Forging new generations of engineers Flexible Manufacturing Systems

Forging new generations of engineers Flexible Manufacturing Systems (0617 -850)

Flexible Manufacturing Systems Introduction to FMS/FAS Flexible Manufacturing Systems (0617 -850)

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. 12/18/2021 Flexible Manufacturing Systems (0617 -850) 3

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. 12/18/2021 Flexible Manufacturing Systems (0617 -850) 4

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. 12/18/2021 Flexible Manufacturing Systems (0617 -850) 5

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. 12/18/2021 Flexible Manufacturing Systems (0617 -850) 6

Manufacturing Workcell (CAD) 12/18/2021 Flexible Manufacturing Systems (0617 -850) 7

Manufacturing Workcell 12/18/2021 Flexible Manufacturing Systems (0617 -850) 8

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. 12/18/2021 Flexible Manufacturing Systems (0617 -850) 9

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. 12/18/2021 Flexible Manufacturing Systems (0617 -850) 10

Volume Vs Variety 12/18/2021 Flexible Manufacturing Systems (0617 -850) 11

Flexibility in a FMS/FAS • • Machine flexibility Production flexibility Mix flexibility Product flexibility Routing flexibility Volume flexibility Expansion flexibility 12/18/2021 Flexible Manufacturing Systems (0617 -850) 12

Components of an FMS/FAS • • Workstations Material handling and storage system Computer control system People to manage and operate the system 12/18/2021 Flexible Manufacturing Systems (0617 -850) 13

Types of Workstations • • • Load/unload Stations Machining Stations Other Processing Stations Assembly Other Stations and Equipment (like Inspection) 12/18/2021 Flexible Manufacturing Systems (0617 -850) 14

Layout Configurations for Material Handling System • In-line layout – In-line Transfer – Conveyor – Rail guided vehicle • Loop layout – Conveyor system – In-Floor towline carts 12/18/2021 Flexible Manufacturing Systems (0617 -850) 15

Layouts Continued • Ladder layout – Conveyor System – Automated Guided Vehicle (AGV) – Rail guided Vehicle • Open field layout – AGV – In-line towline carts • Robot-centered layout 12/18/2021 Flexible Manufacturing Systems (0617 -850) 16

Computer Control Systems • Workstation • Distribution of control instructions to workstations • Production control • Traffic control • Shuttle control • Workpiece monitoring 12/18/2021 Flexible Manufacturing Systems (0617 -850) 17

Computer Controls (cont) • Tool control – Tool locations – Tool life monitoring • Performance monitoring and reporting • Diagnostics 12/18/2021 Flexible Manufacturing Systems (0617 -850) 18

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 12/18/2021 Flexible Manufacturing Systems (0617 -850) 19

Why Implement a FMS/FAS? (continued) • Reduced direct labor requirements and higher labor productivity • Opportunity for unattended production 12/18/2021 Flexible Manufacturing Systems (0617 -850) 20

FMS Implementation Issues • • Part family considerations Processing requirements Physical characteristics or workparts Production volume Scheduling and dispatching Machine loading Part routing 12/18/2021 Flexible Manufacturing Systems (0617 -850) 21

FMS Issues (cont) • • Part grouping Tool management Pallet and fixture allocation Requires management commitment and planning • Major invest of time and money 12/18/2021 Flexible Manufacturing Systems (0617 -850) 22