FLEXIBLE MANUFACTURING SYSTEMS

CANQ
CHAPTER 6

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 Need for FMS

Breakdown of 8760
hours in a year in
Manufacturing

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FLEXIBLE MANUFACTURING SYSTEMS FMS
• Programmable machine tools
• Computer network - fieldbus
• Internal setup - external setup pallets
• Reduces manufacturing lead time
• Flexible
EXAMPLE: FMS FOR GEAR BOX
hộp bánh răng

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 A FLEXIBLE MANUFAXTURING SYSTEM
DESIGN PRODUCTION OF GEARBOXES

PARTS:

• GEAR1, GEAR2, GEAR3 & GEAR4

• SHAFT1 & SHAFT2
• BOX
• COVER

từ machine A server 1
server 2 đưa đến buffer
đến AGV đến operation
để load/unload cái
station
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 PROCESS PLAN FOR GEAR BOX
PROCESS PLAN MATRIX
LOAD HOBBING LATHE MACHINE UNLOAD
GEAR1 5MIN 20MIN 10MIN 1MIN
GEAR2 5MIN 30MIN 15MIN 1MIN
GEAR3 5MIN 25MIN 15MIN 1MIN
GEAR4 5MIN 35MIN 25MIN 1MIN
BOX 10MIN 30MIN 2MIN
COVER 10MIN 10MIN 2MIN
SHAFT1 5MIN 15MIN 5MIN 1MIN
SHAFT2 5MIN 20MIN 5MIN 1MIN

CONFIGURATION OF THE FMS

(MINIMAL SYSTEM 1 MACHINE PER STATION)
• STATION 1: LOADING - COST 0 US$
• STATION 2: GEAR HOBBING - COST 200,000 US$
• STATION 3: TURNING CENTER - COST 100,000 US$
• STATION 4: MACHINING CENTER - COST 300,000 US$
• STATION 5: UNLOADING STATION - COST 0 US$
• TRANSPORTATION SYSTEM - 4 AGV’S TOTAL COST 400,000 US$ 5
OPERATIONAL DATA:

•PRODUCE 12,000 TO 14,000 GEARBOXES / YEAR

•THREE SHIFTS
•AVERAGE MAMHOUR RATE: 10 US$ HOUR
•AMORTIZATION PERIOD: 10 YEARS
• INTERNAL RATE OF RETURN 20%
•GOVERNMENT TAX 50%

DESIGN QUESTIONS TO ANSWER:

•NUMBER OF MACHINES PER STATION

•BUFFER SPACE IN FRONT OF EACH STATION
•NUMBER OF PALLETS IN THE SYSTEM - WIP
•WHAT IS THE MANUFACTURING LEAD TIME
•HOW MANY AGV’S
•UTILIZATION OF EACH STATION
•COST PER PART
lead time bao gồm work request, process and complete
time. cycle time bao gồm 2 cái sau
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 TOOLS FOR SOLVING QUESTIONS:

1. QUEUEING NETWORKS SOFTWARE

(VERY FAST RESULTS - APPROXIMATE RESULTS)

2. SIMULATION
(VERY SLOW - HIGHLY ACCURATE RESULTS)

3. PETRI NETS
(COMPLEX METHOD)

4. LINEAR PROGRAMMING ETC.

(COMPLEX METHOD - ACCURACY DEPENDS)

CLOSED QUEUEING NETWORK APPROACH:

• SOFTWARE CANQ
• CANQ IS A SINGLE CLASS CLOSSED QUEUEING NETWORK
• SIMPLE INPUT
• OUTPUT VERY USEFULL AS FIRST APPROXIMATION
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INPUT TO CANQ PROGRAM PART 1
5 20
(OUTPUT OPTION AND NUMBER OF SYSTEMS)

5 36 8 10 3
(N-WORKST,N-PIECES,N-TYPE,LABOR-COST,N-SHIFTS)

0.200 10
(RATE OF RETURN,YEARS OF MACHINE DEPRECIATION)

TRANS 1 1.0 400 0.0

(NAME TR,N-TRANS,TRANS-TIME,COST,N-LABOR)

LOAD 1 1.0
HOBB 1 200 0.0
LATHE 1 100 0.0
MACH 1 300 0.0
UNLOA 1 1.0
(NAME,N-SERV,VISIT-FREQ,AVG-PR-T,COST,N-LABOR)

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INPUT TO CANQ PROGRAM PART 2
GEAR1 4 .125 (NAME_PART,N-OPER,FRACTION-TOT-OUTPUT,VALUE)
1 5.0 (STAT-NUMB,OPER-TIME,FREQ)
2 20.0 (STAT-NUMB,OPER-TIME,FREQ)
3 10.0 (.....)
5 1.0 (.....)
GEAR2 4 .125
1 5.0
2 30.0
3 15.0
5 1.0 INPUT TO CANQ PROGRAM PART 3
GEAR3 4 .125 SHAF1 4 .125
1 5.0 1 5.0
2 25.0 2 15.0
3 15.0 4 5.0
5 1.0 5 1.0
GEAR4 4 .125 SHAF2 4 .125
1 5.0 1 5.0
2 10.0 2 20.0
3 25.0 4 5.0
5 1.0 5 1.0
BOX 3 .125
1 10.0
4 30.0
5 2.0
COVER 3 .125
1 10.0
4 10.0
5 2.0
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 SUMMARY OUTPUT OF CANQ TABLE 1

SYSTEM WORKSTATIONS/MACHINE COST IN THOUSANDS

NUMBER LOAD HOBB LATHE MACH UNLOA TRANS OUTPUT CAPITAL # OF UTIL UTIL
$0 $200 $100 $300 $0 $400 PART/H COST MAN CAPITAL LABOR

1 1 1 1 1 1 1 0.5 1000 2 0.48 0.25

2 1 2 1 1 1 1 0.9156 1200 2 0.73 0.46
3 1 2 2 1 1 1 0.999 1300 2 0.74 0.5
4 1 3 2 1 1 1 1.1676 1500 2 0.75 0.58
5 2 3 2 1 1 1 1.2 1500 3 0.77 0.4
6 2 3 2 2 1 1 1.4999 1800 3 0.8 0.5
7 2 4 2 2 1 1 1.8285 2000 3 0.88 0.61
8 2 4 3 2 1 1 1.9516 2100 3 0.89 0.65
9 2 4 3 2 1 2 1.9997 2500 3 0.77 0.67
10 2 5 3 2 1 2 2.3301 2700 3 0.83 0.78
11 3 5 3 2 1 2 2.3848 2700 4 0.85 0.6
12 3 5 3 3 1 2 2.4991 3000 4 0.8 0.62
13 3 6 3 3 1 2 2.7663 3200 4 0.83 0.69
14 3 6 4 3 1 2 2.9997 3300 4 0.87 0.75
15 3 7 4 3 1 2 3.4153 3500 4 0.94 0.85
16 3 8 4 3 1 2 3.497 3700 4 0.91 0.87
17 4 8 4 3 1 2 3.5648 3700 5 0.92 0.71
18 4 8 4 4 1 2 3.6854 4000 5 0.88 0.74
19 4 8 5 4 1 2 3.9352 4100 5 0.92 0.79
20 4 8 5 4 1 3 3.9999 4500 5 0.85 0.8

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 SUMMARY OUTPUT CANQ TABLE 2
COST ANALYSIS

SYSTEM OUTPUT RATE

MACHINE LABOR TOTAL TOTAL MACHINE LABOR AVERAGE
NUMBER PART/YEAR COST/YEAR COST/YEAR COST/YEAR COST/HOUR COST/PART COST/PART COST/PART

1 3000 238522.8 120000 358522.8 59.8 79.5 40 119.51

2 5493.9 286227.3 120000 406227.3 67.7 52.1 21.8 73.94

3 5993.9 310079.6 120000 430079.6 71.7 51.7 20 71.75

4 7005.5 357784.1 120000 477784.1 79.6 51.1 17.1 68.2

5 7199.8 357784.1 180000 537784.1 89.6 49.7 25 74.69

6 8999.4 429341 180000 609341 101.6 47.7 20 67.71

7 10971.1 477045.5 180000 657045.5 109.5 43.5 16.4 59.89

8 11709.6 500897.8 180000 680897.8 113.5 42.8 15.4 58.15

9 11998.2 596306.9 180000 776306.9 129.4 49.7 15 64.7

10 13980.7 644011.4 180000 824011.4 137.3 46.1 12.9 58.94

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 SUMMARY OUTPUT CANQ TABLE 2 (CONTINUED)

COST ANALYSIS

SYSTEM OUTPUT RATEMACHINE LABOR TOTAL TOTAL MACHINE LABOR AVERAGE

NUMBER PART/YEAR COST/YEAR COST/YEAR COST/YEAR COST/HOUR COST/PART COST/PART COST/PART
11 14308.9 644011.4 240000 884011.4 147.3 45 16.8 61.78

12 14994.7 715568.3 240000 955568.3 159.3 47.7 16 63.73

13 16597.7 763272.8 240000 1003273 167.2 46 14.5 60.45

14 17998.5 787125.1 240000 1027125 171.2 43.7 13.3 57.07

15 20491.9 834829.6 240000 1074830 179.1 40.7 11.7 52.45

16 20981.9 882534.2 240000 1122534 187.1 42.1 11.4 53.5

17 21389.1 882534.2 300000 1182534 197.1 41.3 14 55.29

18 22112.2 954091 300000 1254091 209 43.1 13.6 56.71

19 23611 977943.3 300000 1277943 213 41.4 12.7 54.12

20 23999.1 1073352 300000 1373352 228.9 44.7 12.5 57.23

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STATION PERFORMANCE MACHINE UTILIZATION
NUMBER LOAD HOBB LATHE MACH UNLOAD TRANS
1 .417 1.000 .542 .417 .083 .250
2 .763 .916 .992 .763 .153 .458
3 .832 .999 .541 .832 .166 .499
4 .973 .778 .632 .973 .195 .584
5 .500 .800 .650 1.000 .200 .600
6 .625 1.000 .812 .625 .250 .750
7 .762 .914 .990 .762 .305 .914
8 .813 .976 .705 .813 .325 .976
9 .833 1.000 .722 .833 .333 .500
10 .971 .932 .841 .971 .388 .583
11 .662 .954 .861 .994 .397 .596
12 .694 1.000 .902 .694 .417 .625
13 .768 .922 .999 .768 .461 .692
14 .833 1.000 .812 .833 .500 .750
15 .949 .976 .925 .949 .569 .854
16 .971 .874 .947 .971 .583 .874
17 .743 .891 .965 .990 .594 .891
18 .768 .921 .998 .768 .614 .921
19 .820 .984 .853 .820 .656 .984
20 .833 1.000 .867 .833 .667 .667
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SELECT SYSTEM NUMBER 10
SYSTEM WORKSTATIONS/MACHINE COST IN THOUSANDS
NUMBER LOAD HOBB LATHE MACH UNLOA TRANS OUTPUT CAPITAL # OF UTIL UTIL
$0 $200 $100 $300 $0 $400 PART/H COST MAN CAPITAL LABOR

10 2 5 3 2 1 2 2.3301 2700 3 0.83 0.78

COST ANALYSIS

SYSTEM OUTPUT RATE

MACHINE LABOR TOTAL TOTAL MACHINE LABOR AVERAGE
NUMBER PART/YEAR COST/YEAR COST/YEAR COST/YEAR COST/HOUR COST/PART COST/PART COST/PART

10 13980.7 644011.4 180000 824011.4 137.3 46.1 12.9 58.94

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NUMBER OF WORKPIECES IN SYSTEM = 36 (WIP)
SYSTEM PERFORMANCE MEASURES
PRODUCTION RATE = 19.7724 PIECES PER HOUR

PRODUCTION RATE BY PART TYPE

NUMBER
GEAR1 2.4716
GEAR2 2.4716
GEAR3 2.4716
GEAR4 2.4716
SHAF1 2.4716
SHAF2 2.4716
BOX 2.4716
COVER 2.4716
AVERAGE TIME IN SYSTEM = 109.24 MINUTES
PROCESSING 36.88 MINUTES
TRAVELING 3.75 MINUTES
WAITING 68.62 MINUTES 15
 NUMBER OF WORKPIECES / LEAD TIME
N PROD RATE AVERAGE TIME IN SYSTEM
1 1.4769 40.63
. . .
31 19.5981 94.91
32 19.6421 97.75
33 19.6809 100.61
34 19.7151 103.47
35 19.7455 106.35
36 19.7724 109.24
37 19.7963 112.14
38 19.8176 115.05
39 19.8365 117.96
40 19.8534 120.89
41 19.8684 123.81
. . .
INF ******** INF
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SUMMARY FOR STATION NUMBER 2 HOB

NUMBER OF SERVER AVE. NO. OF

SERVERS UTILISATION BUSY SERVERS
5 .989 4.943

STEADY STATE AVERAGE NUMBER OF:

PARTS AT STATION 19.089
PARTS IN PROCESS 4.943
PARTS WAITING 14.146

AVERAGE TIME SPENT

AT THIS STATION PER OPERATION PER WORKPIEC
TOTAL TIME (MINUTES) 77.235 57.926
PROCESSING 20.000 15.000
WAITING 37.926 42.926

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SUMMARY FOR STATION NUMBER 6 TRANSPORTER

NUMBER OF SERVER AVE. NO. OF

SERVERS UTILISATION BUSY SERVERS
2 .618 1.236

STEADY STATE AVERAGE NUMBER OF:

PARTS AT STATION 1.988
PARRTS IN PROCES 1.236
PARTS WAITING .752

AVERAGE TIME SPENT

AT THIS STATION PER OPERATION PER WORKPIECE
TOTAL TIME (MINUTES) 1.608 6.031
PROCESSING 1.000 3.750
WAITING 5.031 2.281

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SENSITIVITY INFORMATION

1 MIN DECREASE
PROCESSING TIME WILL DECREASE THE
AT STATION PRODUCTION RATE BY

1 LOAD .042 UNITS/HOUR ( .2123 PERCENT)

2 HOBB .783 UNITS/HOUR ( 3.9591 PERCENT)

3 LATHE .188 UNITS/HOUR ( .9483 PERCENT)

4 MACH .021 UNITS/HOUR ( .1062 PERCENT)

5 UNLOAD .028 UNITS/HOUR ( .1419 PERCENT)

6 TRANS .146 UNITS/HOUR ( .7406 PERCENT)

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CONCLUSION FMS
• INCREASED MACHINE UTILIZATION
• REDUCED DIRECT AND INDIRECT LABOUR
• REDUCED MANUFACTURING LEAD TIME
• LOWER WORK IN PROCESS
• VOLUME FLEXIBILITY
• ROUTING FLEXIBILITY

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