FMS Flexible Manufacturing Systems

Components Of CIM
CAD

CAE

GT

TQM

DFM

IGES,
PDES,
DMIS

Product
design

Bar codes,
EDI

CAD/CAM
CAPP

MRP
JIT/
kanban

Systems
management

DSS/ES/
AI

FMS

Robotics

AGV,
ASRS

Cellular
manufacturing
MAP,
STEP

Manufacture

LAN, TOP,
satellites

NC/CNC/
DNC

Process
planning

CIM

Automated
inspection

Cells
and centers

What is FMS?
FMS ( flexible manufacturing systems)
- a highly automated GT machine cells,
consisting of a group of processing
workstations
(CNC
M/C
tools),
interconnected by an automated handling
and storage systems, controlled by a
distributed computer system.
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Why it is called as FMS?

Since
- It is capable of processing a variety of different
part configurations simultaneously at different
work stations.
- Adjusting the mix of part variety and quantity
in response to changing demand patterns.
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FMS flexible machining systems

- The machining process is the largest applied
area for FMS technology.
- Allowing for wide range of possible
applications beyond machining.
- Relies on the principle of Group Technology.
- Most suited for the mid-variety and midvolume.
- Designed to produce parts within a defined
range of part shapes, sizes and processes.
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Application characteristics of
Flexible Manufacturing Systems

Types of Automation
Program.
Automation

Part
Variety

Flexible
Automation

Manual
Automation

Production Quantity

THE APPLICATION OF FMS AND GROUP

TECHNOLOGY OF PROCESS CHOICE
Increase in
variety
Job

Numerically Controlled
(N.C.) Machines
Group Technology

Low vol.
Batch

F.M.S.
Dedicated
Lines

High vol.
Batch
Line
Increase in volume

BENEFITS of FMS

Increased Machine utilization

Less no of Machines required
Lower Lead times
Reduced floor space area
Higher response to the changes
Reduced inventories
Reduced labor requirements
Ease for UNATTENDED operation
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What makes it Flexible?

The ability to identify and distinguish among

the different parts / shapes processed
Quick changeover of operation instructions
Quick changeover to physical set up.

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To qualify as being flexible

Criteria to be satisfied are,
1) Can the systems process different parts in
a non batch mode? [Part variety test]
2) Can it readily accept the changes in
schedules? [ Schedule change test]
3) Can it recover from malfunctions / break
downs? [Error recovery test]
4) Can new parts be introduced with relative
ease? [New part test]
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Types of Flexibility
Each FMS is designed for sp. application
(parts / processes).
Hence FMS is
Custom engineered and Unique.

Flexibility types:
Machine flexibility, Production flexibility,
Mix flexibility, Product flexibility,
Routing flexibility, Volume flexibility,
Expansion flexibility.
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FMS Classification
FMS classifications,
According to the operations
(i) Processing operations
(ii) Assembly operations
According to Number of Machines:
(i) Single Machine cell ( 1CNC + Sto. Sys.)
(ii) FMC ( 2 / 3 W/s + Hldg. Sys. + L / UL)
(iii) FMS ( 4 / more W / S + Common Hldg
+ Dist. Control systems)
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FMS Classification ( contd.)

According to LEVEL of Flexibility
a) Random order FMS
For more Variety of PART configurations and
Quantity.
b) Dedicated FMS
For limited variety of parts styles.

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FMS Components
1) Workstations

2) Material Handling and Storage

Systems
3) Computer control Systems
4) People

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Flexible Manufacturing System

Computer
control
room
Tools
Conveyor

Machine

Machine
Pallet

Load

Parts

Unload
Terminal

Finished
goods

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WORKSTATIONS
A system intended for doing a set / sequence of
operations
- Depends upon the TYPE of WORK to be
accomplished by the system.
Types:
LOAD / UNLOAD stations:
Machining Stations:
1) CNC machining centers: Vertical, Horizontal
2) Other processing stations:
3) Assembly stations:

CNC machining centers:

- Vertical centers, Horizontal centers.
Horizontal centers possess the features that make
it compatible with FMS.
Such Features are: ATC, ATS, Palletized WPs,
APC,CNC and ability for DNC.
Machining centers
- are mainly for NON-Rotational Parts.

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CNC machining centers (contd.)

For Rotational Parts:
- Turning Module is available.
For multi tooth rotational operations, Mill-Turns
are used.
- Milling Modules and Drilling Modules are
special purpose centers.
- Milling module can be Vertical Spindle,
Horizontal spindle or Multi Spindle types.
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Other Processing Stations

Sheet Metal operations and Press working
operations like Punching, Piercing,
Shearing, Forming and Bending
Operations.
Forging process
Welding unit,
Painting unit and etc.,
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Other Processing Stations Contd.,

Assembly operations, ( Programmable part
placement machines)
Inspection processes ( CMM & MACHINE
VISION )
Other activities: Cleaning , Palletizing and
Central Coolant Delivery systems etc.,)

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MATERIAL HANDLING AND Storage

systems
Functions:
- Random / Independent movement between
stations
- Handle a variety of parts
- Temporary storage
- Convenient access for loading and unloading parts
- Compatible with computer control
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Types of Handling systems

Primary systems & Secondary systems
Primary systems:
Movement from one place to other place
( conveyors, AGVs, etc)
Secondary systems:
Movement of parts within the same destination
[Loading and Unloading]
( Transfer devices and APC etc.,)
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Automated Handling and AS/RS

Automated Material Handling
systems
Conveyer systems
AGVs
Monorails and RGVs,
Cranes and Hoists

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CONVEYORS
a) Powered conveyors b) Non Powered conveyors
Powered:
Power mechanism is contained in a fixed path.
(Using Belts, Ropes, Chains, Rollers and other devices
to propel the loads in a fixed path)
Used commonly in automated systems.
Non-Powered:
This mechanism is not in fixed path.
Manual movement to push the loads along a path (or)
Gravity movement from elevated conditions
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Types of Conveyors
Roller conveyors
Skate wheel conveyors
Belt conveyors
Cable conveyors (Chain, Slat, in-flow towline,
Overhead trolley, Power & Free OHT)
Cart on Track conveyors
Screw conveyors
Chutes, Ramps and Tubes (driven by GRAVITY)
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Conveyors Operations and Features

i)

CONTINUOUS MOTION Conveyors:

( move at a constant velocity along a path)

e g: Belt, Roller, Skate, OHT and Slat conveyors
ii) ASYNCHRONOUS Conveyors:
( Operates with a stop and go motion in which
loads are carried in containers, (Hooks,
Baskets, Carts) Move between stations and
then stop and remain station until released)
e g: Overhead trolley, Power & Free OHT, Cart on
Track conveyors
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Automated Guided Vehicles (AGVs)

A material handling system that uses
independently operated ( self operated) vehicles
guided along the defined pathways.
Powered by on-board batteries.
Pathways are UNOBTRUSIVE
Appropriate where different matls. are moved
from various load points to various unload points.
Best suitable for AMH in BATCH and MASS
production systems. (First developed in1954)
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AGVs ( contd.,)
Types:

a) Driverless trains

b) Pallet Trucks

c) UNIT load carriers

DRIVERLESS TRAINS:
Consists of towing vehicle that pulls one or more trailers to
form a train.
Common application: Moving heavy payloads over a large
distances in warehouses or factories with or without
intermediate pick up and drop off along the route.
(LARGE QUANTITY for LARGE DISTANCE)

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AGV Pallet Trucks:

Used to move palletized loads along pre defined path.
Pallets are loaded on the vehicle using forks.
Worker drives the pallet truck to the guide path,
program its destination and the vehicle proceeds
automatically to the destination for unloading.
Eg: Fork lift AGVs
This vehicle can achieve significant vertical movement
of its forks to reach loads on racks and shelves.

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UNIT load carrier AGVs

Used to move UNIT loads from one station to the
other.
Often equipped with automated loading and
unloading of pallets, totes pans by powered
rollers, moving belts mechanized lift platforms.
Types: Light load carriers (to move small loads of
single loads, small baskets / tote pans)
Assembly line units ( to carry partially
completed subassembly through a sequence of
W/S to build the part.)
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APPLICATIONS in FMS
1.
2.
3.
4.
5.
6.

Material Handling
Storage and Distribution ( AS / RS)
Assembly applications
FMS
Office Mail delivery
Hospital Material Transport

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VEHICLE GUIDANCE
Guidance system is the method by which AGV
pathways are defined and the vehicles are
controlled to follow the pathways.
TYPES:
A) Imbedded Guide wires
B) Paint Stripes
C) Self Guided vehicles
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Imbedded Guide wires

Electrical wires are placed in small channel cut
in the floor surface ( 3 -12 mm wide and 13 26
mm deep) and sealed with cement to eliminate
discontinuity.
The wire is connected to the frequency
generator.
A Magnetic field is induced along the pathway.
This magnetic filed is tracked by the magnetic
sensors for the travel of the vehicle.
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Imbedded Wire guides ( contd.,)

Two sensors are attached to the AGV on either side.

When the Vehicle is located in such a way that the
guide wire is directly between the two coils, The
intensity of the field measured by each coil is
equal.
When the vehicle strays to one side / if the wire
changes the direction, the field intensity by the
two coils is different. This difference is used to
steer the motor to make required changes in the
vehicle direction to equalize the signals, thereby
tracking the wire.
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PAINT STRIPES:
The vehicle is provided with optical sensor to track the
path.
The stripes can be Taped, Sprayed or Painted on the floor.
A wide stripe of paint containing fluorescent particles that
reflects UV light source.
An on board sensor detects the reflected light in the strip
and controls the steering mechanism to follow it.
Paint strips are useful when the installation of wires in the
floor is not practical and where electrical noise renders
the system unreliable.
LIMTATION:
Strip gets deteriorated with TIME. Hence strip must be
kept CLEAN and Periodically PAINTED.
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Robots in Material Handling:

Robots can do
both primary and Secondary handling
activities

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Materials Handling Applications

The movement of parts, tools, materials, and
equipment in a facility
The cost of materials handling can be extreme,
especially when the materials are easily damaged,
hazardous, bulky, or have to be oriented correctly
Material Handling factors favoring automation
The rate of handling is about 15 or less pieces per
minute
The load weight is less than 1000 lb
The orientation of the objects to be grasped is consistent

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Material Feeders

Some robots may be more adept (and more expensive) at picking up

randomly oriented parts, but most inexpensive pick-and-place robots
require a fixed-part orientation arranged by a material feeder:
Bowl feeders -- use vibratory action to move items from the
bottom of the bowl up an internal ramp, being positioned using
gravity devices along the way
Autoscrewdrivers -- feed screws, nuts, rivets, and studs using an
air/vacuum system to hold the part
Gravity feeders -- consist of ramps or tubes which hold the parts
and are used for parts that are not conducive to vibratory feeding

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Loading/unloading parts to/from the machines

The robot unloading parts from die-casting machines
The robot loading a raw hot billet into a die, holding it during
forging and unloading it from the forging die
The robot loading sheet blanks into automatic presses
The robot unloading molded parts formed in injection
molding machines
The robot loading raw blanks into NC machine tools and
unloading the finished parts from the machines
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Automated Storage systems

Conventional systems need HUMAN intervention.
Mechanized and automated systems are to
downsize / eliminate the amount of human
intervention.
Represents a significant investment and new /
different variety of doing activites.
Two major classifications: 1. AS/RS
2. Carousel storage
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Automated Storage systems., (contd)

Merits:
1. High throughput rates
2. Facilitates use of computerized inventory control
3. Facilitates the interface to automated Matl. Hldg.
Demerits:
1. High Cost involved
Applications:
- WIP storage
- Final product warehousing and Distribution center
( unit load storage and handling)
- Order Picking
- Kitting of parts for electronic assembly
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AS / RS
A storage system that performs storage and retrieval
operations with speed and accuracy under a defined
degree of automation.
AS/RS consists of one / more storage aisles service
by S/R machines ( cranes).
AS/RS classifications:
- Unit Load AS/RS
- Deep Lane
- Miniload AS /RS
- Man-on-Load
- Automated item retrieval systems
- Vertical Lift Storage Modules (VLSM)

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Computer control system functions

Control of each workstation

Distribution of control instructions to each workstation

Production control
Traffic control
Shuttle control
Work handling system monitoring
Tool control
System performance and monitoring
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System Reports
Utilisation reports

Production reports
Status reports
Tool reports

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System Reports
Volume of work to be produced by the system
Variation in process routings
Physical characteristics of the workparts
Part families defined according to product commonality
FMS manpower requirements
Appropriate production volume range
Minimum number of machines/FMS: 4
Minimum normal tolerance on work in an FMS: +/- 0.05
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Hierarchical control of an FMS

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