FMS

Concept
A flexible manufacturing system (FMS) is an arrangement of machines interconnected by a transport
system. The transporter carries work to the machines on pallets or other interface units so that work-machine
registration is accurate, rapid and automatic. A central computer controls both machines and transport system.
Or
"FMS consists of a group of processing work stations interconnected by means of an automated material
handling and storage system and controlled by integrated computer control system."
FMS is called flexible due to the reason that it is capable of processing a variety of different part styles
simultaneously at the workstation and quantities of production can be adjusted in response to changing
demand patterns.

Automatic guided vehicles (AGV)

Is a portable robot that follows along marked long lines or wires on the floor or uses radio waves, vision
cameras, magnets, or lasers for navigation. They are most often used in industrial applications to transport
heavy materials around a large industrial building, without an onboard operator or driver. Typical AGV
application transportation of raw materials, work-in-process, and finished goods in support of
manufacturing production lines, and storage/retrieval or other movements in support of picking in
warehousing and distribution applications.
There are several types of AGVs. These include:
1. Automated carts - The simplest kind of AGV with minimal features for lowest cost implementation.
2. Unit load AGVs - Individual vehicles that transport loads (typically pallets, bins, carts or bundles) on
forks or on the AGV’s deck. Roll-handling AGVs
3. Tugger AGVs – Powered units pulling a series of non
4. Automated forklift AGVs - An existing forklift truck whose controls have been converted to allow
unmanned operation

Basic components of FMS (Different workstations, automated material handling & storage system, computer
control system)
1. Workstations
2. Automated Material Handling and Storage system.
3. Computer Control System
1. Workstations: In present day application these workstations are typically computer numerical control
(CNC) machine tools that perform machining operation on families of parts. Flexible manufacturing
systems are being designed with other type of processing equipments including inspection stations,
assembly works and sheet metal presses. The various workstations are
(i) Machining centers
 (ii) Load and unload stations
(iii) Assembly work stations
(iv) Inspection stations
(v) Fo r gi n g s t a t i o n s
(vi) Sheet metal processing, etc.
2. Automated Material Handling and Storage system: The various automated material handling
systems are used to transport work parts and subassembly parts between the processing stations,
sometimes incorporating storage into function.
The various functions of automated material handling and storage system are
(i) Random and independent movement of work parts between workstations
(ii) Handling of a variety of work part configurations
(iii) Temporary storage
(iv) Convenient access for loading and unloading of work parts
(v) Compatible with co mput er cont rol
3. Computer Control System: It is used to coordinate the activities of the processing stations and the material
handling system in the FMS. The various functions of computer control system are:
(i) Control of each work station
(ii) Distribution of control instruction to work station
(iii) Production control
(vi) Traffic control
(v) Shuttle control
(vi) Work handling system and monitoring
(vii) System performance monitoring and reporting

NOTE- The FMS is most suited for the mid variety, mid value production range.

Application characteristics of FMS

Types of FMS layout

1. In-line: There are two types of arrangement in in-line layout, in the first type parts move
in only one direction. Parts enter from one side and out from the other side after being
processed on various workstations as shown in Figure 1. But, in the second type of the
arrangement, parts may flow in both the directions as shown in Figure 2.

2. Loop: In the loop arrangement, the parts enter at one point in the loop and they move
in the loop
as the
machines
are arranged
in the loop
for the
processing
and finally,
it leaves the
loop after
complete
processing
as shown in
Figure 3.
 3. Ladder Workstations are arranged in the ladder form and parts move in the same fashion
as shown in Figure 4.
4. Open field: In the open-field arrangement, the layout of the workstations is slightly
complex and parts are transferred using AGVs. The path of movement is already
programmed. The arrangement is shown in Figure 5.

5. Robot-centred cell: In robot-centred cell, parts are loaded and unloaded and also
transferred from one workstation to another with the help of robot as shown in Figure 6.
Functions of Computer in FMS
The following are functions of computer in FMS:
1. Control of each workstation
2. Distribution of control instruction to workstations
3. Production control
4. Traffic control
5. Shuttle control
6. Work handling system monitoring
7. Tool control
8. System performance and monitoring
Objectives of FMS

1. Improve operational control through:

a. Reduction in the number of uncontrollable variables
b. Providing tools to recognize and react quickly to deviations in the manufacturing plan
c. Reducing dependence on human communication

2. Reduce direct labor through:

a. Removing operators from the machining site (their responsibilities and activities can be broadened)
b. Eliminating dependence on highly skilled machinists (their manufacturing skills can be better utilized
in manufacturing engineering functions)
c. Providing a catalyst to introduce and support unattended or lightly attended machine operation

3. Improve short-run responsiveness consisting of:

a. Engineering changes
 b. Processing changes
c. Machine downtime or unavailability
d. Cutting tool failure
e. Late material delivery

4. Improve long-run accommodations through quicker and easier assimilation of:

a. Changing product volumes
b. New product additions and introductions
c. Different part mixes

5. Increase machine utilization by:

a. Eliminating machine setup
b. Utilizing automated features to replace manual intervention
c. Providing quick transfer devices to keep machines in the cutting cycles

6. Reduce inventory by:

a. Reducing lot sizes
b. Improving inventory turnovers
c. Providing the planning tools for just-in-time manufacturing

Advantages & disadvantages of FMS.

Advantages
 Faster, lower- cost changes
 Lower direct labour cost, due to the reduction in number of workers
 Reduced inventory, due to the planning and programming precision
 Consistent and better quality, due to the automated control
 Lower cost per unit of output, due to greater productivity using the same number of workers
 Savings from the indirect labour, from reduced errors, rework, repairs and rejects
Disadvantages
 Limited ability to adapt to changes in product or product mix
 Substantial pre-planning activity
 Expensive, costing millions of dollars
 Technological problems
 Sophisticated manufacturing systems

EXAMPLE
FMS with Automated Warehouse for Large Size Workpiece
Features
Complete automation with Automated Warehouse, Stacker crane, material handling for longer continuous
unattended operation’s-type single direction work conveying cell loader system Servo Hydraulic punch press
enables quiet processing during the night. Data bank system enables total control over schedules, programs, blank
sheets, finished parts etc. Ideal system designed for diversified, low volume parts production requirements.
Compact FMS Line with Automated Warehous
Features
Complete automation with automated warehouse, stacker crane, material handling, two cell systems for longer
continuous unattended operation. Space saving compact design with same side loading / unloading.FMS system
control over schedules, programs, blank sheets, finished parts etc.Ideal system designed for diversified, low
volume parts production requirements.

FMS:
Concept
The use of CNC machine tools provides flexibility in terms of the low job changing time. However the full
benefits of automation cannot be achieved simply by the use of the CNC machine tool alone. The complete job
making process involves the use of machine tool along with all the associated equipment being made available at
the right time. The associated equipment involves the cutting tool, work piece blank, part program, tool offsets
and the like. As a result the effective CNC machine utilization can be achieved if all these are integrated. Some
typical figures for machine utilization based on the general trend in the industries are given in table

Machine utilization based on the general trend in the industries

Automation Machine Utilization
Basic CNC: Manual tool and work loading. 50%
Basic CNC with automatic work holding and work piece storage, manual loading. 60%
Complete machine automation: Automatic work and tool handling, tool monitoring, 75%
work piece inspection, work and tool storage.
Integration of group machines similar to that shown in third type. 80%
Flexible Manufacturing System: Automated Work piece Movement between 90%
machines.

Thus it can be seen that the full utilization (90% with the rest allocated for maintenance) can be achieved in FMS
by properly integrating all the required functions. A large number of definitions have been provided for FMS as
follows:

"A series of automatic tools or items of fabrication equipment linked together with an automatic material handling
system, a common hierarchical digital preprogrammed computer control, and provision for random fabrication of
parts or assemblies that fall within predetermined families."

"A FMS group of NC machine tools that can randomly process a group of parts, having automated material
handling and central computer control to dynamically balance resource utilization so that the system can adopt
automatically to changes in part production, mixes and levels of output."

Thus it can be seen that a true FMS can handle a wide variety of dissimilar parts, producing them in small
numbers even one at a time, in any order, as needed by making use of all the computer controlled equipment
(workstations and material handling) with the help of a central computer control of all the equipment within.
Typical costs associated with various types of manufacturing systems are shown in table:

Costs associated with various types of manufacturing systems

Costs Small Scale (standalone Medium Scale Large Scale
machine tools) (FMS) (Transfer lines)
Direct labor 53.7 25.7 19.7
Overhead 13.5 13.9 23.7
Capital 17.8 33.1 29.8
Other Costs 25 28.3 26.8
Total 100 100 100