Flexible Manufacturing System- Introduction

 FMS is actually an automated set of numerically controlled machine tools and material handling systems, capable of performing a wide range of manufacturing operations with quick tooling and instruction changeovers. (IGNOU Study Material)

A flexible manufacturing system (FMS) is an integrated computer-controlled complex of numerically controlled machine tools, automated material and tool handling and automated measuring and testing equipment that, with a minimum of manual intervention and short change over time, can process any product belonging to certain families of product its stated capability and to a predetermined schedule.

From: Agile Manufacturing: The 21st Century Competitive Strategy, 2001
https://www.sciencedirect.com/science/article/pii/B9780080435671500358

FMS is  a solution  to overcome challenges of high product variety and small life time production while still making reliable and good quality and cost effective yields. Flexible manufacturing system has advanced as a tool to bridge the gap between high mechanized line and CNC Machines with efficient mid-volume production of a various part mix with low setup time, low work-in-process, low inventory, short manufacturing lead time, high machine utilization and high quality. FMS is especially attractive for medium and low-capacity industries such as automotive, aeronautical, steel and electronics.”

Flexible manufacturing system incorporates the following concepts and skills in an automated production system.

1. Flexible automation
2. Group technology
3. Computer numerical control machine tools
4. Automated material handling between machines

Types of  FMS

“Flexible manufacturing systems can be separated into various types subject to their natures:”

1. DEPENDING UPON KINDS OF OPERATION
Flexible manufacturing system can be illustrious subject to the kinds of operation performed:

a. Processing operation. It performs some activities on a given job. Such activities convert the job from one shape to another continuous up to the final product. It enhances significance by altering the geometry, features or appearance of the initial materials.

b. Assembly operation. It comprises an assembly of two or more parts to make a new component which is called an assembly/subassembly. The subassemblies which are joined permanently use processes like welding, brazing, soldering , adhesive bonding, rivets, press fitting.

2. BASED ON NUMBER OF MACHINES

There are typical varieties of FMS based on the number of machines in the system:

a. Single machine cell (SMC). It consists of completely automated machines which are capable of performing unattended operations within a time period lengthier than one complete machine cycle. It is skillful of dispensing various part mix, reacting to fluctuations in manufacture plan, and inviting introduction of a part as a new entry. It is a sequence dependent production system.

b. Flexible manufacturing cell (FMC). It entails two or three dispensing workstations and a material handling system. The material handling system is linked to a load/unload station. It is a simultaneous production system.

c. An Flexible Manufacturing System (FMS). It has four or more processing work stations (typically CNC machining centers or turning centers) connected mechanically by a common part handling system and automatically by a distributed computer system. It also includes non-processing work stations that support production but do not directly participate in it e.g., part / pallet washing stations, co-ordinate measuring machines. These features significantly differentiate it from Flexible manufacturing cell (FMC).

3. BASED ON LEVEL OF FLEXIBILITY

“FMS is further classified based on the level of flexibility related to the manufacturing system. Two categories are depicted here:”

a. Dedicated FMS. It is made to produce a certain variety of part styles. The product design is considered fixed. So, the system can be designed with a certain amount of process specialization to make the operation more efficient.

b. Random order FMS. It is able to handle the substantial variations in part configurations. To accommodate these variations, a random order FMS must be more flexible than the dedicated FMS. A random order FMS is capable of processing parts that have a higher degree of
complexity. Thus, to deal with these kinds of complexity, sophisticated computer control system is used for this FMS type.

3.2.2 ELEMENTS OF FLEXIBLE MANUFACTURING SYSTEM

A flexible manufacturing system consists of two subsystems:
 Physical subsystem
 Control subsystem

Physical subsystem includes the following elements:

1. Workstations. It consists of NC machines, machine-tools, inspection equipments, loading and unloading operation, and machining area. More recent Flexible manufacturing system,
however, include other types of processing equipment also.

2. Storage-retrieval systems. It acts as a buffer during WIP (workin-processes) and holds devices such as carousels used to store parts temporarily between work stations or operations.

3. Material handling systems. It consists of power vehicles, various types of automated material handling equipment such as conveyors, automated guided vehicles, in floor carts and robots are used to transport the work parts and sub-assemblies to the processing or workstation.


HARDWARE COMPONENTS OF FLEXIBLE MANUFACTURING SYSTEM

1. Pallets and fixtures
2. Machining centers
3. Robots
4. Inspection equipment
5. Chip removal system
6. In process storage facility
7. Material handling systems

Source
Chapter FLEXIBLE MANUFACTURING SYSTEM - Shodhganga
http://shodhganga.inflibnet.ac.in/bitstream/10603/36612/10/10_chapter%203.pdf

Welding in flexible manufacturing systems

Flexible manufacturing systems (FMS) process the work piece from where it may be stored through the welding process and onto its final location in the factory. They can have several positions for loading and unloading the pallets carrying the work pieces. Systems may use one or more robots, and several different types of work- pieces can be welded one after the other, with only short changeover times. The use of buffer stocks enables production to continue completely unattended for some time. The entire facility is monitored and controlled by a supervisory computer system.

Klas Weman, in Welding Processes Handbook (Second Edition), 2012, Woodhead Publishing Series

Benefit of FMS -  Integrated structural configurations

Flexible manufacturing systems (FMS) have allowed a different approach to engine design. The reduced cost of machining has made possible integrated structural configurations, with more functions assigned to the same piece of metal. The overall number of parts can thus be reduced significantly over earlier engines (by up to 40 per cent in some designs), fostering improved reliability, lower weight and increased compactness without compromising on ease of maintenance. FMS also facilitates the offering of market-adapted solutions without raising cost: individual engines can be optimized at the factory for the proposed application.

Doug Woodyard, in Pounder's Marine Diesel Engines and Gas Turbines (Ninth Edition), 2009

Flexible manufacturing system for the production of chairs and table frames

21,948 views  3 Jan 2018

https://www.youtube.com/watch?v=PDSmRPh6TaM

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AWL-Techniek  developed the FMS for Vereinigte Spezialmöbelfabriken GmbH & Co. KG (VS Möbel). This flexible manufacturing system for the production of chairs and table frames has over 9 different processes integrated in 1 machine and produces 40 different end products. It is a classic example of complex system integration.

The video has the 9-step process of:

1) From bulk to single parts

2) Bending of tubes

3) Measuring of quality

4) Flexible buffering

5) Laser cutting of single parts

6) Flexible handling of parts

7) Automated loading and unloading of parts in welding cell

8) Arc welding

9) Finished product ready for shipping

http://www.awl.nl

Lecture note on FMS
https://www.uky.edu/~dsianita/611/fms.html

https://studentmechanica.blogspot.com/2014/01/flexible-manufacturing-systems.html

https://industrialautomationguide.blogspot.com/2017/03/flexible-manufacturing-systems.html

Proceedings of the 5th International Conference on Flexible Manufacturing Systems: 3–5 November 1986 Stratford-upon-Avon, UK

https://books.google.co.in/books?id=mKr9CAAAQBAJ

Flexible Manufacturing Systems in Practice: Design: Analysis and Simulation

Joseph Talavage
CRC Press, 18-Dec-1987 - Technology & Engineering - 272 pages

This book has been written for all those interested in flexible manufacturing systems (FMS) and other forms of computerized manufacturing systems (CMS). It deals with many aspects of the design, operation, and simulation of FMS and explains the origins of FMS.

Preview
https://books.google.co.in/books?id=bGIrs8dYGCAC

Handbook of Flexible Manufacturing Systems

Nand K. Jha
Academic Press, 02-Dec-2012 - Technology & Engineering - 328 pages

This handbook is a compilation of the current practical knowledge of flexible manufacturing systems (FMS). FMS allow manufacturing plants of all sizes to reduce their inventory while increasing their ability to meet consumer demands. By controlling automatic guided vehicles, robots, and machine tools with one central computer, products can now be produced in a variety of styles and models all at the same time. FMS are designed to adapt quickly and economically to changes in requirements and to unpredictable events. This guide explains how to effectively employ these useful new systems.

Includes specifications for software to implement simulation modeling.

Surveys practical applications in the workplace. Presents materials in a step-by-step workbook style.
https://books.google.co.in/books?id=O0Gg1kf8xRUC

"Flexible manufacturing systems: a primer on enhancing productivity while controlling cost."

Richard Cardinali.

Discusses flexible manufacturing systems, measuring the benefits of substituting production flexibility

for inventory.

Logistics Information Management, Vol. 8 No. 6, 1995, pp. 38-4

FMS successes

In the 1980s,  US auto manufacturers sought to implement flexibility in their manufacturing process. For example, General Motors began to  shift to more flexible, higher volume operations. By 1994 their goal

was to build 14 per cent more small cars in four plants than it did in seven. The round-the-clock production ordered GM to close the manufacturing competition gap with Japan. Chrysler Corporation adapted flexible manufacturing at its St Louis minivans plant. This increased profit on each unit produced to as much as $4,000.

Pratt and Whitney  started by reducing inventory and cycle time-duration between a product’s inception and delivery by 57 per cent between January 1990, and April 1993; it also helped in minimizing inventories and maximizing cash flow. Northwest Airlines is transforming its engine shops into

profit centres instead of cost centres, all by using flexibility. Pratt conducted a 6-12-month test on its

flexible techniques at four manufacturing lines. The results were that work-in-process dropped an average of 44 per cent, while delivery performance improved on average by 55 per cent.

Lenz, J.E., Flexible Manufacturing, Benefits for Lower Inventory, Marcel Dekker, New York, NY, 1989.

“FMS: the new wave of manufacturing technology”, Industrial Education, Vol. 75, 13 March 1986, pp. 10-13.

Velocci, A.L. Jr, “Pratt synchronizes its supply chain”, Aviation Week & Space Technology, Vol. 138 No. 23, pp. 154-6.

Brown, J.B., “General Motors open all night”, Nation’s Business, No. 3268, 1 June 1992, pp. 82-3.

Chowdhury, A.R. and Peckman, D.C., “Flexible manufacturing systems: what’s in it for the manufacturer”,

Journal of Epsilon Pi Tau, Vol. XIII No. 1, Winter-Spring 1987, pp. 12-17.

FMS in India

http://hdl.handle.net/10603/207718

Title of the Thesis ADOPTION OF FLEXIBLE MANUFACTURING SYSTEM IN INDUSTRY

Name of the Researcher S H SUNDARANI

Name of the Guide M N Qureshi

Completed Year 18-06-2018

Name of the Department Mechanical Engineering

Name of the University Gujarat Technological University

https://shodhganga.inflibnet.ac.in/handle/10603/207718

इंजिन निर्माणी आवडी

ENGINE FACTORY AVADI

Flexible Manufacturing System:

EFA has got a Flexible Manufacturing System with 4 horizontal machining centers which is a unique asset of this type in the country. It comprises of 4 machining centres, tool magazines, rail guided vehicle(RGV), Automatic storage/retrieval system and a centralised host computer.

It enables the factory to achieve high volume of production of various critical structural elements of engines involving high precision and accuracy.

https://ddpdoo.gov.in/unit/pages/EFA/flexible-manufacturing-system

In keeping up with the current trends in manufacturing domain, EFA has initiated implementation of Industry 4.0 concepts in the following areas: -

4 HMCs, RGV & Tool Pre-setter of Flexible Manufacturing System Plant are integrated with a host computer.

Through this host computer, Plant parameters like tool life, spindle run, real time component machining programme, pallet component loading and unloading details, break down details, production planning, alarms and warnings are analysed.

Further for Industry 4.0 compliance, connectivity from FMS plant to central server is established for reports generation and data collection.

Live Data Tracking of Engine Test cells is implemented to analyse engine test related parameters.

https://ddpdoo.gov.in/unit/pages/EFA/industry-4-01

Performance Evaluation of The Current System and Design of Flexible Manufacturing System: A Case 

Study.

The benefit of proposed FMS is also estimated.

Ajay Singholi, Deepti Chhabra and Sampada Bagai. 

Mechanical & Automation Engineering Department, GGS-Indraprastha University, 

Delhi, India 

 Global Journal of Enterprise Information System

Jan - June 2010,

https://www.gjeis.com/index.php/GJEIS/article/view/161/159

STUDY OF BARRIERS AND IMPLEMENTATION OF FLEXIBLE MANUFACTURING SYSTEM IN INDIAN AUTOMOBILE 

INDUSTRY

A DISSERTATION

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF THE DEGREE OF

MASTER OF TECHNOLOGY IN PRODUCTION AND INDUSTRIAL ENGINEERING

Submitted by:

SAJAL GUPTA

(2K16/PIE/16)

Under the supervision of

Prof. RANGANATH M. SINGARI Dr. SAURABH AGRAWAL

PROFESSOR ASSISTANT PROFESSOR

DEPARTMENT OF MECHANICAL ENGINEERING

DELHI TECHNOLOGICAL UNIVERSITY

(Formerly Delhi College of Engineering)

Bawana Road, Delhi-110042

JULY, 2018

http://dspace.dtu.ac.in:8080/jspui/bitstream/repository/16266/1/PRINT%20THESIS%202018.pdf

Updated on 6.9.2023,  25 Nov 2021,  27 Sep 2021,  12 July 2021,  16 August 2020
24 June 2019