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Flexible Manufacturing Systems _0617-870_

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					    Flexible Manufacturing Systems

              Introduction to FMS/FAS




By Professor S. Manian Ramkumar
Rochester Institute of Technology
Conventional Manufacturing
Consisted of 2 varieties
  1.   Job Shop type systems were capable of
       large variety of product, but at a high
       cost.
  2.   Transfer lines could produce large
       volumes of a product at a reasonable
       cost, but were limited to the production
       of one, two, or very few different parts.
What is FMS/FAS?
   A FMS/FAS is one manufacturing
    machine, or multiple machines that are
    integrated by an automated material
    handling system, whose operation is
    managed by a computerized control
    system. An FMS can be reconfigured
    by computer control to manufacture
    various products.
What is CIM?
   CIM is the integration of the total
    manufacturing enterprise through the
    use of integrated systems and data
    communications coupled with new
    managerial philosophies that improve
    organizational and personal efficiency.
What is a manufacturing Cell?
   A manufacturing cell usually consists of two
    or three processing workstations (typically
    CNC Machining or turning centers) plus a part
    handling system.

The following two slides contain a CAD layout
  and picture of the RIT Mfg Eng Tech Class of
  2000’s manufacturing work cell.
Manufacturing Workcell (CAD)
Manufacturing Workcell
Manufacturing Cells VS FMS
   A FMS/FAS is a manufacturing cell, but
    a cell is not necessarily a FMS/FAS
   A FMS/FAS is a complete system that
    runs automatically
   A manufacturing cell has some or most
    of the components of a FMS/FAS, but
    not all of them.
History of FMS
   1950’s NC machines first appear
   1960’s Computers appear in industry
   Later 1960’s Flexible Manufacturing
    Systems first appeared in the U.S.A. at
    companies like Ingersoll-Rand,
    Caterpillar, John Deere, and General
    Electric Co.
Volume Vs Variety
Flexibility in a FMS/FAS
   Machine flexibility
   Production flexibility
   Mix flexibility
   Product flexibility
   Routing flexibility
   Volume flexibility
   Expansion flexibility
Components of an FMS/FAS
   Workstations
   Material handling and storage system
   Computer control system
   People to manage and operate the
    system
Types of Workstations
   Load/unload Stations
   Machining Stations
   Other Processing Stations
   Assembly
   Other Stations and Equipment (like
    Inspection)
Layout Configurations for Material
Handling System
   In-line layout
       In-line Transfer
       Conveyor
       Rail guided vehicle
   Loop layout
       Conveyor system
       In-Floor towline carts
Layouts Continued
   Ladder layout
       Conveyor System
       Automated Guided Vehicle (AGV)
       Rail guided Vehicle
   Open field layout
       AGV
       In-line towline carts
   Robot-centered layout
Computer Control Systems
   Workstation
   Distribution of control instructions to
    workstations
   Production control
   Traffic control
   Shuttle control
   Workpiece monitoring
Computer Controls (cont)
   Tool control
       Tool locations
       Tool life monitoring
   Performance monitoring and reporting
   Diagnostics
Why Implement a FMS/FAS?
   Increased machine utilization
   Fewer machines required
   Reduction in factory floor space
    required
   Greater responsiveness to change
   Reduced inventory requirements
   Lower manufacturing lead times
     Why Implement a FMS/FAS?
                                (continued)

   Reduced direct labor requirements and
    higher labor productivity
   Opportunity for unattended production
FMS Implementation Issues
   Part family considerations
   Processing requirements
   Physical characteristics or workparts
   Production volume
   Scheduling and dispatching
   Machine loading
   Part routing
FMS Issues (cont)
   Part grouping
   Tool management
   Pallet and fixture allocation
   Requires management commitment and
    planning
   Major invest of time and money

				
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posted:10/10/2011
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