CHAPTER 6
Integrated Manufacturing Systems
Hawassa University Institute Of Technology
Department of Mechanical Engineering
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Contents
What is Flexible Manufacturing Systems (FMS)?
Components of Flexible Manufacturing Systems (FMS)
Types of Flexible Manufacturing Systems (FMS)
Layouts of Flexible Manufacturing Systems (FMS)
Objectives and Aims of FMS
Advantages and Disadvantages of FMS implementation
Quantitative analysis of FMS
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What is an FMS?
6.1 Introduction
In the middle of 1960s, market competition became more intense.
During 1960 to 1970 cost was the primary concern. Later quality
became the priority.
As the market became more and more complex, speed of delivery
became something customer also needed
Thus the innovation of FMS became related to the effort of gaining
competitive.
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Contd.
Definition:
A flexible manufacturing system (FMS) is an arrangement of
machines interconnected by a trans port system. Or
FMS consists of a group of processing work stations
interconnected by means of an automated material handling and
storage system and controlled by integrated computer control
system.
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Contd.
FMS is called flexible due to the reason that it is capable of
processing a variety of different part styles simultaneously at the
workstation and quantities of production can be adjusted in
response to changing demand patterns.
5 Fig. 6.1 Types of flexibilities
Contd.
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.
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Contd.
2) System flexibilities
Volume flexibility: A measure of a system’s capability to be
operated profitably at different volumes of the existing part types
Expansion flexibility: The ability to build a system and expand it
incrementally
Routing flexibility:: A measure of the alternative paths that a part
can effectively follow through a system for a given process plan.
Process flexibility: A measure of the volume of the set of part
types that a system can produce without incurring any setup
Product flexibility: The volume of the set of part types that can be
manufactured in a system with minor setup
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Contd.
3) Aggregate flexibilities
Program flexibility: The ability of a system to run for reasonably
long periods without external intervention
Production flexibility: The volume of the set of part types that a
system can produce without major investment in capital equipment
Market flexibility: The ability of a system to efficiently adapt to
changing market conditions
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6.2 Basic components of FMS
The basic components of FMS are:
1. Workstations
2. Automated Material Handling and Storage system.
3. Computer Control System
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Cont.
1. Workstations:
In present day application these workstations are typically
computer numerical control (CNC) machine tools that perform
machining operation on families of parts.
The various workstations are:-
(i) Machining centers
(ii) Load and unload stations
(iii) Assembly work stations
(iv) Inspection stations
(v) Forging stations
(vi) Sheet metal processing, etc.
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Contd.
2. Automated Material Handling and Storage system:
Used to transport work parts and subassembly parts between the
processing stations, sometimes incorporating storage into function.
The various functions of automated material handling and storage
system are
i. Random and independent movement of work parts between
workstations
ii. Handling of a variety of work part configurations
iii. Temporary storage
iv. Convenient access for loading and unloading of work parts
v. Compatible with computer control
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Contd.
3. Computer Control System:
It is used to coordinate the activities of the processing stations and
the material handling system in the FMS.
The various functions of computer control system are:
i. Control of each work station
ii. Distribution of control instruction to work station
iii. Production control
iv. Traffic control
v. Work handling system and monitoring
vi. System performance monitoring and reporting
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Contd.
The FMS is most suited for the mid variety, mid value
production range.
Fig. 6.2 Application characteristics of FMS
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6.3 Different types of FMS
The different types of FMS are
Sequential FMS Engineered FMS
Random FMS Modular FMS
Dedicated FMS
Sequential FMS:
It manufactures one-piece part batch type and then planning
and preparation is carried out for the next piece part batch
type to be manufactured.
It operates like a small batch flexible transfer line.
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Contd.
Random FMS
It manufactures any random mix of piece part types at any one time.
Dedicated FMS
It continually manufactures, for extended periods, the same but
limited mix of piece part batch types.
Engineered FMS
It manufactures the same mix of part types throughout its lifetime.
Modular FMS
A modular FMS, with a sophisticated FMS host, enables and FMS
user to expand their FMS capabilities in a stepwise fashion into any
of the previous four types of FMS.
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6.4 Types of FMS layouts
The different types of FMS layouts are:
1. Progressive or Line Type
2. Loop Type
3. Ladder Type
4. Open field type
5. Robot centered type
1. Progressive or Line type:
The machines and handling system are arranged in a line and it is
very similar to transfer type.
It is most appropriate for a system in which the part progress from
one workstation to the next in a well defined sequence with no
back flow.
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Cont..
2. Loop Type
The parts usually move in one direction around the loop, with the
capability to stop and be transferred to any station.
The loading and unloading station are typically located at one end of
the loop
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Cont..
3. Ladder Type
The loading and unloading station is typically located at the same
end.
The sequence to the operation/transfer of parts from one machine
tool to another is in the form of ladder steps.
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Cont..
4. Open Field Type
The loading and unloading station is typically located at the same end.
The parts will go through all the substations, such as CNC machines, coordinate
measuring machines and wash station by the help of AGV’s from one substation
to another.
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Cont..
5. Robot Centered Type:
Robot centered cell is a relatively new form of flexible system in
which one or more robots are used as the material handling systems.
Industrial robots can be equipped with grippers that make them well
suited for handling of rotational parts.
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6.5 Aims of FMS
A study, carried out with West Germany manufacturing has shown
the major aims of installing FMS to be:
To reduce costs To increase Technical Performance:
Better utilization of the production Increased production levels
equipment.
Greater product mixture
Reduction of piece part unit costs. Simultaneous product mixture
manufacturing
To improve Order Development:
Integration of the production
Shorter lead times/delivery times system
Determination of production
Shorter reset of times
capacities
To assist future Corporate Security:
Increased Competitiveness
Increased Quality
Improved Company Image
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6.6 Advantages and Disadvantages of FMS
implementation
6.6.1 Advantages of FMS implementation
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
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Cont..
6.6.2 Disadvantages of FMS implementation
Limited ability to adapt to changes in product or product mix
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
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6.7 Quantitative analysis of FMS
FMS analysis techniques can be classified as follows:
(l) Deterministic models,
(2) Queueing models,
(3) Discrete event simulation, and
(4) Other approaches
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Cont..
(l) Deterministic models
Important aspects of FMS performance can be mathematically
described by a deterministic model called the bottleneck
model, developed by Solberg.
It can be used to provide starting estimates of FMS design
parameters such as production rate and number of
workstations.
The term bottleneck refers to the fact that the output of the
production system has an upper limit, given that the product
mix flowing through the system is fixed.
The model can be applied to any production system that
possesses this bottleneck feature, for example, a manually
operated machine cell or a production job shop. It is not
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limited to FMSs.
Cont..
But, Deterministic models do not permit evaluation of
operating characteristics such as the build-up of queues and
other dynamics that can impair performance of the production
system.
Consequently, deterministic models tend to overestimate FMS
performance.
On the other hand, if actual system performance is much
lower than the estimates provided by these models, it may be a
sign of either poor system design or poor management of the
FMS operation.
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Cont..
(2) Queueing models
Queueing models can be used to describe some of the
dynamics not accounted for indeterministic approaches.
These models are based on the mathematical theory of queues,
They permit the inclusion of queues, but only in a general way
and for relatively simple system configurations.
The performance measures that are calculated are usually
average values for steady-state operation of the system.
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Cont..
(3) Discrete event simulation,
In the later stages of design, discrete event simulation probably offers the
most accurate method for modeling the specific aspects of a given
FMS.
The computer model can be constructed to closely resemble the
details of a complex FMS operation Characteristics such as layout
configuration, number of pallets in the systems and production
scheduling rules can be incorporated into the FMS simulation model.
Indeed, the simulation can be helpful in determining optimum values
for these parameters.
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