Chapter 5

Flexible Manufacturing Systems

 History.
• The FMS was first conceptualized for machining, and it required
the prior development of NC.
• This concept is credited to David Williamson, a British engineer
during mid- 1960s.
• In late 1960s the first FMS machining system was installed at
Ingersoll-Rand company in Virginia.
• Germany implemented its first FMS in 1969, in cooperation with
the university of Stuttgart.
• Russia and Japan implemented FMS in 1972.
 Introduction
 most automated and technologically sophisticated of the
machine cell types used to implement cellular manufacturing.
 has multiple automated stations and is capable of variable
routings among stations, while its flexibility allows it to
operate as a mixed model system.
 The FMS concept integrates many of the advanced
technologies:
 flexible automation,
 CNC machines,
 distributed computer control, and
 automated material handling and storage
 Flexibility
• flexibility can have different interpretations; but it generally
refers to the system’s responsiveness to changing demand
patterns, so that the mix of part styles in the system, and the
production volumes that can be met, can be adjusted rapidly to
meet changing requirements.

• To be considered flexible there are four reasonable tests that

can be applied to the system to determine its level of
flexibility; these are:
1. Part variety test—can the system process different part
styles in a non-batch mode?
2. Schedule change test—can the system readily accept
changes in the production schedule, either in the product
mix or the expected production volume?
3. Error recovery test—can the system recover
gracefully from equipment malfunctions and
breakdowns, so that production is not completely
disrupted?
4. New part test—can new part designs be introduced into
the existing product mix with relative ease?
• The system is flexible if we can answer “yes” to all of these
questions, with the most important criteria for flexibility being
numbers 1 and 2. Numbers 3 and 4 are softer criteria that may
be implemented at various levels. The automated manufacturing cell
with two machine tools and robot
shall be considered flexible if it: (1)
can machine different part mixes
taken from the
carousel by the robot; (2) allows for
changes in the production schedule,
without affecting the operation of the
robotic arm and the two machine tools; (3)
is able to carry-on operating even if one
machine tool breaks down; and (4) can
accommodate new part designs if the
numerical control programme to do so is
written off-line and then downloaded by
the system for execution
 What is FMS?
• A flexible manufacturing system is a automated machine cell,
consisting of a group of processing workstations,
interconnected with automated material handling and storage
system.
• The FMS is most suited for the mid-variety, mid-volume
production range
 Why FMS ?
• External changes such as change in product design and
production system.
• Optimizing the manufacturing cycle time
• Reduced production costs
• Overcoming internal changes like breakdowns etc.
 What makes it flexible?
• Three capabilities that a manufacturing system must possess to
be a flexible.
1. The ability to identify and distinguish among the different
part styles processed by the system.
2. Quick changeover of operating instructions, and
3. Quick changeover of physical setup.
 Classification of FMS
• Flexible manufacturing systems can be distinguished
according to the number of machines in the system. The
following are typical categories:
– Single machine cell
– Flexible manufacturing cell
– Flexible manufacturing system
 Single Machine Cell (SMC)
• A single machine cell consists of one CNC machining center
combined with a parts storage system for unattended
operation.
• Completed parts are periodically unloaded from the parts
storage unit, and raw work parts are loaded into it
 Flexible Manufacturing Cell (FMC)
• A flexible manufacturing cell consists of two or three
processing workstations (typically CNC machining centers)
plus a part handling system.
• The part handling system is connected to a load/unload station.
 Flexible Manufacturing System (FMS)
• A flexible manufacturing system has four or more processing
workstations connected mechanically by a common part
handling
Figure : Features of the three categories of flexible cells
and systems
 Level of flexibility
• The FMS can be examined to determine the level of flexibility
it maintains. There are two levels:
Dedicated FMS
• designed to produce a limited variety of part styles, and the
complete universe of parts to be made on the system is known
in advance.
• Group technology is likely to be based on product
commonality rather than geometric similarity.
• Product design is relatively stable, so the system is designed
with a certain amount of process specialization in place;
machines designed for specific processes can be implemented
within the system, which leads to an increased production rate
from the system.
Random-order FMS
• designed to produce a large part family, where there are
substantial variations in part configurations, and where it is
likely that new part designs will be introduced into the
system, with engineering changes occurring to existing parts.
• The production schedule may also be flexible, changing from
day to day.
• The random-order FMS must be more flexible than the
dedicated FMS to accommodate these requirements.
• It is equipped with general purpose machines to deal with
product variations, and is capable of processing parts in
random order. A more sophisticated computer control system
is also required for this FMS type.
Figure: Comparison of dedicated and random-order FMS types
 Basic components of FMS

1. Workstations
2. Automated Material Handling and Storage systems
3. Computer Control System
 Workstation
• Substations
1. Load/Unload Stations
2. Machining Stations
3. Other processing stations
4. Assembly
 Material handling system
• Automated fork lifting and Rail traveler.
• Computer control Programmable logic Controller
 Human Resources
• Human are needed to manage the operations of the FMS.
Functions typically performed by human includes:
– Loading raw work parts into the
– system,
– Unloading finished parts (or
– assemblies) from the system,
– Changing and setting tools,
– Equipment maintenance and repair,
– NC part programming in a machining
 Layouts of FMS

– Progressive or Line Type

– Loop Type
– Ladder Type
– Open field type
– Robot centered type
1.Progressive Layout

2. Loop Layout
3.Ladder Type Layout 4.Open Field Layout
5. Robot Centered Layout
 Application of FMS

• Metal-cutting machining
• Metal forming
• Assembly
• Joining-welding (arc , spot), gluing
• Surface treatment
• Inspection
• Testing
 Advantages of FMS
• To reduce set up and queue times
• Improve efficiency
• Reduce time for product completion
• Utilize human workers better
• Improve product routing
• Produce a variety of Items under one roof
• Improve product quality
• Serve a variety of vendors simultaneously
• Produce more product more quickly
 Disadvantages of FMS
•Expensive.
•Substantial pre-planning activity.

Challenges with FMS

• Determining if FMS the best production system for your
company
• Possible expansion costs associated with implementing FMS
Conclusion
• FMS is a revolution in the field of Manufacturing Technology.
• FMS can be designed to meet the specific demand of each
company
• FMS is used for multitask operation.
• FMS requires substantial investment of time and resources.