Professional Documents
Culture Documents
(FMS)
By Rakesh Chander Saini rcsaini.blogspot.com
Routing flexibility
Process flexibility
Capability of a machine to perform a variety of operations on a variety of part types and sizes Alternative machines, sequences or resources can be used for manufacturing a part for changes resulting from equipment breakdowns, tool breakages, controller failures, etc. Ability to absorb changes in the product mix by performing similar operations, producing similar products or parts. Ability to change over to a new set of products economically and quickly in response to markets Ability to produce a range of products without adding capital equipment Ability to change a manufacturing system with a view to accommodating a changed product envelope
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Product flexibility
Types of FMS
FMS are classified by different way i.e. process, product variety, No. of M/C, level of flexibility, etc. No. of M/C
Single Machine Cell: One CNC m/cing centre combined with a part storage system.
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Types of FMS
Flexible Manufacturing Cell 2 or 3 processing workstation+ part handling system(load/unload station) i.e. CNC m/cing centre
Flexible Manufacturing System
4 or more processing workstation connected with mechanically by a common parts handling system and electronically by a distributed computer system.
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Types of FMS
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Types of FMS
Level of Flexibility
Dedicated FMS
limited variety of part style Using SPM Flexible transfer line
Random-order FMS
Large part family Using general purpose m/c Sophisticated computer control system required
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FMS COMPONEANTS
1. 2. 3. 4. Workstation Material Handing and Storage System Computer Control System Human Resource
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FMS Components-Workstation
Load/Unload Station
Load raw work-part and unload finished workpart Ergonomically designed to permit convenient and safe movement of work-part Right work-part loading in right pallet
Processing Station
CNC m/cing CNC turning centre with ATC* and APC*
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FMS Components-Workstation
Processing Station
Sheet-metal work Punching Shearing Bending Forming Forging Process, etc.
Assembly Inspection
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Functions of the Handling System Random, independent movement of workparts between stations. Handle a variety of workpart configurations. Temporary storage. Convenient access for loading and unloading workparts. Compatible with computer control.
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Material Handling Equipment The material handling function in a FMS is often shared between two systems: 1. Primary handling system - establishes the basic layout of the FMS and is responsible for moving workparts between stations in the system. 2. Secondary handling system - consists of transfer devices, automatic pallet changers, and similar mechanisms located at the workstations in the FMS.
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1. In-line layout
2. Loop layout 3. Ladder layout 4. Open field layout 5. Robot-centered cell
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Industrial robot
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Availability
Utilization
Summarizes daily and weekly quantities of different parts produced. Compares actual quantities against production schedule.
Provides information on various aspects of tool control, such as a listing of tools at each workstation and tool life status. Instantaneous snapshot of the present condition of the FMS. Line supervision can request this report at any time to learn the current status of any of the above operating parameters.
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Status
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FMS Benefits
Increased machine utilization. FMSs achieve a higher average utilization than stand alone machines in a conventional machine shop. Reasons include: (1) 24 hour per day operation, (2) automatic tool changing at machine tools, (3) automatic pallet changing at workstations, (4) queues of parts at stations, and (5) dynamic scheduling of production that takes into account irregularities from normal operations. It should be possible to approach 80% to 90% asset utilization.
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FMS Benefits
Fewer machines required: Because of higher machine utilization. Reduction in factory floor space required: Compared to a job shop of equivalent capacity, a FMS generally requires less floor area. Reductions in floor space requirements = 40% to 50%. Greater responsiveness to change: A FMS improves response capability to part design changes, introduction of new parts, changes in production schedule and product mix, machine breakdowns, and tool failures. Adjustments can be made in the production schedule from one day to the next to respond to rush orders and special customer requests.
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FMS Benefits
Reduced inventory requirements: Because different parts are processed together rather than separately in batches, WIP is less than in batch production. Inventories of starting and finished parts reduced also. Reductions = 60% to 80%. Lower manufacturing lead times: Closely correlated with lower WIP is MLT. This means faster customer deliveries. Reduced direct labor requirements and higher labor productivity. Savings = 30% to 50% Opportunity for unattended production.
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Production volume. The production quantities determine how many machines will be required. Production volume is also a factor in selecting the most appropriate type of material handling equipment for the system.
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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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FMS Example
One Design + One Assembly Process = Multiple Models
When different models are designed to be assembled in the same sequence they can be built in the same plant. This maximizes efficiency and allows the company to respond quickly to changing customer
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Thank You
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