Project On Automatedprocesses-Fms: Flexible Manufacturing System

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PROJECT ON

AUTOMATEDPROCESSES-FMS
FLEXIBLE MANUFACTURING SYSTEM

SUBMITTED TO – SUBMITTED BY -
PROF. SUBIR GUHA MOHD.ARISH
PGDM
ROLL NO. 40118
AUTOMATED PROCESSES – FMS
{Flexible manufacturing system}

A flexible manufacturing system (FMS) is a group of numerically-controlled machine tools,


interconnected by a central control system. The various machining cells are interconnected,
via loading and unloading stations, by an automated transport system. Operational flexibility
is enhanced by the ability to execute all manufacturing tasks on numerous product designs in
small quantities and with faster delivery. It has been described as an automated job shop and
as a miniature automated factory. Simply stated, it is an automated production system that
produces one or more families of parts in a flexible manner. Today, this prospect of
automation and flexibility presents the possibility of producing nonstandard parts to create a
competitive advantage.

Definition-

“A Flexible Manufacturing System (FMS) is a production system consisting of a set


of identical and/or complementary numerically controlled machine which are connected
through an automated transportation system”.

Each process in FMS is controlled by a dedicated computer (FMS cell computer).

The concept of flexible manufacturing systems evolved during the 1960s when robots,
programmable controllers, and computerized numerical controls brought a controlled
environment to the factory floor in the form of numerically-controlled and direct-
numerically-controlled machines.

For the most part, FMS is limited to firms involved in batch production or job shop
environments. Normally, batch producers have two kinds of equipment from which to
choose: dedicated machinery or unautomated, general-purpose tools. Dedicated machinery
results in cost savings but lacks flexibility. General purpose machines such as lathes, milling
machines, or drill presses are all costly, and may not reach full capacity. Flexible
manufacturing systems provide the batch manufacturer with another option—one that can
make batch manufacturing just as efficient and productive as mass production.

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AUTOMATED PROCESSES – FMS
{Flexible manufacturing system}
The first FMS was patent in 1965 by Theo Williamson who made numerically controlled
equipment.

Equipment of FMS -

Primary equipment

Work centers

 Universal machining centers (prismatic FMSs)


 Turning centers (rotational FMSs)
 Grinding machines

 Nibbling machines

Process centers

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AUTOMATED PROCESSES – FMS
{Flexible manufacturing system}
 Wash machines
 Coordinate measuring machines
 Robotic work stations

 Manual workstations

Secondary equipment

Support stations
 Pallet/fixture load/unload stations
 Tool commissioning/setting area
Support equipment
 Robots
 Pallet/fixture/stillage stores
 Pallet buffer stations
 Tools stores
 Raw material stores
 Transport system(AGVs,RGVs,robots)
 Transport units(pallets/stillages)

OBJECTIVES OF FMS -

Stated formally, the general objectives of an FMS are to approach the efficiencies and
economies of scale normally associated with mass production, and to maintain the flexibility
required for small- and medium-lot-size production of a variety of parts.

Two kinds of manufacturing systems fall within the FMS spectrum. These are assembly
systems, which assemble components into final products and forming systems, which
actually form components or final products. A generic FMS is said to consist of the following
components:

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AUTOMATED PROCESSES – FMS
{Flexible manufacturing system}
1. A set of work stations containing machine tools that do not require significant set-up
time or change-over between successive jobs. Typically, these machines perform
milling, boring, drilling, tapping, reaming, turning, and grooving operations.
2. A material-handling system that is automated and flexible in that it permits jobs to
move between any pair of machines so that any job routing can be followed.
3. A network of supervisory computers and microprocessors that perform some or all of
the following tasks: (a) directs the routing of jobs through the system; (b) tracks the
status of all jobs in progress so it is known where each job is to go next; (c) passes the
instructions for the processing of each operation to each station and ensures that the
right tools are available for the job; and (d) provides essential monitoring of the
correct performance of operations and signals problems requiring attention.
4. Storage, locally at the work stations, and/or centrally at the system level.

The jobs to be processed by the system. In operating an FMS, the worker enters the job to be
run at the supervisory computer, which then downloads the part programs to the cell control
or NC controller.

TYPES OF FMS-

 Sequential FMS

 Random FMS

 Dedicated FMS

 Engineered FMS

 Modular FMS 

APPLICATION OF FMS-

 Metal-cutting machining

 Metal forming

 Assembly

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AUTOMATED PROCESSES – FMS
{Flexible manufacturing system}
 Joining-welding (arc , spot), gluing

 Surface treatment

 Inspection

 Testing

Different FMSs levels are:

Flexible Manufacturing Module (FMM). Example: a NC machine, a pallet changer and a


part buffer;

Flexible Manufacturing (Assembly) Cell (F(M/A)C). Example: Four FMMs and an AGV
(automated guided vehicle);

Flexible Manufacturing Group (FMG). Example : Two FMCs, a FMM and two AGVs
which will transport parts from a Part Loading area, through machines, to a Part Unloading
Area;

Flexible Production Systems (FPS). Example: A FMG and a FAC, two AGVs, an
Automated Tool Storage, and an Automated Part/assembly Storage;

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AUTOMATED PROCESSES – FMS
{Flexible manufacturing system}
Flexible Manufacturing Line (FML). Example: multiple stations in a line layout and
AGVs

BENEFITS OF FMS -

The potential benefits from the implementation and utilization of a flexible manufacturing
system have been detailed by numerous researchers on the subject. A review of the literature
reveals many tangible and intangible benefits that FMS users extol. These benefits include:

 less waste
 fewer workstations
 quicker changes of tools, dies, and stamping machinery

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AUTOMATED PROCESSES – FMS
{Flexible manufacturing system}
 reduced downtime
 better control over quality
 reduced labor
 more efficient use of machinery
 work-in-process inventory reduced
 increased capacity
 increased production flexibility

The savings from these benefits can be sizable. Enough so that Ford has poured $4,400,000
into overhauling its Torrance Avenue plant in Chicago, giving it flexible manufacturing
capability. This will allow the factory to add new models in as little as two weeks instead of
two months or longer. Richard Truett reports, in Automotive News, that the flexible
manufacturing systems used in five of Ford Motor Company's plants will yield a $2.5 billion
savings. Truett also reports that, by the year 2010, Ford will have converted 80 percent of its
plants to flexible manufacturing.

LIMITATIONS OF FMS -

Despite these benefits, FMS does have certain limitations. In particular, this type of
system can only handle a relatively-narrow range of part varieties, so it must be used
for similar parts (family of parts) that require similar processing. Due to increased
complexity and cost, an FMS also requires a longer planning and development period
than traditional manufacturing equipment.
Equipment utilization for the FMS sometimes is not as high as one would expect.
Japanese firms tend to have a much higher equipment utilization rate than U.S.
manufacturers utilizing FMS. This is probably a result of U.S. users' attempt to utilize

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AUTOMATED PROCESSES – FMS
{Flexible manufacturing system}
FMS for high-volume production of a few parts rather than for a high-variety
production of many parts at a low cost per unit. U.S. firms average ten types of parts
per machine, compared to ninety-three types of parts per machine in Japan.
Other problems can result from a lack of technical literacy, management
incompetence, and poor implementation of the FMS process. If the firm misidentifies
its objectives and manufacturing mission, and does not maintain a manufacturing
strategy that is consistent with the firm's overall strategy, problems are inevitable. It is
crucial that a firm's technology acquisition decisions be consistent with its
manufacturing strategy.
If a firm chooses to compete on the basis of flexibility rather than cost or quality, it
may be a candidate for flexible manufacturing, especially if it is suited for low- to
mid-volume production. This is particularly true if the firm is in an industry where
products change rapidly, and the ability to introduce new products may be more
important than minimizing cost. In this scenario, scale is no longer the main concern
and size is no longer a barrier to entry.
However, an FMS may not be appropriate for some firms. Since new technology is
costly and requires several years to install and become productive, it requires a
supportive infrastructure and the allocation of scarce resources for implementation.
Frankly, many firms do not possess the
necessary resources. Economically justifying an FMS can be a difficult task—
especially since cost accounting tends to be designed for mass production of a mature
product, with known characteristics, and a stable technology. Therefore, it is
difficult to give an accurate indication of whether flexible manufacturing is justified.
The question remains of how to quantify the benefits of flexibility. In addition,
rapidly-changing technology and shortened product life cycles can cause capital
equipment to quickly become obsolete.
For other firms, their products may not require processes at the technological level of
an FMS. IBM found that a redesigned printer was simple enough for high-quality
manual assembly and that the manual assembly could be achieved at a lower cost than
automated assembly. Potential FMS users should also consider that some of the costs
traditionally incurred in manufacturing may actually be higher in a flexible automated
system than in conventional manufacturing.

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AUTOMATED PROCESSES – FMS
{Flexible manufacturing system}

1. LIVE EXAMPLE OF FMS-

One of the most common examples of a flexible manufacturing system can be seen in the
manufacturing of automobiles. Certain equipment is used to attach doors to a sedan. With just
a few simple adjustments, that same line and equipment may be used to attach doors to a
sport utility vehicle or some other type of vehicle. Often, the switchover can take place with
very little disruption to the line, and may even happen during shifts.

In fact, the automobile industry can potentially save a substantial amount of money using a
flexible manufacturing system. A report in 2008 indicated that Ford Motor Company
saved approximately $2.5 billion US Dollars by putting flexible systems in at five
manufacturing plants. The company estimated it can save at least half of the cost of
manufacturing updated models using the systems.

In some cases, the machines may not only be used to produce or assemble different parts for
different models, but to make customizations. These customizations, without a flexible
system in place, would take much longer, and be much more expensive for the customer.
Using machines with the ability to be flexible can not only speed the process up, but can
improve customer satisfaction by bringing down the price.

Practical Implication of ford FMS -

Through the use of reprogrammable tooling in the body shop, standardized equipment in the
paint shop and common build sequence in final assembly, Ford can build multiple models on
one or more platforms in one plant.

Body Shop Paint Shop Final Assembly

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In the body shop, where the In the final assembly area, flexibility
AUTOMATED PROCESSES – FMS
sheet metal comes together to
In the paint shop, flexibility
means robotic applicators are means the build sequence is the

{Flexible manufacturing system}


form the vehicle’s body, flexibility programmed to cover various same among multiple models on
means more than 80 percent of body styles – as they move one or more platforms allowing for
the tooling is not specific to one through the paint booth – with efficient utilization of people and
model. It can be reprogrammed equal precision. This results in equipment.
to weld a car or a truck or a minimizing waste and
crossover of similar size. environmental impact while
maximizing quality.

2. FMS- an example of technology and an alternative layout -

The idea of an FMS was proposed in England (1960s) under the name "System 24", a flexible
machining system that could operate without human operators 24 hours a day under
computer control. From the beginning the emphasis was on automation rather than the
"reorganization of workflow".

Early FMSs were large and very complex, consisting of dozens of Computer Numerical
Controlled machines (CNC) and sophisticate material handling systems. They were very
automated, very expensive and controlled by incredibly complex software. There were only a
limited number of industries that could afford investing in a traditional FMS as described
above.

Currently, the trend in FMS is toward small versions of the traditional FMS, called flexible
manufacturing cells (FMC).

Today two or more CNC machines are considered a flexible cell and two or more cells are
considered a flexible manufacturing system.

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AUTOMATED PROCESSES – FMS
{Flexible manufacturing system}
Thus, a Flexible Manufacturing System (FMS) consists of several machine tools along with
part and tool handling devices such as robots, arranged so that it can handle any family of
parts for which it has been designed and developed.

REFERENCES
 PRODUCTION AND OPERATION MANAGEMENT – BY
EVERETT E. ADAM ,Jr. RONAL J. EBERT
 Google .com

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