FMS (Flexible Manufacturing System)

PRESENTED BY : Suffian Bin Ayob

Contents
Introduction Why use F.M.S.? What Is F.M.S.? Components of F.M.S. FMS Layout Example Of FMS application FMS Photo Advantages of FMS application

Introduction
Since the dawn of civilisation, man has been continuously trying to ease and improve his work by developing better tools. This process started with the development of stone tools and will culminate into development of a totally automated factory. This factory would be able to do all the things associated with a product, right from designing it to packaging. Since the human operator tends to be the weakest link in the production process, the need for automation has been felt throughout the industry. A Flexible Manufacturing System (F.M.S.) is a part of this process and a step towards complete automation of the factory. A F.M.S. is a form of flexible automation in which several machine tools are linked together by a material-handling system, and all aspects of the system are controlled by a central computer.

Why use F.M.S.?

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.

Why use F.M.S.?

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.

Figure 1: - Volume versus variety capabilities of various Manufacturing Systems, Courtesy Material and Processes in Manufacture, Lindberg

What Is F.M.S.
1. 2. 3. A flexible manufacturing system (FMS) is a configuration of computer-controlled, semi-independent workstations where materials are automatically handled and machine loaded. An FMS is a type of flexible automation system that builds on the programmable automation of NC and CNC machines. Programs and tooling setups can be changed with almost no loss of production time for moving from production of one product to the next. Such systems require a large initial investment ($5 to $20 million) but little direct labor to operate. An FMS system has three key components: Several computer-controlled workstations, such as CNC machines or robots, that perform a series of operations A computer-controlled transport system for moving materials and parts from one machine to another and in and out of the system Loading and unloading stations

What is FMS?
an automated, mid-volume, mid-variety, central computer controlled manufacturing system Activities covered: machining, sheet metal working, welding, fabricating, assembly Physical components: Potentially independent NC machine tools capable of performing multiple functions and having automated tool interchange capabilities Automated material handling system to move parts between machine tools and fixturing stations All the components are hierarchically computer controlled Equipment such as coordinate measuring machines and part-washing devices

Components of F.M.S.
A FMS consists of: Physical subsystem/Hardware a) Workstations: NC machine tools, inspection equipment, part-washing devices, load & unload area. b) Storage-retrieval systems (AS/RS) c) Material handling systems Control subsystem/Software a) Control hardware b) Control software

FMS Layout

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Raw material storage (Roller Conveyor)

Example Of FMS application

Figure (1) shows the layout of a typical FMS, which produces turning and machining centers. Specific characteristics of this FMS include the following: The computer control room (right) houses the main computer, which controls the transporter and sequence of operations. Three CNC machines, each with its own microprocessor, control the details of the machining process. Two AGVs, which travel around a 200-foot-long oval track, move materials on pallets to and from the CNCs. When the AGVs batteries run low, the central computer directs them to certain spots on the track for recharging. Indexing tables lie between each CNC and the track. Inbound pallets from an AGV are automatically transferred to the right side of the table, and out-bound pallets holding finished parts are transferred to the left side for pickup.

Example Of FMS application

A tool changer located behind each CNC loads and unloads tool magazines. Each magazine holds an assortment of tools. A machine automatically selects tools for the next specific operation. Changing from one tool to another takes only 2 minutes. Two load and unload stations are manually loaded by workers; loading takes10 to 20 minutes. An automatic AS/RS (upper right) stores finished parts. The AGV transfers parts on its pallet to an indexing table, which then transfers them to the AS/RS. The process is reversed when parts are needed for assembly into finished products elsewhere in the plant.

FMS PHOTO

FMS PHOTO

FMS PHOTO

ADVANTAGES OF FMS APPLICATION

1) A faster response to market changes in design or the creation of new designs 2) Improved product quality 3) Direct and indirect labour costs are reduced 4) Production Planning is improved 5) Machine utilisation levels are improved 6) The work in progress inventory is improved since the time spent in the systems is reduced.

KEBAIKAN APLIKASI FMS

1. Proses pembuatan cepat. 2. Tidak memerlukan pekerja yang ramai. 3. Pengurangan inventori komponen. 4. Masa penyediaan pendek untuk membuat produk baru. 5. Kualiti produk stabil. 6. Pengurangan kos pengeluaran. 7. Pengurangan masa kitaran. 8. Menambahkan produktiviti. 9. Menukar rekabentuk dan produk baru dengan cepat. 10. Menarik minat tenaga kerja mahir kerana tempat loji ini tidak kotor dan membosankan.

Glossary
Numerically Controlled(NC) Machines Large machine tools programmed to produce small- to medium-sized batches of intricate parts. Computerized Numerically Controlled (CNC) Machines Stand-alone pieces of equipment, each controlled by its own microcomputer. Industrial Robots Versatile,computer-controlled machines programmed to perform various tasks.

materials handling The processes of moving, packaging, and storing a product. automated guided vehicle(AGV) A small, driverless,battery-driven truck that moves materials between operations, following instructions from either an onboard or a central computer. Most older models follow a cable installed below the floor, but the newest generation follows optical paths and can go anywhere with aisle space and a relatively smooth floor

 automated guided vehicle(AGV) A small, driverless,battery-driven truck that moves materials between operations, following instructions from either an onboard or a central computer. Most older models follow a cable installed below the floor, but the newest generation follows optical paths and can go anywhere with aisle space and a relatively smooth floor

 automated storage and retrieval system (AS/RS) A computer-controlled method of storing and retrieving materials and tools using racks, bins,and stackers. flexible manufacturing system (FMS) A configuration of computer-controlled,semiindependent workstations where materials are automatically handled and machine loaded.