Flexible Manufacturing System

Hello friends, I hope you all are fine. Today's post is on flexible manufacturing system.

So let's start with definition of a Flexible manufacturing system.

Definition

“FMS consists of a group of processing workstations interconnected by means of an automated
material handling and storage system and controlled by the integrated computer control system.”
FMS is an automated mid-volume made variety Central computer-controlled manufacturing system.

 History of FMS 

The first  FMS was patented in 1965 by William's son who made numerically controlled equipment.

Classification of FMS 

Flexible manufacturing systems classified according to the number of machines in the system the following are typical categories: 

• Single machine cell
• Flexible manufacturing cell 
• Flexible manufacturing system

 Single machine cell (SMC): A single machine cell consists of one CNC machine center combined with their parts storage system for unattended operations (i.e. running a machine tool with no operator in attend)

• Completed parts are periodically unloaded from the parts storage unit and raw work parts are loaded into it.

Flexible manufacturing cell (FMC): A flexible manufacturing cell consists of two or three processing workstations (typically CNC machining centers) plus part handling system.

• The part handling system is connected to a load or unload station.

Flexible manufacturing system (FMS): A flexible manufacturing system has four or more processing workstations connected mechanically by common part handling.

• Flexible manufacturing system is controlled by a central computer.

Differences between FMC and FMS 

Flexible manufacturing cell :

• Low flexibility
• Small stored part program inventory and accessibility
• Moderate equipments are used and resource cost is less 
• Narrow benefits obtained from this but these are easily identified and quantified 
• Moderate level of management commitment and support required 
• Low staffing and training impact
• Low to moderate risk and complexity
• Short planning to implementation cycle

Flexible manufacturing system (FMS):

• High flexibility 
• High stored part program inventory and accessibility 
• equipments are used and resource cost is more 
• Benefits are broad but hard to identify and quantify
• High level of management commitment and support required 
• High staffing and training impact
• High risk and complexity
• Long planning to implementation cycle 

Basic components of FMS:

1. Workstations 
2. Automated material handling and storage systems 
3. Computer control system 

1.Workstations: It consists of NC machines, machine tool, inspection equipments, loading and unloading operation and machining area. More recent include other types of processing equipment.

2. Automated material handling and storage system: The various automated material handling system are used to transport work parts and sub-assembly parts between the processing stations.

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

3. Computer control system: It is used to coordinate the activities of the processing stations and the material handling system in FMS.

• The various functions of the computer control system are:  

         (a.) control of each workstation  
         (b.) Production control 
         (c.) traffic control  
         (d.) Shuttle control.

Benefits of FMS:

• Reduced cycle times
• Low work in process inventory
• Low direct labour cost
• Reduction of lead time
• Improved machine utilization
• Reduction of labour time 
• Improve to due date reliability 
• Increase quality
• Produce more product more quickly 
• Improve efficiency 
• To reduce set up and queue times
• Improve product routing
• Increase production rate 

Disadvantages of FMS:

• Expensive 
• Substantial pre-planning activity 
• Requirement of skilled labor
• Complicated system 

Flexibility in FMS:

Flexibility in manufacturing means the ability to deal with slightly or greatly mixed parts, to allow variation in parts assemblies and variation in process sequence, change the production volume and change the design of certain products being manufactured. 

Application of FMS :

• Metal cutting machine
• Metal forming 
• Assembly 
• Surface treatment
• Inspection 
• Testing 

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