Unit-1

Flexible manufacturing systems

Introduction
In today’s environment industries are forced to develop and introduce their products
more frequently to maintain and increase in share of world market. The manufacturing facility
should be flexible to produce variety of products without any delays with high quantity, with
competitive prices. computer control machines and material handling system make a
manufacturing facility more flexible.
Eg., simple CNC machines produce many parts with similarity.
Flexible Manufacturing System
A flexible manufacturing system (FMS) is an integrated group of processing CNC
machines and material-handling equipment under computer control for the automatic
processing of palletized parts. FMSs represent a compromise between the high flexibility of
versatile job shops and the high production rate of a dedicated mass production system (e.g.,
transfer lines). It is capable of producing limited number of preplanner part families and
utilizes similarities between members of a parts family based on group technology. FMSs are
most suited for the mid-variety, mid-volume production range, Moreover, flexible
manufacturing is capable of responding quickly to increasing product variants and decreasing
quantities per variant. FMS is a method used to manufacture and produce goods that are able
to adapt changes These changes may include addition of new product types or remodelling
of existing product types.
In simple it is defined as an automated machine cell, consisting of a group of
processing workstations, interconnected with automated material handling and storage
system.
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.
What is flexibility?
It can be defined as the ability to deal with slightly or greatly mixed parts, to allow
variation in part assembly or variation in process sequence, change in production volume and
change the design of certain product being manufactured.
Types of flexibility
1. Basic Flexibilities
Material Handling Flexibility – Different part types can be transported and positioned
properly at various machine tools in a system.
Machine Flexibility – The ease due to which machine can possess multiple operations. It is
the capability to adapt a given machine in the system to a wide range of production
operations and part styles. The greater the range of operations and part styles the greater
will be the machine flexibility. The various factors on which machine flexibility depends are:
 Setup or changeover time
 Ease with which part-programs can be downloaded to machines
 Tool storage capacity of machines
Operation Flexibility – Alternative operation sequences can be used for a processing part
type.
2. System Flexibility
Product Flexibility – The volume of set of part types that can be manufactured in a system
with minor setup. . It refers to ability to change over to a new set of products economically
and quickly in response to the changing market requirements. The change over time includes
the time for designing, planning, tooling, and fixturing of new products introduced in the
manufacturing line-up. It depends upon following factors:
 Relatedness of new part design with the existing part family
 Off-line part program preparation
  Machine flexibility
Process Flexibility – The volume of set of part types that system can produce without
incurring any setup. It is defined as the ability to change the product mix while maintaining
the same total production quantity that is, producing the same parts only in different
proportions. It is also known as process flexibility. Mix flexibility provides protection against
market variability by accommodating changes in product mix due to the use of shared
resources. However, high mix variations may result in requirements for a greater number of
tools, fixtures, and other resources. Mixed flexibility depends on factors such as:
 Similarity of parts in the mix
 Machine flexibility
 Relative work content times of parts produced
Routing Flexibility – The alternative path that a part can effectively follow through a system
for a given process plan. It can define as capacity to produce parts on alternative workstation
in case of equipment breakdowns, tool failure, and other interruptions at any particular
station. It helps in increasing throughput, in the presence of external changes such as product
mix, engineering changes, or new product introductions. Following are the factors which
decides routing flexibility:
 Similarity of parts in the mix
 Similarity of workstations
Volume Flexibility – Measure of a system’s capability to be operated profitably at different
volumes of existing apart type. It is the ability of the system to vary the production volumes
of different products to accommodate changes in demand while remaining profitable. It can
also be termed as capacity flexibility. Factors affecting the volume flexibility are:
 Level of manual labor performing production
 Amount invested in capital equipment
Expansion Flexibility – Ability to build a system and expand. It is defined as the ease with
which the system can be expanded to foster total production volume. Expansion flexibility
depends on following factors:
 Cost incurred in adding new workstations and trained workers
 Easiness in expansion of layout
 Type of part handling system used
 3. Aggregate Flexibilities
Production Flexibility – The volume of set of part types that a system can produce without
major investment in capital equipment. It is the range of part styles that can be produced on
the systems. The range of part styles that can be produced by a manufacturing system at
moderate cost and time is determined by the process envelope. It depends on following
factors:
 Machine flexibility of individual stations
 Range of machine flexibilities of all stations in the system
Market Flexibility – The ability of a system to efficiently adapt to changing market conditions.
Program Flexibility – The ability of a system to run for reasonably long periods without
external intervention.
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:”
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
skilful 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.”
“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.”
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.”

FMS components
 Workstations
 Material Handling and Storage Systems
 Computer Control Systems
 Human Resources
Workstations
The processing or assembly equipment used in an FMS depends on the type of work
accomplished by the system. In a system designed for machining operations, the principle
types of processing station are CNC machine tools. However, the FMS concept is also
applicable to various other processes as well. Following are the types of workstations typically
found in an FMS.
• Machining centers/stations
• Load and unload stations
• Assembly work stations
• Inspection stations
• Forging stations
• Sheet metal processing
Material Handling and Storage System
The second major component of an FMS is its material handling and storage
system. functions of the handling system, material handling equipment typically used in an
FMS, and types of FMS layout.
Functions of the Handling System
• Random, independent movement of work-parts between stations.
• Handle a variety of work-part configurations.
• Temporary storage
• Convenient access for loading and unloading work-parts.
• Compatible with computer control.
 1. Random, independent movement of work-parts between stations. This means
that parts must be capable of moving from anyone machine in the
system to any other machine. to provide various routing alternatives for the different
parts and to make machine substitutions when certain stations are busy.
2. 3Handle a variety of work-part configurations. For prismatic parts, this is usually
accomplished by using modular pallet fixtures in the handling system. The fixture is
located on the top face of the pallet and is designed to accommodate different part
configurations by means of common components, quick change features, and other
devices that permit a rapid buildup of the fixture for a given part. The base of the pallet
is designed for the material handling system. For rotational parts, industrial robots are
often used to load and unload the turning machines and to move parts between
stations.
3. Temporary storage. The number of parts in the FMS will typically exceed the number
of parts actually being processed at any moment. Thus, each station has a small queue
of parts waiting to be processed. which helps to increase machine utilization.
4. 5Convenient access for loading and unloading work-parts. The handling system
must include locations for load/unload stations.
5. Compatible with computer control. The handling system must be capable of
being controlled directly by the computer system to direct it to the various
workstations, load/unload stations, and storage areas
Material Handling Equipment. The types of material handling systems used to transfer parts
between stations in an F.\1S include a variety of conventional material transport equipment
inline transfer mechanisms and industrial robots.
The material handling function in an FMS is often shared between two systems:
(1) a primary handling system and
(2) a secondary handling system.
The primary handling system establishes the basic layout of the FMS and is
responsible for moving work-parts between stations in the system. The types of material
handling equipment typically utilized for FMS layouts are summarized.
The secondary handling system consists of transfer devices, automatic pallet changers.
and similar mechanisms located at the workstations in the FMS. The function of the secondary
handling system is to transfer work from the primary system to the machine tool or other
processing station and to position the parts with sufficient accuracy and repeatability to
perform the processing or assembly operation. Other purposes served by the secondary
handling system include: (1) reorientation of the work-part if necessary to present the surface
that is to be processed and (2) buffer storage of parts to minimize work change time and
maximize station utilization. In some FMS installations, the positioning and requirements at
the individual workstations are satisfied by the primary work handling system. In these cases,
the secondary handling system is not included,The primary handling system is sometimes
supported by an automated storage system .An example of storage in an FMS is illustrated in
Figure 16.6. The FMS is integrated with an automated storage/retrieval system (AS/RS), and
the S/R machine serves the work handling function for the workstations as well as delivering
parts to and from the storage racks,
FMS Layout Configurations. The material handling system establishes the FMS layout. Most
layout configurations found in today's FMSs can he divided into five categories:
(1) inline layout,
(2) loop layout
(3) ladder layout.
(4) open field layout, and
(5) robot-centered cell.

Inline layout
An Automated guided vehicle is most efficient when the movement is in straight-lines
along the AGV path in a single-row machine layout. Machines are arranged only on one side
of AGV path [78], and in double row machine layout, machines are arranged on both sides. A
possible arrangement of this layout is shown
Loop layout
“The loop layout uses conveyor systems that allow unidirectional flow of parts around the
loop. A secondary material handling system is provided at a workstation which permits the
flow of parts without any obstruction. A possible arrangement of this layout is

Ladder type layout

Ladder type layout “Ladder type layout consists of rungs on which workstations are
located. This reduces the average travel distance thereby reducing the transfer time between
workstations. A possible arrangement of this layout is shown
Carousel layout
“In the Carousel layout configuration, parts flow in one direction around the loop. The load,
unload stations are placed at one end of loop, A possible arrangement of this layout is shown
in fig

Robot centered layout

If a handling robot is used in a Flexible manufacturing system cell , the machines are laid out
in a circle, such a layout is called circular layout. A possible arrangement of this layout
open field layout
“The open field layout is also an adoption of the loop configuration. The open field layout
consists of loops and ladders organized to achieve the desired processing requirements. This
is used for the processing of a large family of parts. The number of different machines may be
limited, 51 and the parts are routed to different workstations depending on availability of
machines. A possible arrangement of this layout is shown in fig-3.8[11].”

Computer Control System

The FMS includes a distributed computer system that is interfaced to the
workstations, material handling system, and other hardware components. A typical FMS
computer system consists of a central computer and microcomputers controlling the
individual machines and other components. The central computer coordinates the activities
of the components to achieve smooth overall operation of the system. Functions performed
by the FMS computer control system can be grouped into the following categories:
 Workstation control. In a fully automated FMS, the individual processing or assembly
stations generally operate under some form of computer control. For a machining
system, CNC is used to control the individual machine tools.
 Distribution of control instructions to workstations. Some form of central
intelligence is also required to coordinate the processing at individual stations. In a
machining FMS, part programs must be downloaded to machines, and DNC is used for
this purpose, The DNC system stores the programs, allows submission of new
programs and editing of existing programs as needed, and performs
other DNC functions
 Production control. The part mix and rate at which the various parts are launched
into the system must be managed. Input data required for production control includes
desired daily production rates per part. numbers of raw work-parts available, and
number of applicable pallets.' The production control function is accomplished by
routing an applicable pallet 10 the load/unload area and providing instructions to the
operator for loading the desired work-part.

 Traffic control. This refers to the management of the primary material handling
system that moves workparts between stations. Traffic control is accomplished by
actuating switches at branches and merging points. stopping parts at machine tool
transfer locations, and moving pallets to load/unload stations.
  Shuttle control. This control function is concerned with the operation and control
of the secondary handling system at each workstation. Each shuttle must be
coordinated with the primary handling system and synchronized with the operation
of the machine tool it serves,

a
 Work-piece monitoring. The computer must monitor the status of each cart
and/or pallet in the primary and secondary handling systems as well as the status of
each of the various workpiece types.
 Tool control. In a machining system, cutting tools are required. Tool control is
concerned with managing two aspects of the cutting tools:
  Tool location. This involves keeping track of the cutting tools at each workstation, If
one or mere tools required to process a particular workpiece is not present at the
station that is specified in the part's routing, the tool control subsystem takes one or
both of the following actions: (a) determines whether an alternative workstation that
has the required tool is available and/or (b) notifies the opera tor responsible for tooling
in the system that the tool storage unit at the station must be loaded with the required
cutter(s).
 Tool life monitoring. 1.nthis aspect of tool control, a tool life isspecif.ied to
the computer for each cutting tool in the FMS. A record of the machining time usage
i••maintained for each of the tools, and when the cumulative machining time reaches
the specified life of the tool, the operator is notified that a tool replacement is needed.
 Performance monitoring and reporting. The computer control system is programmed
to collect data on the operation and performance of the FMS. This data is periodically
summarized, and reports are prepared for management on system performance. Some
of the important reports that indicate FMS performance are listed in Table 16.6
 Diagnostics. This function is available to a greater or lesser degree on many
manufacturing systems to indicate the probable source of the problem when a
malfunction occurs. It can also be used to plan preventive maintenance iu the system
and to identify Impending failures. The purpose of the diagnostics function is to reduce
breakdowns and downtime and increase availability of the system.
The modular structure of the FMS application software for system control is illustrated in
Figure 16.11. It should be noted that an FMS possesses the characteristic architecture or a
DNC system. As in other DNC systems. Two-way communication is used. Data and commands
an: sent from the central computer to the individual machines and other hardware
components, and data on execution and performance are transmitted from the components
hack up to the central computer. In addition, an uplink from the FMS to the corporate host
computer is provided
Human Resources
One additional component in the FMS is human labor. Humans are needed to manage the
operations of the FMS. Functions typically performed by humans include:
 loading raw workparts 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 system,
 programming and operating the computer system, and
 overall management of the system

FMS Benefits
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:
 Increased machine utilization
 Fewer machines required
 Reduction in factory floor space required
 Greater responsiveness to change.
 Reduced inventory requirements
 Lower manufacturing lead times
 Reduced direct labor requirements
 Opportunity for unattended production
 Increased machine utilization. FMSs achieve a higher average utilization than
machines in a conventional batch production machine shop. Reasons for this include:
• 24 hr/day operation.
• automatic tool changing are machine tools.
• automatic pallet changing at workstations.
• queues of parts at stations, and
• dynamic scheduling of production that takes into account irregularities from
normal operations. It should be possible to approach 80-90% asset utilization
by implementing FMS technology
• Fewer machines required Because of higher machine utilization. fewer machines are
required.
• Reduction in factory floor space required. Compared with a job shop of
equivalent capacity, an fMS generally requires less floor area. Reductions in floor
space requirements are estimated to he 40-50%, [23].
• Greater responsiveness to change. An FMS improves response capability to part
design changes. introduction of new part s, changes in production schedule and
product mix. machine breakdowns. and cutting tool failures. Adjustments can be
made in the production schedule from one day to the next to respond to rush orders
and special customer requests.
• Reduced inventory requirements, Because different parts are processed
together rather than separately in batches. Work-in-process (WIP) is less than in a
batch production mode. The inventorv of starting and finished parts can be reduced
as well. Inventory reductions of 60-80% are estimated.
 • Lower manufacturing lead times. Closely correlated with reduced WIP is the
time spent in process by the parts. This means faster customer deliveries
• Reduced direct labor requirements and higher labor productivity. Higher
production rates and lower reliance on direct labor translate to greater productivity
per labor hour with an FMS than with conventional production methods. Labor savings
of 30-.50%, arc estimated
• Opportunity for unattended production. The high level of automation in an FMS
allows it to operate for extended periods of time without human attention. In the
most optimistic scenario, parts and tools are loaded into the system at the end of the
day shift, and the FMS continues to operate throughout the night so that the finished
parts can be unloaded the next morning
FMS Applications
In general it has been found that manufacturing operations can readily exploit
concepts of flexible automation, for such tasks as machining, for example—but also for other
tasks that may be met in the production environment, such as assembly, forging, and sheet
metal pressworking. In machining there has been a historical preference for milling and
drilling type operations in FMSs. These operations process non-rotational parts using CNC
machining centres. Until recently, FMSs that could handle rotational parts, and put in place
turning centre workstations that could process these, were much less common. The systems
installed for rotational part processing tend to have fewer machines that its non-rotational
counterpart. The reasons for the difference in the pace of development of rotational and non-
rotational FMSs include:
Non-rotational parts are usually too heavy for a human operator to load easily into
the machine tool; this gave rise to creation of specialized pallet fixtures and material handling
systems to perform this task without human intervention—all of which became chief
components in the creation of FMSs. Non-rotational parts tend to be more expensive than
rotational parts, which required them to be made as efficiently as possible; hence the use of
FMS for these parts, before much consideration was given for an equivalent FMS for
rotational parts.
Few other applications include:
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EXTRA TOPICS COVERED
Concept of FMS
The current market scenario is such that a customer has the requirement to demand
a wide variety of good quality product at a very short notice. The traditional systems of
product manufacture like Transfer Line system were unable to cope up with the market
requirements. The Transfer Line system of manufacture had a very high production level but
offered limited flexibility. On the other hand, Workshop system of product manufacture
offered a very high degree of flexibility but had a very low production level. These systems
were unable to satisfy the requirements of variety, quantity and speed at the same time. This
lead to the work of development of a system, which combines the seemingly conflicting
objectives of high flexibility and high productivity.

The emergence of F.M.S. technology has proved to be an ideal solution to this

problem. With the help of F.M.S. we are able to produce a wide variety of products without
making any changes in the hardware set-up. As a result of this the changeover time between
two products can be reduced to the time required by the machine tools to receive the
necessary instructions. It also reduces the lead-time drastically. This is of prime importance
as lead-time is equated with the cost of the product. It is a market-sensitive technology as it
can produce the required proportion of product variety quickly and efficiently.
Y FMS??
Flexible manufacturing systems may be expensive to implement at first. However,
they’ll help save money in the future. They reduce the costs of operation because their ability
to adapt to changes helps to prevent defective products as well as wasted time and resources.
On top of that, they require fewer workers to operate them compared to other manufacturing
systems, so companies can save on labour costs. But perhaps the biggest benefit of flexible
manufacturing systems is that they help companies become more efficient. They work to keep
everything running smoothly in most situations. If something within the process changes, they
can easily adapt and keep production flowing to reduce delays and bottlenecks. This helps to
create faster production times and, as a result, increased customer service and satisfaction.
Though costly at first, flexible manufacturing systems will help businesses to create better
products, become more efficient, and increase revenue as time goes on.