CIM MODULE 2.pptx

MODULE 2
COMPUTERIZED
MANUFACTURING
PLANNING AND
CONTROL SYSTEM

INTRODUCTION
 In a CIM environment , most planning activities are performed with the
help of computers.
 There are three major planning activities are performed with help of CIM
are 1. PROCESS PLANNING 2. MATERIALS REQUIREMENTS
PLANNING 3. CAPACITY REQIUREMENTS PLANNING.
Traditional Process Planning:
 There are variations in the level of detail found in route sheets among
different companies & industries. In the one extreme, process planning is
accomplished by releasing the part print to the production shop with the
instructions “make to drawing.”
 Examples: In one case, a total of 42 different routings were developed for
various sizes of a relatively simple part called an “expander sleeve.”
 There were a total of 64 different sizes & styles, each with its own part
number.
 The 42 routings included 20 different machine tools in the shop. The
reason for this absence of process standardization was that many different
individuals had worked on the parts: 8 or 9 manufacturing engineers, 2
planners and 25 NC part programmers.

Automated Process Planning:
 Because of the problems encountered with manual process planning,
attempts have been made in recent years to capture the logic, judgment, and
experience required for this important function and incorporate them into
computer programs.
 Based on the characteristics of a given part, the program automatically
generates the manufacturing operation sequence. A computer-aided process
planning (CAPP) system offers the potential for reducing the routine clerical
work of manufacturing engineers.
Definition :
 Process planning is concerned with determining the sequence of individual
manufacturing operations needed to produce a given part or product.
 Resulting operation sequence is documented on a form typically referred to
as operation sheet. The operation sheet is a listing of the production
operations and associated machine tools for a work part or assembly.
 Process planning is an important stage of product development since
production tooling like jigs, fixtures, special tools etc. can be designed only
after the process is finalized.
OR
Process planning defined as “ the activity that translates part design
specifications from an engineering drawing into the manufacturing operation
instructions required to convert a part from a rough to a finished state.”

PROCESS PLANNING Vs PRODUCTION PLANNING
 Process planning is concerned with the engineering and
technical issues of how to make the product and its parts.
 Process planning deals with type of equipment and tooling
that are required to fabricate the parts and assemble the
product.
but,
Production planning is concerned with ordering materials,
procuring tools and equipment and obtaining the resources
to make the product in sufficient quantities to satisfy the
demand for it.

Production is a process whereby raw material is converted into
semi-finished products and thereby adds to the value of utility of products,
which can be measured as the difference between the value of inputs and
value of outputs

Role OR contents of process planning
1. Interpretation of product design data
2. Selection of machining processes.
3. Selection of machine tools.
4. Determination of fixtures and datum surfaces.
5. Sequencing the operations.
6. Selection of inspection devices.
7. Determination of production tolerances.
8. Determination of the proper cutting conditions.
9. Calculation of the overall times.
10. Generation of process sheets including NC data.

Part name: Shaft, generator Material: 1050 H18 Al
Part number: 081099 Cycle time: 100 HRS
Operation
No.
Description
of operation
Machine Tool Jigs Gauges Time
analysis
10
20
30
40
Face end
Rough turn
Drill 7.5dia.
Mill 6.5mm
deep
L45
L45
Drill
Mill
G0810
G0810
D09
M32
5.2 min
3.0 min
3.2 min
6.2 min
Process planning for parts and assemblies.
Table shows Route sheet or Operation sheet
Approaches to Process planning
1. Manual approach
2. Variant or retrieval type CAPP system
3. Generative CAPP system

In a computerized process planning system a formal structure and
knowledge database are required in order to transform the engineering
design information into the process definition.
 CAPP link b/w the CAD & CAM
COMPUTER AIDED PROCESS PLANNING
As already mentioned there are two approaches:
i. Variant process planning
ii. Generative process planning
Variant Process Planning
 A variant process planning system uses the similarity among components
to retrieve the existing process plans.
 A process plan that can be used by a family of components is called a
standard plan.
 A standard plan is stored permanently with a family number as its key.
 A family is represented by a family matrix which includes all possible
members.
The variant process planning system has two operational stages:
• A preparatory stage and
• A production stage.

 During the preparatory stage, existing components are coded, classified, and
subsequently grouped into families.
The process begins by summarizing process plans already prepared for
components in the family. Standard plans are then stored in a data base and indexed
by family matrices (Fig).
Fig. Process Family Matrix
 The operation stage occurs when the system is ready for production. An
incoming part is first coded.
 The code is then input to a part family search routine to find the family
to which the component belongs.

The family number is then used to retrieve a standard plan. Some other
functions, such as parameter selection and standard time calculations, can also
be added to make the system more complete (Fig.2).
This system is used in a machine shop that produces a variety of small
components.
Fig. 2 Part Search and Retrieval

Design of Variant Process Planning System
 The following are the sequences in the design of a variant process planning
system:
i. Family formation.
ii. Data base structure design.
iii. Search algorithm development and implementation .
iv. Plan editing.
v. Process parameter selection/updating .
 Part family classification and coding were discussed earlier. This is based
on the manufacturing features of a part.
 Components requiring similar processes are grouped into the same family.
A general rule for part family formation is that all parts must be related.
 Then, a standard process plan can be shared by the entire family. Minimum
modification on the standard plan will be required for such family members.
Family formation.

Data Base Structure Design
The data base contains all the necessary information for an application, and
can be accessed by several programs for specific application. There are three
approaches to construct a data base: hierarchical, network, and relational.
Search Procedure
 The principle of a variant system is to retrieve process plans for similar
components.
 The search for a process plan is based on the search of a part family to
which the component belongs.
 When, the part family is found, the associated standard plan can then
be retrieved.
 A family matrix search can be seen as the matching of the family with a
given code. Family matrices can be considered as masks.
 Whenever, a code can pass through a mask successfully, the family is
identified.
Plan Editing and Parameter Selection
Before a process plan can be issued to the shop, some modification
of the standard plan may be necessary, and process parameters must be added
to the plan. There are two types of plan editing:
 One is the editing of the standard plan itself in the data base, and
 the other is editing of the plan for the component.

Generative Process Planning
 Generative process planning is a system that synthesizes process
information in order to create a process plan for a new component
automatically.
 In a generative planning system, process plans are created from
information available in manufacturing data base without human intervention.
 Upon receiving the design model, the system can generate the required
operations and operation sequences for the component.
 The generative part consists of:
• Component representation module
• Feature extraction module
• Feature process correlation module
• Operation selection and sequencing module
• Machine tool selection module
• Standard time / cost computation module
• Report generation module
• Geometrical and manufacturing data of the part.
• computerized searches and decision logics.

Fig. shows the modular structure of a generative CAPP system.

 Several of methods have been proposed for creating generative process
plans.
 A few methods that have been implemented successfully are:
i. Forward and backward planning
ii. Input Format
iii. CAPP based on CAD models
iv. CAPP based on decision logic either using decision trees or decision tables
v. CAPP based on artificial intelligence ,
To generate a process plan for anew component, the following
procedures.
 The part drawing is received from the design department.
 The design specifications which are present in the part drawing is to
be converted into computer compatible description of the part.
 The three techniques frequently used for this description include:
1. G T code.
2. Descriptive language.
3. CAD.
 In each technique, the complete design specification for the part is
converted into a format compatible with the system.
 The technical knowledge of manufacturing and the logical data required for
process planning is captured in the computer. ie. Knowledge Data Base.

 The generative CAPP system uses this knowledge data base to determine
different operations to be performed on the part.
 Generative approach uses Decision Logic Systems such as expert system
to select proper data required to manufacturing the given part from the
knowledge data base and generates a process plan in the form of
“ROUTE SHEET”
Forward and Backward Planning
 In generative process planning, when process plans are generated, the
system must define an initial state in order to reach the final state (goal).
The path taken represents the sequence of processes.
 For example, the initial state is the raw material and the final state is the
component design.
Process Planning Systems
 The majority of existing process planning systems is based on variant
process planning approach. Some of them are:
 CAPP, MIPLAN, MITURN, MIAPP, UNIVATION, CINTURN,
COMCAPPV, etc. However, there are some generative system, such as
METCAPP, CPPP, AUTAP, and APPAS. Some of the planning systems
are discussed in the following paragraph. These are systems continuously
evolving in many cases.

Benefits of CAPP
Process planning with the aid of computer
• Process planning is concerned with the preparation of route sheets that list
the sequence of operations and work centers require to produce the product
and its components.
• Manufacturing firms try to automate the task of process planning using
CAPP systems due to many limitations of manual process planning. These
includes:
– Tied to personal experience and knowledge of planner of production
facilities, equipment, their capabilities, process and tooling. This results in
inconsistent plans.
– Manual process planning is time consuming and slow.
– Slow in responding to changes in product design and production.
• The experience of manufacturing of different engineers, who are likely to
retire, can be made available in future by CAPP.
• CAPP is usually considered to be part of CAM, however this results CAM
as stand-alone system.
• Synergy of CAM can be achieved by integrating it with CAD system and
CAPP acts as a connection between the two.
• Readymade CAPP systems are available today to prepare route sheets.

 The systematic approach and the availability of standard process plans in
the data files permit more work to be accomplished by the process
planners there by increasing the productivity of process planners.
 Route sheets or operation sheets can be produced in a shorter lead time
compared to manual operations.
 Computer prepared route sheets are neater and easier to read than
manually prepared route sheets.
 Other application program such as Cost estimating and Work standards
can be interfaced with CAPP programs.
 An interface with MRP and ERP software's is possible.

MANUFACTURING / PRODUCTION PLANNING AND
CONTROL SYSTEM:
 Production planning and control deals with logistics problems that are
encountered in manufacturing. Also deals with scheduling the production,
delivery of parts, planning the man power and equipment resources for
the production.
 PRODUCTION PLANNING AND CONTROL DEALS WITH THE
ISSUES LIKE,
 What products are to be produced.
 How many products are to be produced
 When to produced
 How to obtain raw materials
 How to schedule the production
 How to deliver the parts
 How to plan the man power
 How to obtain the equipment resources

The primary objective of a manufacturing planning and control system
(MPCS) in any organization is to ensure that the desired products are
manufactured
 at the right time,
 in the right quantities,
 meeting quality specifications, and
 at minimum cost.
The manufacturing planning and control system (MPCS) in a company
is achieved by
 integrating the activities as:
 determining product demand,
 translating product demand into feasible manufacturing plans,
 establishing detailed planning of material flows,
 capacity to support the overall manufacturing plans, and
 helping to execute these plans by such actions as
detailed cell scheduling
purchasing

The benefits achieved through the use of integrated MPCS are:
 reduced inventories
 reduced capacity
 reduced labor costs
 reduced overtime costs
 shorter manufacturing lead time
faster responsiveness to internal and external changes as:
machine and other equipment failure
product mix
demand changes
The major elements of a integrated MPCS are:
 Demand management
 Aggregate production planning
 Master production scheduling
 Rough-cut capacity planning
 Material requirement planning
 Capacity planning
 Order release
 Shop floor scheduling and control

The flow of information among various elements of an
MPCS:

 DEMAND MANAGEMENT:
Demand for products is the driving force for any production activity.
 Demand management is therefore an important input to production
planning.
Demand management contains activities as:
 􀁸 demand forecasting
 􀁸 order transaction entry
 􀁸 customer-contact activities
 􀁸 physical distribution management
Demand forecasting:
 Forecasting is concerned with estimating future demand ( or requirement)
for products.
 Forecasting is necessary for production planning.
There are three approaches to forecasting:
1. The qualitative approach
2. The explanatory approach
3. The descriptive approach

Activities in a production planning and control system
 Aggregate production planning
 Master production scheduling
 Material requirement planning
 Capacity planning
 Engineering and manufacturing database
 Inventory control
 Shop floor scheduling and control
 Purchase department

AGGREGATE PRODUCTION PLANNING:
 In a high-variety, discrete manufacturing environment, demand for
product may fluctuate considerably. On the other end, the resources of the
company (number of machines, number of workers, etc.) remain constant
during the planning horizon (normally 12 months). The best approach to
obtain feasible solutions is to aggregate the information being processed.
 For aggregation purposes the product demand should be expressed in a
common measurement unit such as production hours. Production planning is
concerned primarily with determining optimal production, inventory, and
work force levels to meet demand fluctuation.

Basic strategies to absorb the demand fluctuations are:
* Maintain uniform production rate and absorb demand fluctuations.
* Maintain work force but change the production rate by permitting planned
overtime, idle time and subcontracting.
* Change the production rate by changing the size of the work force through
planned hiring and layoffs.
 * Explore the possibility of planned backlogs if customers are willing to
accept delays in delivery of products.
EXAMPLE:
Data on the expected aggregated sales of three products, A, B, and C, over
planning horizon of six 4-week periods are as follows:
Overtime is allowed up to 60 units/period

MASTER PRODUCTION SCHEDULE:
 The primary use of an aggregate production plan is to level the production
schedule so that the production costs are minimized.
 However, the output of an aggregate plan does not indicate individual
product. This means that the aggregated plan must be disaggregated into
individual product. The result of such a disaggregation methodologies is
what is known as master production schedule.
 Master production schedule does not present an executable manufacturing
plan. Because the capacities and the inventories have not been considered
in this stage. Therefore, further analysis for the material and capacity
requirements is required to develop an executable manufacturing plan.
 MPS uses weeks or months as time periods and these time periods are
called as “ Time Buckets”.

ROUGH-CUT CAPACITY PLAN:
 The objective of rough-cut capacity planning is to ensure that the master
production schedule is feasible. For each product family the average
amount of work needed an key work centers per unit per unit can be
calculated from each item’s bill of materials and production routings
(process planning sheets).
EXAMPLE:
 Consider two families of steel cylinders and the resource profile developed
in standard hours of resources per 200 units of end-product family as
follows:

MATERIAL REQUIREMENT PLANNING (MRP)
 The material requirements planning system is system essentially an
information system consisting of logical procedure for managing
inventories of component assemblies, subassemblies, parts, and raw
materials in a manufacturing environment.
 The primary objective of an MRP system is to determine how many of
each item in the bill of materials must be manufactured or purchased and
when.
 Material Requirements Planning (MRP) is a computational technique that
converts the master schedule for end products into a detailed schedule for
the raw materials & components used in the end products.
 The detailed schedule identifies the quantities of each raw material &
component item. It also indicates when each item must be ordered &
delivered to meet the master schedule for final products.
 MRP is often thought of as a method of inventory control.
Both an effective tool for minimizing unnecessary inventory
investment & a useful method in production scheduling & purchasing of
materials.

 The distinction between independent demand & dependent demand is
important in MRP.
Independent demand means that demand for a product is unrelated
to demand for other items. Final products & spare parts are examples of
items whose demand is independent. Independent demand patterns must
usually be forecasted.
Dependent demand means that demand for the item is directly related
to the demand for some other item, usually a final product. The
dependency usually derives from the fact that the item is a component of
the other product.
 Component parts, raw materials, & subassemblies are examples of
items subject to dependent demand.
 For example, even though demand for automobiles in a given month can
only be forecasted, once the quantity is established & production is
scheduled, we know that five tires will be needed to deliver the car (don’t
forget the spare).
 MRP is the appropriate technique for determining quantities of dependent
demand items. These items constitute the inventory of manufacturing:
raw materials, work-in-process (WIP), component parts &
subassemblies. That is why MRP is such a powerful technique in
planning & control of manufacturing inventories.
 For independent demand items, inventory control is often accomplished
using order point systems.

DEFINITION
“ MRP is a Computer based information system for ordering and
scheduling of raw materials and other components used to produce
and products”
 MRP specifies the quantities of raw materials to be used to produce
end products.
 MRP specifies whether to purchase a parts/ materials or make a
product and in what quantities.
 MRP specifies when to deliver the parts/materials to meet Master
Production Schedule.
 Main purpose of MRP is to ensure that materials and components are
available in right quantities at right time so that the finished products
can be completed according to MPS.
 MRP is used to minimize unnecessary inventory costs and is always
considered as a method of Inventory control.

BILL OF MATERIALS FILE
A product may be made from one or more assemblies, subassemblies and
components.
 A bill of material is an engineering document that specifies that the
components and subassemblies required to make each end item (product).
 The bill of material ( BOM ) file provides information the product
structure by listing the components parts and subassemblies that make up
each product, It is use to computer the raw material and components
requirement for end products listed in the master schedule.
 BOM file is also called as Product structure file.
 A bill of material not only lists all the required parts but also is structured
to reflect the sequence of steps required to produce the end products.
 The BOM has a series of levels, each of which represents a stage in the
manufacture of the end products.
 The highest level or zero level of BOM represents the final assembly or
end product.

Inventory status file
 The inventory status file gives complete and up to date information on the
on – hand quantities, gross requirements, scheduled receipts, and planned
order release for the item.
 It also includes other information such as lot of sizes, lead times, safety
stock levels and scrap allowances.
 The inventory status file keeps the data about the projected use and
receipts of each item and determines the amount of inventory that will be
available in each time bucket.
 The inventory file must be kept up to data taking into consideration the
daily inventory transaction such as receipts, scrapped materials, order
releases and planned orders.

 The types of data contained in the inventory
record are divided into three segments.
 Item master data : This provides the item’s identification ( part
number ) and other data about the part such as order quantity and
lead times.
 Inventory status : This gives a time-phased record of inventory
status. In MRP, its is import to know not only the current level of
inventory but also any future changes that will occur against the
inventory. Therefore , the inventory status segment lists the gross
requirements for the item, schedules receipts, on-hand status, and
planned order releases,
 Subsidiary data. The third file segment provided subsidiary data
such purchase orders, scrap or rejects and engineering changes.

CAPACITY PLANNING:
 The output of MRP does not produce an executable manufacturing plan,
because it contains material requirement information only but does not
contain information about the manufacturing capacity of the plant.
 To develop an executable manufacturing plan, it is essential to establish
the feasibility of the planned order releases obtained from the MRP
system.
 “Capacity planning is concerned with ensuring the feasibility of
production plans by determining resources such as labour and equipment
with a view to developing what is known as an executable manufacturing
plan”.
 The process of capacity planning is complex and involves a number of
decisions:
􀁸 Exploring overtime/multiple shifts/subcontracting options.
􀁸 Developing alternative process plans for effective resource utilization
􀁸 Splitting lots.
􀁸 Increasing or decreasing employment levels to respond to capacity
changes.
􀁸 Inventory options.
􀁸 Increasing capacity by adding capital equipment such as machine tools.

SHOP FLOOR CONTROL:
 When the planned orders are released to the shop floor for manufacturing,
the primary objective is to deliver the product at the right time, in the right
quantities, meeting quality specifications. But some unexpected event
(machine breakdown for example) may cause delays.
 In order to take action (changing the scheduling for example), the up to
date information from the shop floor must be send to the management a
fast and a steady manner.
 A number of methods are used for data collection in industries, such as:
* Hand written reports.
* Manual data entry terminals.
* Bar code readers and sensors such as optical and magnetic reading
devices that automatically update an item’s progress through the shop
floor.
* Voice data entry system.
The major functions of a shop-floor control system are
* To schedule job orders on the work centers,
* To sequence the jobs in order on a work center,
* To provide accurate and timely order status information.

MODULE 3
FLEXIBLE
MANUFACTURING
SYSTEM

FUNDAMENTALS OF GROUP TECHNOLOGY
Group technology is manufacturing philosophy in which similar
parts are identified and grouped together to take advantage of their
similarities in design and productions.
Similar parts are arranged into part families, where each part family
possesses similar design and manufacturing characteristics.
For example : A plant producing 10,000 different part numbers may be able
to group the vast majority of these parts into 30 or 40 distinct families.
 Group technology and cellular manufacturing are applicable to a wide
variety of manufacturing situations.
 The plant currently uses traditional batch production and a process type
layout.
 The parts can be grouped into part families.
 Identifying the part families.
 Rearranging production machines into machine cells.
 Cellular manufacturing is an application of group technology in which
dissimilar machines or processes have been aggregated into cells, each of
which is dedicated to the production of a part, product family or limited
group of families.

 GT promotes standardization of tooling, fixtures and setups.
 Material handling is reduced because the distance s within a machine cell
are much shorter than within the entire factory.
 Process planning and production scheduling are simplified.
 Set up time is reduced, resulting in lower manufacturing lead times.
 Work in process is reduced.
 Worker satisfaction usually improves when workers collaboration in a GT
cell.
 Higher quality work is accomplished using group technology.
 The improvement is typically achieved by organizing the production
facilities into manufacturing cells that specialize in production of certain
part families

Part Families
 A group of parts that possess similarities in geometric shape and size, or
in the processing steps used in their manufacture
 Part families are a central feature of group technology
 There are always differences among parts in a family
 But the similarities are close enough that the parts can be grouped into the
same family
Two parts that are identical in shape and size but quite different in
manufacturing:
(a)1,000,000 units/yr, tolerance = ±0.010 inch, 1015 CR steel, nickel
plate
(b)100/yr, tolerance = ±0.001 inch, 18-8 stainless steel

• Ten parts that are different in size and shape, but quite similar in terms of
manufacturing
• All parts are machined from cylindrical stock by turning; some parts
require drilling and/or milling
Ways to Identify Part Families / methods of part families.
 visual inspection method.
 part classification and coding.
 Production flow analysis.

 Visual inspection method is the least sophisticated and least expensive
method .
 It involves the classification of parts into families by looking at either the
physical parts and arranging them into groups having similar features.
Parts Classification and Coding
Features of classification and coding systems are one of the
following:
 Systems based on part design attributes.
 Systems based on part manufacturing attributes.
 Systems based on both design and manufacturing attributes.
Part Design Attributes
 Major dimensions
 Basic external shape
 Basic internal shape
 Length/diameter ratio
 Material type
 Part function
 Tolerances
 Surface finish

Part Manufacturing Attributes
 Major process
 Operation sequence
 Batch size
 Annual production
 Machine tools
 Cutting tools
 Material type
Three structures used in classification and coding
schemes
􀁸 Hierarchical structure, known as a mono-code, in which the
interpretation of each successive symbol depends on the value of the
preceding symbols
􀁸 Chain-type structure, known as a polycode, in which the interpretation
of each symbol in the sequence is always the same; it does not depend on
the value of preceding symbols
􀁸 Mixed-mode structure, which is a hybrid of the two previous codes

Production Flow Analysis
 Production flow analysis is an approach to part family identification and
machine cell formation that was pioneered by J Burbidge.
 It is a method for identifying part families and associated machine
groupings that users the information contained on production route
sheets rather than part drawings.
 Work parts with identical or similar routings are classified into part
families.
 These families can then be used to form logical machine cells in a group
technology layout. since PFA uses manufacturing data rather than design
data to identify the part families.
 TWO POSSIBLE ANOMALIES that can occur in part classification and
coding.
 First, parts whose basic geometrics are quite different may nevertheless
require similar or even identical process routings.
 Second, parts whose geometries are quite similar may nevertheless
require process routings that are quite different.

PART FLOW ANALYSIS STEPS
 DATA COLLECTION
 SORTATION OF PROCESS ROUTINGS
 PFA CHART
 CLUSTER ANALYSIS.

Flexible Manufacturing System
􀁸 A highly automated GT machine cell, consisting of a group of processing
stations (usually CNC machine tools), interconnected by an automated
material handling and storage system, and controlled by an integrated
computer system
􀁸 The FMS relies on the principles of GT
􀁸 No manufacturing system can produce an unlimited range of products
􀁸 An FMS is capable of producing a single part family or a limited range of
part families.

Flexibility Tests in an Automated Manufacturing System
 􀁺 Automated manufacturing cell with two machine tools and robot.
 The ability to identify and distinguish among the different incoming
part or product styles processed by the system.
 Quick changeover of operating instructions.
 Quick changeover of physical setup.
 Flexibility is an attribute that applies to both manual & automated
systems.

Types of FMS
FMS can be distinguished according to the
1. NO. OF MACHINES IN THE SYSTEM.
 Single machine cell.
 Flexible manufacturing cell.
 Flexible manufacturing system.

 . “Single machine cell (SMC). It consists of completely
automated machines which are capable of performing
unattended operations within a time period lengthier than
one complete machine cycle. It is skilful of dispensing
various part mix, reacting to fluctuations in manufacture
plan, and inviting introduction of a part as a new entry. It is
a sequence dependent production system.”
 Flexible manufacturing cell (FMC). It entails two or three
dispensing workstations and a material handling system.
The material handling system is linked to a load/unload
station. It is a simultaneous production system

 An Flexible Manufacturing System (FMS). “It has four or
more processing work stations (typically CNC machining
centers or turning centers) connected mechanically by a
common part handling system and automatically by a
distributed computer system. It also includes non-processing
work stations that support production but do not directly
participate in it e.g., part / pallet washing stations, co-
ordinate measuring machines. These features significantly
differentiate it from Flexible manufacturing cell (FMC).”

2. DEPENDING UPON KINDS OF OPERATION
◦ Processing operation.
◦ Assembly operation.
3. BASED ON LEVEL OF FLEXIBILITY
a. Dedicated FMS.
“It is made to produce a certain variety of part styles. The product
design is considered fixed. So, the system can be designed with a
certain amount of process specialization to make the operation more
efficient.”
 A dedicated FMS is designed to produce a limited variety of part styles,
and the complete universe of parts to be made on the system is known
in advance.
 The machines can be designed for the specific processes required to
make the limited part family, thus increasing the production rate of the
system.
 Example : Flexible transfer line.

 Random order FMS.
“It is able to handle the substantial variations in part
configurations. To accommodate these variations, a random order FMS
must be more flexible than the dedicated FMS.
A random order FMS is capable of processing parts that have a
higher degree of complexity. Thus, to deal with these kinds of
complexity, sophisticated computer control system is used for this FMS
type.”
 New part designs will be introduced into the system and engineering
changes will occur in parts currently produced, and the production
schedule is subjected to change from day to day.
 It is equipped with general purpose machines to deal with the variations
in product and is capable of processing parts in various sequences
( random order).

FMS LAYOUT CONFIGURATIONS
 1.In-line
 2.Loop
 3.Ladder
 4.Open field
 5.Robot-centered cell.
IN-LINE LAYOUT
Key: Aut = automated station; L/UL = load/unload station;
Insp = inspection station; AGV = automated guided vehicle;
AGVS = automated guided vehicle system

LOOP LAYOUT

LADDER LAYOUT

OPEN FIELD LAYOUT

FMS COMPONENTS
1. WORKSTATIONS.
2. MATERIAL HANDLING and STORAGE SYSTEM
3. COMPUTER CONTROL SYSTEM.
WORKSTATIONS
1. LOAD / UNLOAD STATIONS.
2. MACHINING STATIONS.
3. OTHER PROCESSING STATIONS.
MATERIAL HANDLING and STORAGE SYSTEM
1.Allows random, independent movement of work parts between stations.
2. Enables handling of a variety of work part configurations.
3. Provides convenient access for loading and unloading work parts.
4. Creates compatibility with computer control.

COMPUTER CONTROL SYSTEM.
 Workstation control.
 Distribution of control instructions to workstations.
 Production control.
 Traffic control.
 Shuttle control.
 Work piece monitoring.
 Tool control.
 Performance monitoring and reporting.
 Diagnostics.

CIM MODULE 2.pptx

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