Computer Integrated Manufacturing and

Robotics
(IPPC-307)
Flexible Manufacturing System

Dr. Bikash Kumar

Assistant Professor, IPE Department
National Institute of Technology Jalandhar
Email: [email protected]

DR. B. R. AMBEDKAR
NATIONAL INSTITUTE OF TECHNOLOGY
JALANDHAR
(An Institute of National Importance, established by MHRD)
Syllabus

• Flexible Manufacturing Systems: Concept, flexible & rigid

manufacturing, manufacturing cell and FMS structure,
types, components of FMS, Distributed Numerical Control
(DNC), Building Blocks of FMS, Flexible Assembly System.

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What is a Flexible Manufacturing System?

• Flexible Manufacturing System (FMS) is a highly automated

GT machine cell.
• Consists of one or more processing stations (usually CNC
machine tools), interconnected by an automated material
handling and storage system and controlled by a distributed
computer system.
• Capable of processing a variety of different part styles
simultaneously at the various workstations
• The mix of part styles and quantities of production can be
adjusted in response to changing demand patterns.

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Contd…

• An FMS is a “reprogrammable” manufacturing system

capable of producing a variety of products automatically.
Conventional manufacturing systems have been marked by
one of two distinct features:
✓ The capability of producing a variety of different product
types, but at a high cost (e.g., job shops).
✓ The capability of producing large volumes of a product
at a lower cost, but very inflexible in terms of the
product types which can be produced (e.g., transfer
lines).
• An FMS is designed to provide both of these features.

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FMS Definition

• “A system that consists of numerous programmable

machine tools connected by an automated material
handling system”.
• A flexible manufacturing system (FMS) 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.
• FMS is a manufacturing philosophy based on the concept of
effectively controlling material flow through a network of
versatile production stations using an efficient and versatile
material handling and storage systems

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Contd…

Computer
control
Tools room
Tools

Conveyor

Machine Machine

Pallet
Pallet

Load
Load Unload
Unload
Terminal Finished
Parts Terminal
goods

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Benefits
• Shorter lead times,
• Meeting demand fluctuations handling volume and
• Variety reduction in space and people and
• Obtaining better control due to automation
• 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
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Limitations

• Initial installation cost and operational costs are high

• It is necessary to have enough volumes to justify the use of
FMS.
• Expensive, costing millions of dollars
• Substantial pre-planning activity
• 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

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Flexibility

• The three capabilities that a manufacturing system must

possess in order to be flexible were identified as
1. The ability to identify the different incoming part or
product styles processed by the system,
2. Quick changeover of operating instructions, and
3. Quick changeover of physical setup.

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Contd…

• To develop the concept of flexibility in an automated

manufacturing system, consider a machine cell consisting of
two CNC machine tools that are loaded and unloaded by an
industrial robot from a parts storage system.

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Contd…

• The cell operates unattended for extended periods of time.

• Periodically, a worker must unload completed parts from
the storage system and replace them with new work parts.
• By any definition, this is an automated manufacturing cell,
but is it a flexible manufacturing cell?
• However, if the cell only operates in a batch mode, in which
the same part style is produced by both machines in lots of
several hundred units, then this does not qualify as flexible
manufacturing.

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Contd…

• To qualify as being flexible, an automated manufacturing

system should satisfy the following four tests of flexibility:
1. Part-variety test. Can the system process different part or
product styles in a mixed model (non-batch) mode?
2. Schedule-change test. Can the system readily accept
changes in production schedule, that is, changes in part
mix and/or production quantities?
3. Error-recovery test. Can the system recover gracefully
from equipment malfunctions and breakdowns, so that
production is not completely disrupted?
4. New-part test. Can new part designs be introduced into
the existing part mix with relative ease
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Contd…

• If the answer to all of these questions is “yes” for a given

manufacturing system, then the system is flexible.
• The most important tests are (1) and (2).
• Test (3) is applicable to multi-machine systems but in single-
machine systems when the one machine breaks down it is
difficult to avoid a halt in production.
• Test (4) would seem to not apply to systems designed for a
part family whose members are all known in advance.
• However, such a system may have to deal with design
changes to members of that existing part family.

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Types of FMS

• FMS can be distinguished according to the kinds of

operations they perform: processing operations or
assembly operations.
• An FMS is usually designed to perform one or the other but
rarely both.
• Two other ways to classify flexible manufacturing systems
are by number of machines and level of flexibility.

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Number of Machines

• Flexible manufacturing systems have a certain number of

processing machines.
• The following are typical categories:
1. Single-machine cell,
2. Flexible manufacturing cell, and
3. Flexible manufacturing system.

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Single-machine Cell

• A single-machine cell consists of one CNC machining center

combined with a parts storage system for unattended
operation, as in Figure.

Single-machine cell
consisting of one CNC
machining center and
parts storage unit.

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Flexible Manufacturing Cell (FMC)

• A flexible manufacturing cell (FMC) consists of two or three

processing workstations (typically CNC machining centers or
turning centers) plus a parts-handling system.
• The parts-handling system is connected to a load/unload
station.

A flexible manufacturing
cell consisting of three
identical processing
stations (CNC machining
centers), a load/unload
station, and a parts-
handling system.

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Flexible Manufacturing System (FMS)

• A flexible manufacturing system (FMS) has four or more

processing stations connected
✓ Mechanically by a common parts-handling system and
✓ Electronically by a distributed computer system

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Differences Between FMS and FMC

FMS FMC
➢Has four or more ➢Has two or three
machines machines
➢Larger and more ➢Simpler computer control
sophisticated computer system
control system ➢Limited error recovery by
➢Minimized effect of fewer machines
machine breakdowns

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Summary

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Compares the three systems in terms of the four
flexibility tests

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Level of Flexibility

• Another way to classify flexible manufacturing systems is

according to the level of flexibility designed into the system.
• Two categories of flexibility are discussed here:
1. Dedicated and
2. Random-order

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Dedicated FMS

• A dedicated FMS is designed to produce a limited variety of

part styles, and the complete universe of parts to be made
on the system is known in advance.
Random-order FMS
• more appropriate when
1. the part family is large,
2. there are substantial variations in part configurations,
3. there will be new part designs introduced into the system
and engineering changes in parts currently produced, and
4. the production schedule is subjected to change from day-
today.
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Contd…

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FMC/FMS Components
• The three basic components are
1. Workstations,
2. Material handling and storage system,
3. Computer control system
• In addition, even though an FMS is highly automated, people are
required to manage and operate the system.
• Functions typically performed by humans include
✓ loading raw work parts into the system,
✓ unloading finished parts (or assemblies) from the system,
✓ changing and setting tools,
✓ performing equipment maintenance and repair,
✓ performing NC part programming,
✓ programming and operating the computer system, and
✓ managing the system.
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Workstations

• The processing or assembly equipment used in an FMC or

FMS depends on the type of work accomplished by the
system.
• In one designed for machining operations, the principal
types of processing station are CNC machine tools.
• Following are the types of workstations typically found in an
FMS.
✓ Load/Unload Stations: mechanized cranes and other handling devices
✓ Machining Stations: CNC machining centers
✓ Assembly: Industrial robots
✓ Other Stations and Equipment: Coordinate measuring machines,
centralized chip-removal systems

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Material Handling and Storage System

Functions of the Handling System

• Random independent movement of work parts between
stations
• Handling a variety of work part configurations
• Temporary storage
• Convenient access for loading and unloading work parts
• Compatibility with computer control

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Material Handling Equipment

• The types of material handling systems used to transfer

parts between stations in an FMS include
✓ A variety of conventional material transport equipment in-
line transfer mechanisms, and
✓ Industrial robots
• The material handling function in an FMS is often shared
between two systems:
1. A primary handling system and
2. A secondary handling system.

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Contd…

• The primary handling system establishes the basic layout of

the FMS and is responsible for moving parts between
stations.
• 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 to perform the processing or assembly operation.

Reorientation of the
work part if necessary
to present the surface
that is to be processed

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FMS Layout Configurations

• The material handling system establishes the FMS layout.

• Most layout configurations found in today’s flexible
manufacturing systems can be classified into one of four
categories:

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In-line layout

• In the in-line layout, the machines and handling system are

arranged in a straight line.
• In its simplest form, the parts progress from one
workstation to the next in a well-defined sequence with
work always moving in one direction and no back-flow.
FMS in-line layouts:
(a) one-direction flow similar to a
transfer line,
(b) linear transfer system with
secondary parts-handling and
storage system at each
station to facilitate flow in
two directions. Key: Load =
parts loading station, Unload
= parts unloading station,
Mach = machining station,
Man = manual station, Auto =
automated station.
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Contd…

• The in-line layout can be combined with an integrated parts-

storage system.

FMS in-line layout with integrated part-storage system. Key: Load = parts loading
station, Unload = parts unloading station, Mach = machining station, Man = manual
station, Auto = automated station.

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Loop layout
• The workstations are organized in a loop that is served by a parts
handling system in the same shape.
• Parts usually flow in one direction around the loop with the capability
to stop and be transferred to any station.
• A secondary handling system is shown at each workstation to allow
parts to move around the loop without obstruction.
• The load/unload station(s) are typically located at one end of the loop.

FMS loop layout with secondary parts-

handling system at each station to allow
unobstructed flow on the loop, and

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Contd…

• An alternative form of loop layout is the rectangular layout.

• This arrangement might be used to return pallets to the
starting position in a straight line machine arrangement.

Rectangular layout for

recirculation of empty
pallets to the parts loading
station. Key: Load = parts
loading station, Unload =
parts unloading station,
Mach = machining station,
Man = manual station, Auto
= automated station.

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Open field layout

• Consists of multiple loops and

branches, and may include
sidings as well.
• Generally appropriate for
processing large families of
parts.
• The number of different
machine types may be limited,
and parts are routed to different
workstations depending on
which one becomes available
first.
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Robot-centered layout
• Uses one or more
robots as the material
handling system.
• Industrial robots can
be equipped with
grippers that make
them well suited for
the handling of
rotational parts, and
robot-centered FMS
layouts are often used
to process cylindrical
or disk-shaped parts.

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Computer Control System

• The FMS includes a distributed computer control 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 controlling the individual
machines and other components.
• The central computer coordinates the activities of the
components to achieve smooth overall operation of the
system.

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Functions of FMS computer control system

• Workstation control.
• Distribution of control instructions to workstations.
• Production control.
• Traffic control.
• Shuttle control.
• Tool control.
• Performance monitoring and reporting.
• Diagnostics

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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 system, and
✓ Programming and operation the computer system.

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