemplify this category
2. Variable routing
• Work units are moved through a variety of
different station sequences
• Most job shops exemplify this category
(a) Fixed Routing and (b) Variable Routing
c) Computer Control System
• Typical computer functions in a
manufacturing system:
– Communicate instructions to workers
– Download part programs to computer-controlled
machines
– Control material handling system
– Schedule production
– Failure diagnosis when malfunctions occur
– Safety monitoring
– Quality control
– Operations management
5.1 Manufacturing Systems
5.1.2 Classification of Manufacturing Systems
• Factors that define and distinguish
manufacturing systems:
1) Types of operations
2) Number of workstations
3) System layout
4) Automation and manning level
5) Part or product variety
1) Types of Operations Performed
• Processing versus assembly operations
• Type(s) of materials processed
• Size and weight of work units
• Part or product complexity
– For assembled products, number of components per
product
– For individual parts, number of distinct operations to
complete processing
• Part geometry
– For machined parts, rotational vs. non-rotational
2) Number of Workstations
• Convenient measure of the size of the system
– Let n = number of workstations
– Individual workstations can be identified by
subscript i, where i = 1, 2, ..., n
• Affects performance factors such as workload
capacity, production rate, and reliability
– As n increases, this usually means greater workload
capacity and higher production rate
– There must be a synergistic effect that derives from n
multiple stations working together vs. n single stations
3) System Layout
• Applies mainly to multi-station systems
• Fixed routing vs. variable routing
– In systems with fixed routing, workstations are
usually arranged linearly
– In systems with variable routing, a variety of layouts
are possible
• System layout is an important factor in
determining the most appropriate type of
material handling system
4) Automation and Manning Levels
• Level of workstation automation
– Manually operated
– Semi-automated
– Fully automated
• Manning level Mi = proportion of time worker
is in attendance at station i
– Mi = 1 means that one worker must be at the station
continuously
– Mi  1 indicates manual operations
– Mi < 1 usually denotes some form of automation
4) Part or Product Variety: Flexibility
• The degree to which the system is capable of dealing
with variations in the parts or products it produces
• Three cases:
1. Single-model case - all parts or products are identical
2. Batch-model case - different parts or products are
produced by the system, but they are produced in batches
because changeovers are required
3. Mixed-model case - different parts or products are
produced, but the system can handle the differences
without the need for time-consuming changes in setup
 Three Cases of Product Variety

(a) Single-model case, (b) batch model case, and

(c) mixed-model case
Enablers of Flexibility
• Identification of the different work units
– The system must be able to identify the differences
between work units in order to perform the correct
processing sequence
• Quick changeover of operating instructions
– The required work cycle programs must be readily
available to the control unit
• Quick changeover of the physical setup
– System must be able to change over the fixtures and
tools required for the next work unit in minimum
time
5.1.3 Overview of Classification Scheme
• Single-station cells
–n=1
– Manual or automated
• Multi-station systems with fixed routing
–n>1
– Typical example: production line
• Multi-station systems with variable routing
–n>1
Manufacturing Systems for a) Medium/ High; b) Low Product Complexity
a) Medium or High Product Complexity

b) Low Product Complexity

5.2 Flexible Manufacturing Systems
Flexible Manufacturing System - Defined
• A highly automated GT machine cell, consisting of a
group of processing stations (usually CNC machine
tools), interconnected by an automated material
handling and storage system, and controlled by an
integrated computer system
• The FMS relies on the principles of GT
– No system can produce an unlimited range of products
– An FMS is capable of producing a single part family or a
limited range of part families

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Where to Apply FMS Technology
• The plant presently either:
– Produces parts in batches or
– Uses manned GT cells and management wants to
automate the cells
• It must be possible to group a portion of the parts
made in the plant into part families
– The part similarities allow them to be processed on the
FMS workstations
• Parts and products are in the mid-volume, mid-
variety production range

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Flexibility Criteria
1. Part variety test - Can it machine different part
configurations in a mix rather than in batches?
2. Schedule change test - Can production schedule and
part mix be changed?
3. Error recovery test - Can it operate if one machine
breaks down?
– Example: while repairs are being made on the
broken machine, can its work be temporarily
reassigned to the other machine?
4. New part test - As new part designs are developed,
can NC part programs be written off‑line and then
downloaded to the system for execution?
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 Alternative flexibility criteria
Flexibility type Definition Factors
Machine Adaptability to range of Set up, reprogramming, skill
flexibility prdn oprn and part styles versatility, tool storage
capacity
Production Range of part styles Individual m/c flexibility,
flexibility system flexibilyt
Mix flexibility Product mix without Part similarity, work content
change in quantity time
Product Design change, New part design off-line
Flexibility programming
Route Alternative workstation Similarity of product mix, WS
Flexibility sequence on breakdown duplication, common tooling
Volume working on high & low Level of manual labor,
Flexibility quantity (= investment)
Expansion Expansion to increase Expansion cost, layout
flexibility production expansion, MHS,
Types of FMS
• Kinds of operations
– Processing vs. assembly
– Type of processing
• If machining, rotational vs. non-rotational
• Number of machines (workstations):
1. Single machine cell (n = 1)
2. Flexible manufacturing cell (n = 2 or 3)
3. Flexible manufacturing system (n = 4 or more)

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 Single-Machine Manufacturing Cell

A single-machine CNC cell

(Cincinnati Milacron) 24
Flexible Manufacturing Cell

25
Five-machine FMS for machining (Cincinnati
FMS Level of Flexibility
1. Dedicated FMS
– Designed to produce a limited variety of part styles
– The complete universe of parts to be made on the system is
known in advance
– Part family likely based on product commonality rather
than geometric similarity
2. Random-order FMS
– Appropriate for large part families
– New part designs will be introduced
– Production schedule is subject to daily changes

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Features of the Three Categories

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 5.3 FMS Components
1. Workstations
2. Material handling and storage system
3. Computer control system
4. Human labor

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5.3.1 Workstations
• Load and unload station(s)
– Factory interface with FMS
– Manual or automated
– Includes communication interface with worker to
specify parts to load, fixtures needed, etc.
• CNC machine tools in a machining type system
– CNC machining centers
– Milling machine modules
– Turning modules
• Assembly machines

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5.3.2. Material Handling and Storage
• Functions:
– Random, independent movement of parts between
stations
– Capability to handle a variety of part styles
• Standard pallet fixture base
• Workholding fixture can be adapted
– Temporary storage
– Convenient access for loading and unloading
– Compatibility with computer control

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5.3.2. Material Handling Equipment
• Primary handling system establishes basic FMS layout
• Secondary handling system - functions:
– Transfers work from primary handling system to
workstations
– Position and locate part with sufficient accuracy and
repeatability for the operation
– Reposition part to present correct surface for processing
– Buffer storage to maximize machine utilization

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Five Types of FMS Layouts
• The layout of the FMS is established by the
material handling system
• Five basic types of FMS layouts
1. In‑line
2. Loop
3. Ladder
4. Open field
5. Robot‑centered cell

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 FMS In-Line Layout

• Straight line flow, well-defined processing sequence

similar for all work units
• Work flow is from left to right through the same
workstations
• No secondary handling system

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 FMS In-Line Layout

• Linear transfer system with secondary parts

handling system at each workstation to facilitate
flow in two directions

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 FMS Loop Layout

• One direction flow, but variations in processing

sequence possible for different part types
• Secondary handling system at each workstation

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 FMS Rectangular Layout

• Rectangular layout allows recirculation of

pallets back to the first station in the
sequence after unloading at the final station

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 FMS Ladder Layout

• Loop with rungs to allow

greater variation in
processing sequence

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 FMS Open Field Layout

• Multiple loops and

ladders, suitable for
large part families

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 Robot-Centered Cell

• Suited to the handling

of rotational parts and
turning operations

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5.3.3. FMS Computer Functions
1. Workstation control - Individual stations require
controls, usually computerized
2. Distribution of control instructions to workstations -
Central intelligence required to coordinate processing
at individual stations
3. Production control - Product mix, machine
scheduling, and other planning functions
4. Traffic control - Management of the primary handling
system to move parts between workstations
5. Shuttle control - Coordination of secondary handling
system with primary handling system
6. Workpiece monitoring - Monitoring the status of each
part in the system
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FMS Computer Functions
7. Tool control
– Tool location - Keeping track of each tool in the system
– Tool life monitoring - Monitoring usage of each cutting tool
and determining when to replace worn tools
8. Performance monitoring and reporting
– Availability, utilization, production piece counts, etc.
9. Diagnostics
– Diagnose malfunction causes and recommend
repairs

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Computer Control System
• The FMS includes a distributed computer
system that is interfaced to the
workstations, material handling system, and
other hardware components.
• The system consists of
– a central computer coordinates the activities of
the components to achieve smooth overall
operation of the system
– Microcomputers controlling the individual
machines and other components.
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 TABLE 16.6 Typical FMS Performance Reports
Type of Description
Report
AvailabilityAvailability is a reliability measure that summarizes the uptime
proportion of the workstations. Details such as reasons for
downtime are included to identify recurring problem areas.
Utilization This report summarizes utilization of each workstation in the
system as well as the average utilization of the FMS for specified
periods (days, weeks, months}
Production summarizes data on daily and weekly quantities of different parts
performance produced by the FMS. The reports compare the actual quantities
against the production schedule
Tooling Tooling reports provide information on various aspects of tool
control, such as a listing of tools at each workstation and tool life
status
Status The status report provides an instantaneous "snapshot" of the
present condition. This report enable any time to learn about
parameters such as workstation utilization, availability, reliability,
cumulative piece counts, pallets and tooling

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Modular structure of FMS application software
• FMS possesses the characteristic DNC system
architecture.
– two-way communication is used.
• Data and commands are sent from the central
computer to the individual machines and other
hardware components,
• data on execution and performance are
transmitted from the components back to the
central] computer. In addition, an uplink from
the FMS to the corporate host computer is
provided.
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Fig.. A schematic illustration of a CIM system, FMS.
4. Duties Performed by Human Labor
– Loading and unloading parts from the system
– Changing and setting cutting tools
– Maintenance and repair of equipment
– NC part programming
– Programming and operating the computer system
– Overall management of the system

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5.4 FMS Applications
• Machining – most common application of FMS
technology
• Assembly
• Inspection
• Sheet metal processing (punching, shearing,
bending, and forming)
• Forging

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FMS at Chance-Vought Aircraft (Cincinnati Milacron)

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FMS for Sheet Metal Fabrication
5.5 FMS Benefits
• Increased machine utilization
– Reasons:
• 24 hour operation likely to justify investment
• Automatic tool changing
• Automatic pallet changing at stations
• Queues of parts at stations to maximize utilization
• Dynamic scheduling of production to account for changes
in demand
• Fewer machines required
• Reduction in factory floor space required

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FMS Benefits …
• Greater responsiveness to change
• Reduced inventory requirements
– Different parts produced continuously rather than in batches
• Lower manufacturing lead times
• Reduced labor requirements
• Higher productivity
• Opportunity for unattended production
– Machines run overnight ("lights out operation")

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5.6 FMS Planning and Design Issues
• Implementation of FMS need to consider issues:
(1) FMS planning and design issues and
(2) FMS operational issues.
5.6.1 FMS Planning and Design Issues
• FMS planning initial phase like GT cell, include:
– Part family considerations: a limited range of product styles,
– Processing requirements. to determine types of processing
equipment.
– Physical characteristics of the workparts: size and weight of
the parts determine the size of the machines and MHS
– Production volume: to determine number machines and MH.

52
5.6 FMS Planning and Implementation Issues
5.6.2 FMS Operational Issues
• FMS resources must be optimized to achieve
operational objectives related to profit, quality, and
customer satisfaction:
– Scheduling (based on master prdn schedule) and dispatching
– Machine loading- allocating and tooling among the
machines
– Part routing: selecting routes to maximize use of workstation
– Part grouping: group selection for simultaneous production,
given limitations on available tooling and other resources.
– Tool management: decisions when to change tools,
allocation of tooling, and similar issues.
– Pallet and fixture allocation - Limits on fixture types may
limit part types that can be processed
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5.7 Quantitative Analysis of FMS
FMS analysis techniques:
1. Deterministic models - useful in beginning stages of FMS
design to rough estimates of system parameters such as
production rate, capacity, utilization; do not permit evaluation
of operating characteristics such as queues and other dynamics
2. Queueing models - used to describe some of dynamics for
relatively simple system configurations based on steady-state
operation average values
3. Discrete event simulation - offers the most accurate method
for modeling FMS aspects; helpful in determining optimum
values like layout configuration, pallet number and scheduling
rules
4. Other approaches, including heuristics - include
mathematical programming and various heuristic approaches.
Bottleneck Model
• Refers to upper limit of output in fixed mix; simple and intuitive value.
Terminology and Symbols:
• Part mix (pj) - fraction of total system output (P) for style,
• Workstations and servers.
– Let Si = the number of servers at workstation i, where i = 1,2. ,n,
• Process routing. sequence, workstations and processing times.
– Let tijk = processing time, i = station, j = product, k = sequence. eg, 4 th operation in the
process plan for part A on machine 2 and takes 8.5 min; thus, t 2A4 = 8.5 min. process plan j is
unique to part j as no alternative in bottleneck model.
• Work handling system.
– Let it be station n + 1, no of carriers (e.g., conveyor, carts, AGVs, monorail, vehicles, etc.) is
analogous to no of servers. Let sn+1 = no of carriers in the FMS handling system
• Transport time. Let tn+1 = the mean transport time to a station.
• Operation frequency. Let f ijk = operation frequency for operation k in process
plan j at station i

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FMS Operational Parameters.
Average workload for a station is defined as the mean
total time spent at the station per part.

• Where WLi = average workload for station i (min),

tijk = processing time for operation k in process plan j
at station i (min), fijk = operation frequency for k in j
at i. and Pj = mix fraction for part j.
• Work handling system (station n+1) workload is,

• where nt= mean number of transports,

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FMS Operational Parameters.
EXAMPLE 16.6 Determining nt,
Consider two stations: (1) a load/unload station and (2) a
machining station, just one part processed through the system,
part A, so part mix fraction PA = 1.0. The frequency of all
operations is fiAk = 1.0. The parts are loaded at station 1, routed
to station 2 for machining, and then sent back to station 1 for
unloading (3 operations).
nt = 1(1.0) + 1(1.0) + 1(1.0) - 1 = 3 - 1 = 2
• Or , process routing is (1) ---> (2) ----> (1); number of
arrows gives the number of transports: nt = 2.
• The workload of the handling system (WLn+1) in min:
WLn+1 – nttn+1 ; (16.4)
and tn+1 = mean transport time per move (min). 57
System Performance Measures.
It include production rate of all (part style, utilization,
and no of busy servers); max possible rate constrained by
bottleneck station, might be MHS,
• Workload/ server ratio (WLt/si) for each station.
– Let WL*, S*, and t* equal to workload, no of servers, and
processing time, respectively, for bottleneck station.
(1) FMS max prdn rate (R*p), pc/min, of all parts is
R*p=s*/WL* (16.5)
• If parts pass through other than bottleneck station,
production rates increases to reach their respective
bottleneck limits,
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System Performance Measures.
(2) Individual part production rates can be obtained by
R*pj = Pt(R*p) = Pis*/WL*
• Where Rpj = max prdn rate of part style j (pc/min), and p j = part mix fraction for
part style j
(3) The mean utilization (Ut) of each workstation is given as:
Ui =WLi/si(R*p) = WLi/si s*/WL* , (16.7)
The utilization of bottleneck station is 100% at R*P.
• Ui for all statin, can be calculated as follows:
(16.8)
• where Ubar is unweighted average of workstation utilizations.
(4) Overall FMS utilization (Us) can be obtained using a weighted average, for n
regular stations, and transport system is omitted.
(16.9)
– Where, Si & Ui = no of servers & utilization at station i respectively.
(5) The number of busy servers (BSi). All servers at bottleneck station are at max
prdn rate. The values can be as follows:
BSi = WLi (R*p) = WLi s*/WL* (16,10)

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Solution: (a) To compute FMS production rate, first
compute workloads at each st and get bottleneck station.
– WL1 = (4 + 2)(0.4)(1.0) + (4 + 2)(0.6)(1.0) = 6.0 min.
– WL2 = 30(0.4)(1.0) + 40(0.6)(1.0) = 36.0 min.
– WL3 = 10(0.4)(1.0) + 15(0.6)(1.0) = 13.0 min.
• The routing for both parts is the same: 1 >> 2 >> 3 >> 1, There
are three moves, n, = 3.
WL4 = 3(3.0)(0.4)(1.0) + 3(3.0)(0.4)(1.0) = 9.0 min
• The bottleneck station is the largest WLi/Si ratio.
• For station 1. WL1/s1 = 6.0/1 = 6.0 min.
• For station 2, WL2/S2 = 36.0/2 = 18.0 min.
• For station 3, WL3/s3 = 13.0/1 = 13.0 min.
• For station 4, part handling system, WL4/S4 = 9.0/4 = 2.25 min.
• The maximum ratio occurs at station 2, bottleneck st. 61
• Rp* = 2/36.0 = 0.05555 pc/min = 3.333 pc/hr