Flexible manufacturing system full

-:Submitted By:-
Ranjeet Kumar
09113039
Industrial & Production Engineering
National Institute of Technology,Jalandhar

Content:-
 Introduction
 Component of F.M.S
Processing Station
Material Handling
Computer Control
 Levels of Flexibility
 Types of F.M.S Layout
 Objectives of F.M.S

by-ranjeetnitj@gmail.com (NIT Jalandhar)


What is F.M.S ?
-A flexible Manufacturing System (F.M.S) is an
arrangement of machines ,interconnected by a
transport system . The transport carries work to the
machine on pallets or other interface units so the
work-machine registration on is accurate , rapid
and automatic.
OR
-F.M.S consist of a group of Processing work
Stations interconnected by means of an automated
material handling and storage system and
controlled by integrated Computer Control .

In manufacturing flexibility means-
The Capability of Producing Different parts
without major retooling.
A measure of of how fast the company converts
its process(es) From making an old line of
product to produce a new product.
The ability to change a production schedule ,to
modify a part or to handle multiple parts.
So a flexible manufacturing system is a
manufacturing system in which there is some
amount of flexibility that allows the system to
react in the case of changes whether predicted or
unpredicted. by-ranjeetnitj@gmail.com (NIT Jalandhar)

Basic component of F.M.S-
Work stations or Processing Stations
Automated material handling
Computer control system
Work station or processing station:-In Present
day, Work station are typically computer
numerical control(C.N.C) Machine tool that
performs different machining operation on
families of parts .Flexible manufacturing system
are being designed with other type of processing
equipment including inspection station ,
assembly work and sheet metal process. The
various types of workstation are:-

 Machining Center:-It is a Sophisticated CNC
machine that performs milling ,drilling, tapping
and boring operation at the same location with
variety of tools.
or
It is highly automated straight alone machine
which can be used as a component of F.M.S. The
special feature like automated tool changing ,
tool storage ,use of pallatised work parts
,C.N.C contol makes it more compatible with
F.M.S & Milling, drilling, boring and tapping
operation can achieve with this.

Machining
Center


 Head Changer:-Head changer is a special
machine tool with the capability of change Tool
heads . Tool heads are usually multiple spindle
tool module that can be stored in a Rake Drum
located on or near the machine.
 Head Indexes:-In this heads are attach semi
permanently to an Indexing mechanism on the
machine tools.eg-Gear Cutting.


Indexing plate


 Assembly Work Station :-Industrial Robots are
usually consider to be the most appropriate
automated assembly work station in the F.M.S
,they can be programmed to perform task with
variation in sequences.
 Inspection Station:-Inspection Station are
designed for inspecting the completed work , In
F.M.S inspection can be happen either at work
station or by designing Special Inspection
Station for this purpose

Industrial Robots assembling the Car:-


Load and Unload Station:-as identifies from the
name load and unload station are used for
loading and unloading of work parts in the F.M.S.
The various Feature of Load and Unload stations
are:-
-It act as a physical interface between the F.M.S
and rest of the Factory.
-Raw work parts enter the system at load station,
while finished work parts exit at unload station
-Manual loading/unloading is more prevalent


2. Automated Material Handling & Storage
System:-
The various Automated material
handling system are used to transport work
parts and subassembly parts between the
processing station .The other function of
automatic material handling and storage
system are:-
 Random and Independent movement of work
parts between processing stations.
 Handling of variety of work part configuration
 Temporary storage
 Convenient access for Loading and unloading

For automated material handling and storage of
work parts is done by A.G.V(Automated Guided
Vehicles),A.S.R.S & Conveyors . we are describing
A.G.V Below:-
Automated Guided Vehicle:-Automated Guided
Vehicles (AGVs) are vehicles that are equipped with
automatic guidance systems and are capable of
following prescribed paths. Unlike traditional
robots, AGVs are not manipulators, they are
driverless vehicles that are programmed to follow
a guide path. In automated factories and facilities
AGV’s move pallets and containers. In offices they
may be used to deliver and pick up the mail.

Features of A.G.V:-
It transport material from loading to unloading
station.
It Reduces labor cost.
Highly flexible ,intelligent and versatile
material handling system.
Because it is driverless vehicle so it is safe & more
accurate.


Types Of A.G.V:-There are many types of A.G.V but
3 are basic types describe below:-
AGVS Towing Vehicles :-it was the first type
introduced and are still a very popular type today.
Towing vehicles can pull a multitude of trailer
types and have capacities ranging from 8,000
pounds to 60,000 pounds and are usually manned
by an operator who adds and removes the trailers
at designated stops.
AGVS Unit Load Vehicles :-these are equipped
with decks, which permit unit load transportation
and often automatic load transfer. The decks can
either be lift and lower type, powered of non-
powered roller, chain or belt decks or custom decks.

Tow Type A.G.V:-


Unit Load A.G.V:-


Side Loading and High Lifting Types:-
Side loading vehicle with telescopic
fork for load handling on both sides.
Load capacity up to 3,000 lbs.
Lift heights up to 20 feet
Bi-directional motion
Ideal for material delivery
and finished goods warehousing
It is also a driverless A.G.V.


Third and most important part of F.M.S is
Computer
Control system:-
3. Computer Control System:-It is used to co-
ordinate the activities of processing station and
material handling System in the F.M.S. The various
function of computer control system are:-
Control of each work station.
 Distribution of control instruction to work
station.
Production control.
 Traffic control.
Shuttle control.
Work handling system and monitoring.

Levels of Flexibility
There are three basic level of manufacturing
flexibility:-
(a) Basic flexibilities
Machine flexibility: The different operation types
that a machine can Perform is called machine
flexibility . More operation performance more
flexible the machine . Process and product
flexibility are dependent on machine flexibility.

Material handling flexibility: A measure of the
ease with which different part types can be
transported and properly positioned at the various

 Operation flexibility: A measure of the ease with
which alternative operation sequences can be
used for processing a part type.


(b) System flexibilities
Volume flexibility: It is the ability of the System
to Varied the production volume of different
product to accommodate changes.
Expansion flexibility: The ability to build a
system and expand it incrementally by volume ,
production or processes.
Routing flexibility: A measure of the alternative
paths that a processing part can effectively follow
through a system for a given process plan.
OR


It can be defined as a capacity to produce or
make an alternative work station . This Type of
flexibility requires where there is an equipment
break down ,tool failure or other interruption in the
processing.
Process flexibility: A measure of the volume of
the set of part types that a system can produce
without incurring any setup.
Product flexibility: It Refers to ability to change
over to a new set of Product Economically &
quickly Response to the changing market condition
& Requirements. The change over time


include the Time of designing ,Planning, Tooling
&
Fixing of new product .
(c) Aggregate flexibilities
Program flexibility: The ability of a system to run
for reasonably long periods without external
intervention.
Production flexibility: It is the volume of the set
of part types that a system can produce without
major investment in capital equipment.
Market flexibility: The ability of a system to
efficiently adapt to changing market conditions. It

-:LAYOUT CONFIGURATION:-
Types of F.M.S Layout
Configuration:-
There are five types of F.M.S Layout Configuration:-
1. Progressive or Line type : The machines and
handling system are arranged in a line as shown in
Fig. It is most appropriate for a system in which the
part progress from one workstation to the next in a
well defined sequence with no back flow. The
operation of this type of system is
very similar to transfer type. Work always flows in
unidirectional path as shown in Fig.

2. Loop Type: The basic loop configuration is as
shown in Fig.. The parts usually move in
one direction around the loop, with the capability
to stop and be transferred to any station. The
loading and unloading station are typically
located at one end of the loop Fig.


3. Ladder Type: The configuration is as shown in
Fig. The loading and unloading station
is typically located at the same end. The sequence
to the operation/transfer of parts from one machine
tool to another is in the form of ladder steps as
shown in Fig.


Progressive type Loop Type

Ladder type

4. Open Field Type : In the open field type, The
loading and unloading station is typically
located at the same end. The parts will go
through all the substations, such as CNC
machines, coordinate measuring machines and
wash station by the help of AGV’s from one
substation to another.
5.Robot Centered Type: Robot centred cell is a
relatively new form of flexible system in which
one or more robots are used as the material
handling systems .Industrial robots can be
equipped with grippers that make them well suited
for handling of rotational parts.

Robot Centered cell:-


Objectives or AIMS of F.M.S :-
 Decreased Lead Times
 Increased machine utilization
 Improved Due Date Reliability
 Decreased Store Inventors levels
 Remove Labour Cost
 Decreased Work in Progress
 Increased Quality


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