DEFINITION
A flexible manufacturing system ( FMS) is
a set of numerically controlled machine
tools and supporting workstations
connected by an automated material
handling system and controlled by a central
computer
ELEMENTS OF FMS
• Automated tool delivery and changing
• Automated material handling
• coordinated control
FMS FEATURES
• Many part types can be loaded
• Parts can arrive at machines in any sequence
• Parts identified by codes
• Many machines can be included
• Modular design
• Reduced direct labor costs
• Can easily be turned over to new set of products if
the need arises
ORIGINS OF FMS
• Link lines (1960’s)
• NC machines and conveyors
• Batch processing
Distinguishing characteristics:
Flexible Manufacturing Cell (FMC)
• A flexible manufacturing cell consists of two or three processing
workstations (typically CNC machining centers) plus a part handling
system.
• The part handling system is connected to a load/unload station.
Flexible Manufacturing System (FMS)
• A flexible manufacturing system has four or more processing workstations
connected mechanically by a common part handling system and
electronically by a distributed computer system.
FMS COMPONENTS
• Work station
• Material handling and storage system
• Computer control system
• Human labour
• Robotics
• Controller
PART MOVEMENT
• Conveyors
• Tow carts
• Rail carts
• AGV’S
SUPPORTING WORKSTATIONS
• Load/unload stations
• Automatic part washers
• Coordinate measuring machines
CONTROLLER
• Computer
• Worker (attendant)
• Tracking system for
– parts
– machines
There are three levels of
manufacturing flexibility.
1-Basic Flexibilities
Machine flexibility - the ease with which a machine can process
various operations
Material handling flexibility -a measure of the ease with which
different part types can be transported and properly positioned at the
various machine tools in a system
Operation flexibility - a measure of the ease with which
alternative operation sequences can be used for processing a part type
2.SYSTEM FLEXIBLITY
Volume flexibility
Expansion flexibility
Routing flexibility
Process flexibility
Product flexibility
3.AGGREGATE FLEXIBILITY
Program Flexibility
Production Flexibility
Market Flexibility
FLEXIBLE ASSEMBLY SYSTEMS
• For the combination of raw materials and
components into products with functional
characteristics.
• Automated vs manned systems
• Example: Vibratory bowl feeders and vision
systems
• Role of Design for Assembly
Differences Between FMS and FMC
FMS FMC
Has four or more Has two or three
machines machines
Larger and more Simpler computer
sophisticated control system
computer control Limited error
system recovery by fewer
Minimized effect of machines
machine breakdowns
BENEFITS OF FMS
Reduced work in process
Increased machine utilization
Better management control
Reduced direct and indirect labor
Reduced manufacturing lead-time
Consistent and better quality
Reduced inventory
The Disadvantages of FMS
Expensive, costing millions of dollars
Sophisticated manufacturing systems
Limited ability to adapt to changes in product
Technological problems of exact component
positioning and precise timing necessary to process
a component
Future Benefits of FMS
Technology will make 100% inspection feasible
Computer diagnosis will improve estimation of
machine failure, and guide work crews repairing
failures
The use of robots that have vision, and tactile sensing
Minimum human labor in manufacturing systems
More sophisticated tools with increased computing
power
Better management software, hardware, and fixturing
techniques
Developed standards that will let us install new
machines easily
