A flexible manufacturing system ( F M S )

is a highly automated GT machine cell,

consisting of a group or processing
workstations (usually CNC machine tools),
interconnected by an automated material
handling and storage system, and controlled
by a distributed computer system.
The FMS is most suited for the mid-variety,
mid-volume production range
The concept of flexible manufacturing systems
evolved during the 1960’s when robots,
programmable controllers, and computerized
numerical controls brought an environment to
the factory floor in the form of numerically-
controlled and direct-numerically-controlled
machines.
The main goal of a flexible manufacturing
system (FMS) is to offer the speed needed
to change with market conditions quickly,
but not sacrifice any quality.
Basic components of FMS

•Workstations
•Automated Material Handling and
Storage systems
•ComputerControlSystem
• Humans
Following are the types of workstations typically found in an

FMS:

1. Load/Unload Stations.

2. Machining Stations.

3. Other processing Stations. (punching, shearing, welding,

etc.)

4. Assembly Station.

5. Other Stations and Equipment. (Inspection, Vision, etc)

Material Handling and Storage System

Functions of the Handling System

1. Independent movement of workparts between stations.
2. Handle a variety of workpart configurations.
3. Temporary storage.
4. Convenient access for loading and unloading workparts.
5. Compatible with computer control.
•
Material Handling Equipment
The material handling function in an FMS is often shared between two
systems:
• Primary handling system establishes the basic layout of the FMS and is
responsible for moving workparts between stations in the system.
(Conveyor)
2. Secondary handling system consists of transfer devices,
automatic pallet changing, 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 process
or assembly operation.
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.
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
Human Resources
•Human are needed to manage the operations of the
FMS.
Functions typically performed by human includes:
Loading raw work parts 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
Classification of FMS…
•Flexible manufacturing systems can be
distinguished according to the number of
machines in the system.
The following are typicalcategories:
Single machine cell
Flexible manufacturing cell
Flexible manufacturing system
Single Machine Cell (SMC)
•A single machine cell consists of one CNC
machining center combined with a parts
storage system forunattended operation.
•Completed parts are periodically unloaded
from the parts storage unit, and raw
workparts are loaded into it
Flexible Manufacturing Cell (FMC
• A flexible manufacturing cell consists of two or
three processing workstations (typically CNC
machining centers)plusapart 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
 Equipments of FMS

Equipment that does this most effectively is likely

designed for two or more purposes.

 Primary equipment work centers

• Universal machining centers
• Turning centers
• Grinding machines
• Nibbling machines
 Process centers
• Wash machines
• Coordinate measuring machines
• Robotic work stations
• Manual workstations
These benefits include ;

 Better control over quality

 Reduced labor
 More efficient use of machinery
 Work-in-process inventory reduced
 Increased capacity
 Increased production flexibility
 Increased system reliability
 Less waste
 Fewer workstations
 Reduced downtime
Advantages
•Faster, lower- cost changes from one part to another
which will improve capital utilization
•Lower direct labor cost, due to the reduction in number of
workers
•Reduced inventory, due to the planning and programming
precision
•Consistent and better quality, due to the automated control
•Lower cost/unit of output, due to the greater productivity
using the same number of workers
•Savings from the indirect labor, from reduced errors,
rework, repairs and rejects
Disadvantages
•Limited ability to adapt to changes in product or product mix (ex.
machines are of limited capacity and the tooling necessary for
products, even of the same family, is not always feasible in a
given FMS)
•Substantial pre-planning activity
•Expensive, costing millions of dollars
•Technological problems of exact component positioning and
precise timing necessary to process a component
•Sophisticated manufacturing systems
Application of FMS
• Metal-cutting machining
• Metal forming
• Assembly
• Joining-welding (arc , spot), gluing
• Surface treatment
• Inspection
• Testing
 Another Example


Two part types & Three Machines P1 P2

Four operations needed to

process
M1 P1 O1 O2 O3 O5

M1 can
Three perform
operations Four operations
needed to
process P2
M2 O2 O3 O5

This choice tries to minimize M2 can perform three operations

part transfer between M3 O4 O5
machines
M3 can performGECCO
two2002,
operations
New York
 

Two part types & Three Machines P1 P2

M1 O1 O2 O3 O5

M2 O2 O3 O5

This choice tries to distribute

M3 O4 O5
workload (operations) evenly
between machines