Flexible Manufacturing system: - The Flexible manufacturing system is one of

the machine cell types used to implement cellular manufacturing. It is the most
automated and technologically sophisticated of the group technology cells. An
FMs typically possess multiple automated stations and is capable of variable
routings among stations. Its flexibility allows it to operate as a mixed model
system. An FMS integrates into one highly automated manufacturing system
many of the concepts and technologies. The concept of FMS originated in Britain
in the early 1960s. The first FMS installations in the United States occurred
around 1967, These initial systems performed machining operations on families
of parts using Nc machine tools.
FMS technology cab ne applied in production situations similar to those
identified for cellular manufacturing.
What is meant by Flexible Manufacturing System?
A Flexible manufacturing system (FMS) is a highly automated GT machine cell,
consisting of a group of processing workstations (usually CNC machine tools),
interconnected by an automated material handling and storage system, and
controlled by a distributed computer system. The reason the FMS is called
Flexible is that it is capable of processing a variety of different part styles
simultaneously at the various workstations, and the mix of part styles and
quantities of production can be adjusted in response to changing demand
patterns.
The FMS is most suited for mid variety and mid-volume production range. A
flexible manufacturing system relies on the principles of Group technology. No
manufacturing system can be completely flexible. There are limits to the range
of parts or products that can be made in an FMS. Accordingly, a FMS is designed
to produce parts (or products) within a defined range of styles sizes, and
processes. In other words, an FMS is capable of producing a single part family or
limited range of part families.
What does Flexibility mean?
1. Can identify and operate different part/product styles
2. Quick changeover of process/operating instructions
3. Quick changeover of physical setup
Features of FMS: -
1. An FMS is distinguished from an automated production line by its ability to
process more than one product style simultaneously.
2. At any moment, each machine in the system may be processing a
different part type.
3. FMS lets us to make changes in the production schedule in order to meet
the demands on different products.
4. New product styles can be introduced into production with an FMS, so long
as they are to be used on the products that system can process.
5. This kind of system is therefore ideal when there are likely to be changes
in demands.
Components of an FMS: -
Ther are several components of a flexible manufacturing system. The basic
components include i. Workstations, ii. Material handling and storage
systems. iii. Computer control system. In addition, it also may have
a). Robot (b). Numerical control machine tools. (C). Work holding and tooling
considerations (d). Manual and automated assembly cells (e). Inspection
equipment.
i. Work Stations: - The processing and assembly equipment used in an flexible
manufacturing system depends on the type of work accomplished by the
system. In a system designed for machining operations, the principal types of
processing stations are CNC machine tools. How ever, the FMS concept s
applicable to various other process as well., some of them are
a. Load/Unloading operation
b. Machining operation
c. other processing stations
d. Assembly operations.

ii. Material Handling and storage system: - The second major

component of a FMS is its material handling and storage system. In FMS the
material handling and storage system performs the following functions
a. Allows random, independent movement or work parts between stations.
b. Enables handling of variety of worpart configurations.
c. Provides temporary storage.
d. Provides convenient access for loading and unloading work parts.
e. Creates compatibility with computer control.

iii. 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 micro computers controlling the individual
machines and other components. The central computer coordinates the
activities of the components to achieve smooth overall operation of the
system.
The typical functions performed by the FMS computer control system can be
as follows
a. Workstation control
b. Distribution of control instructions to work stations
c. Production control
d. Traffic control
e. Shuttle control
f. Workpiece monitoring
g. Tool control
h. Performance monitoring and reporting
i. Diagnostics.
Benefits of FMS: -
A number of benefits can be expected in successful FMS application. The
principal benefits are
1. Increased Machine Utilization: - Flexible manufacturing system achieve a
higher average utilization than machines in a conventional batch
production machine shop. Reasons include 24hour per day operation,
automatic tool changing of machine tools, automatic pallet changing at
work stations, queues of parts at stations and dynamic scheduling of
production that compensates for irregularities.
2. Fewer machines required: - Because of higher machine utilization, fewer
machines are required.
3. Reduction in the amount of factory floor space required: - Compared to job
shop or equivalent capacity, a FMs generally requires less floor area.
4. Greater responsiveness to change: - An FMS improves response capability
to part design changes, introduction of new parts changes in production
schedule and product mix, machine breakdowns and cutting tool failures.
5. Reduced inventory requirements: - Because different parts are processed
together rather than separately in batches work-in-process is less than in a
batch production mode.
6. Lower manufacturing lead time: - Closely correlated with reduced work-in-
process is the time spent in process by the parts. This means faster
customer deliveries.
7. Reduced direct labour requirements and higher labour productivity: -
Higher production rates and lower reliance on direct labour mean greater
productivity per labour hour with an FMS than with conventional
production methods.
8. Opportunity for unattended production: - The high level of automation is
flexible manufacturing system allows it to operate for extended periods of
time without human attention.

Demerits of FMS: -
1. High Initial Investment:
 Implementing an FMS requires significant capital expenditure on
machinery, software, and system integration. This can be a major barrier,
especially for small and medium-sized enterprises.
2. Complexity and Maintenance:
 FMS involves sophisticated technology, making it a complex system to
manage. This complexity translates to increased maintenance
requirements and the need for highly skilled technicians.
 Troubleshooting and repairing FMS can be challenging and costly.
3. Requirement of Skilled Labor:
 Operating and maintaining an FMS demands a workforce with specialized
skills in programming, robotics, and automation. Finding and retaining
such skilled personnel can be difficult and expensive.
4. Extensive Planning and Implementation Time:
 Setting up an FMS is a lengthy process that requires meticulous planning,
design, and integration. This can lead to production disruptions and
delays.
 5. Risk of System Failures:
 Due to the interconnected nature of FMS, a failure in one component can
potentially disrupt the entire production line. This necessitates robust
backup systems and contingency plans.
6. System rigidity after implementation:
 While the system is designed to be flexible, once it is implemented, large
changes can be costly and time consuming.
7. Dependence on Technology:
 FMS are heavily reliant on technology, making them vulnerable to software
glitches, hardware failures, and cybersecurity threats.

Applications of FMS:
FMS is applicable to a variety of manufacturing operations. FMS Technology is
most widely applied In manufacturing operations, others applications include
a. Metal cutting
b. Metal forming
c. Assembly
d. Joint welding, gluing
e. Surface treatment
f. Inspection
g. Testing

Flexibility in Pull and Push type: -

Push System:
 Concept:
o In a push system, production is based on forecasted demand.
Products are "pushed" through the production process, often
resulting in inventory buildup.
 Flexibility:
o Limited Flexibility: Push systems tend to be less flexible. They are
optimized for stable demand and long production runs.
o Challenges:
 If demand fluctuates significantly, push systems can lead to
overproduction or shortages.
 Adapting to sudden changes in customer preferences or
market conditions can be difficult.
 Changes in product design can be hard to implement quickly.
o Where it may be used:
 Products with very stable demand.
 Products where long lead times are acceptable.
Pull System:
 Concept:
o In a pull system, production is triggered by actual customer demand.
Products are "pulled" through the production process, minimizing
inventory.
 Flexibility:
o High Flexibility: Pull systems are inherently more flexible. They are
designed to respond rapidly to changes in demand.
 o Advantages:
 Reduced inventory and waste.
 Increased responsiveness to customer needs.
 Ability to handle product variations and customization.
o Requirements:
 Requires a robust and agile supply chain.
 Relies on accurate and timely information flow.
o Where it may be used:
 Markets with volatile demand.
 Products with short life cycles.
 Customized or made-to-order products.

FMS Layout: -
It is the physical arrangement of the various components within a Flexible
Manufacturing System. This arrangement is crucial for optimizing the flow of
materials and information, and ultimately, the efficiency of the manufacturing
process.
Most layout configuration found in todays FMS can be classified into five
categories
1. In-Line layout 2. Loop Layout 3. Ladder Layout
4. Open field layout 5. Robot-cantered cell

a. In the Inline layout, the machines and handling systems are arranged in a
straight line. In its simplest form, the parts progress from one workstation to the
next in a well-defined sequence with work always moving in one direction and
no back flow.

b. In the Loop layout the workstations are organized in a loop that is served by a
parts handling system as shown in the figure. Parts usually flow in one direction
around the loop with the capability to stop and be transferred to any station. A
secondary handling system is shown at each work station to permit parts to
move without obstruction around the loop. The load/unload stations are typically
located on end of the loop.
c. The ladder layout consists of a loop with rungs between the straight sections of
the loop, on which workstations are located. The rung increases the number of
possible ways of getting from one machine to the next and obviate the need for
secondary handling system, thereby reducing transport time between stations.

d. The open field layout consists of multiple loops and ladders and may include
sidings as well. This layout type is generally appropriate for processing a large
family of parts. The number of different machine types may be limited and parts
are routed to different workstations depending on which one becomes available
first.

e. The robot centered layout uses one or more robots as the material handling
system. Industrial robots can be equipped with grippers that make them well
suited for the handling of rotational parts, and robot-cantered FMS layouts are
often used to process cylindrical or disk-shaped parts.
Types of FMS:
Flexible manufacturing systems can be distinguished according to the kinds of
operations they perform as processing operations or assembly operations

Two other ways to classify flexible manufacturing system are by number of

machines and level of flexibility.
Number of machines:
1. Single machine cell 2. Flexible manufacturing cell and
3.Flexible manufacturing system.
A single cell consists of one CNC machining centre 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. The
cell can be designed to operate in a batch mode, a flexible mode or a
combination of two.
A flexible manufacturing cell (FMC) consists of two or three processing work
stations plus a part a handling system. The parts handling is connected to a
load/unload station. The handling system usually includes a limited parts
storage capacity.
A flexible manufacturing system (FMS) has four or more processing stations
connected mechanically by a common parts handling system and electronically
by a distributed computer system. Thus, an important distinction between an
FMS and an FMS is in the number of machines. An FMC has two or three
machines, while an FMS has four or more. FMS generally includes non-
processing work stations that supports production but do not directly participate
in it.
By level of flexibility: -
Dedicated FMS: - Designed to produce limited variety of part styles and the
complete universe of parts to be made on the system us known in advance The
part family is likely to be based on product commonality rather than geometric
similarity. The product design is considered stable.
Random order FMS: - It is more appropriate when the part family is large,
there are substantial variation in part configurations, new part designs will be
introduced into the system and engineering changes will occur in parts currently
produced and the production schedule is subject to change from day to day.
 Different types of FMS: -
1. Sequential FMS:- It is manufactured one piece part batch type and then
planning and preparation is carried out for the next piece part batchtype to
manufactured.
2. Random FMS:- It manufactures any random mix of piece part types at any
one time.
3. Dedicated FMS:- It continually manufactures for extended periods the same
but limited mix of piece part batch types.
4. Engineered FMs:- It manufactures the same mix of part types throughout its
lifetime.
5. Modular FMS:- A modular FMS with sophisticated FMS host , enables and FMS
user to expland their FMS capabilities in a step wise fashion into any of the
previous four types of FMS