Introduction to Flexible Manufacturing System (FMS)
Summary
TLDRThis video introduces Flexible Manufacturing Systems (FMS), which are automated, interconnected machine cells controlled by a distributed computer system. FMS is ideal for mid-volume and mid-variety production, offering adaptability to changes in design, schedule, and volume. It comprises workstations, material handling systems, human resources, and computer control. The video discusses the history of FMS, its types, layout configurations, benefits, and considerations for implementation, positioning FMS as a key player in the shift towards Industry 4.0.
Takeaways
- 😀 Flexible Manufacturing Systems (FMS) are highly automated systems that combine processing stations, material handling, and storage systems, all controlled by a distributed computer system.
- 🛠️ FMS is designed for mixed-model, medium volume production, capable of handling 100 to 10,000 units per year.
- 🔄 The 'flexibility' in FMS allows for processing different part styles simultaneously and adjusting production quantities and designs according to customer demand.
- 🤖 The system can quickly adapt to changes in design, schedule, or production volume, both predictable and unpredictable.
- 🏭 The four basic components of FMS include workstations, automated material handling and storage systems, human resources, and a computer control system.
- ⚙️ Workstations in FMS typically consist of CNC machines for machining, assembly stations, welding stations, and stations for cleaning, inspection, and painting.
- 🚜 Material handling and storage systems are crucial for moving workpieces between workstations, providing temporary storage, and facilitating easy loading and unloading.
- 👷 Human resources in FMS manage and maintain the system, perform tasks that machines cannot do, and are involved in quality inspection, programming, and tool changing.
- 💻 The computer control system serves as an interface for human interaction, coordinates production traffic, and provides performance monitoring and diagnostics.
- 🔍 To qualify as an FMS, a system must pass tests on its ability to process different parts, adapt to changes, recover from malfunctions, and introduce new parts.
- 🏗️ FMS has evolved from the Industrial Revolution and is now an integral part of the move towards Industry 4.0, characterized by cyber-physical systems, smart factories, and AI.
Q & A
What is a Flexible Manufacturing System (FMS)?
-A Flexible Manufacturing System (FMS) is a highly automated group technology machine cell that includes one or more processing stations, typically CNC machines, interconnected by automated material handling and storage systems, and controlled by a distributed computer system.
Why is the system referred to as 'flexible'?
-The system is called 'flexible' because it can process different part styles simultaneously at various workstations and can adjust the design and quantities of production according to customer demand patterns. It can also quickly react to changes in design, schedule, or production volume.
What are the four basic components of an FMS?
-The four basic components of an FMS are: 1) Workstations, 2) Automated material handling and storage system, 3) Human resources, and 4) Computer control system.
What types of workstations are typically found in an FMS?
-Typically found workstations in an FMS include machining stations with CNC machines, loading and unloading stations, assembly stations or welding stations, and stations for cleaning, inspection, and painting.
How does the material handling and storage system function in an FMS?
-The material handling and storage system in an FMS is responsible for moving workpieces between workstations, handling various workpiece configurations, serving as a temporary storage system, and providing convenient access for loading and unloading at workstations.
What roles do human resources play in an FMS?
-Human resources in an FMS are responsible for managing and maintaining the system, performing tasks that cannot be done by machines, making complex decisions, quality inspection, programming, planning operations, and performing tasks like loading and unloading workpieces and tool changing.
What is the function of the computer control system in an FMS?
-The computer control system in an FMS serves as an interface between humans and other system components, coordinates inputs by human supervisors, controls production traffic and movement of workpieces, and provides performance monitoring and reporting. It can also conduct full diagnostics for the system.
How can a manufacturing system be qualified as an FMS?
-A manufacturing system can be qualified as an FMS if it can process different part styles in mixed model mode, readily accept changes in production schedule and quantities, recover quickly from equipment malfunctions or breakdowns, and introduce new parts with relative ease.
What are the three types of FMS categorized by the number of machines?
-The three types of FMS categorized by the number of machines are: 1) Single machine cell, 2) Flexible manufacturing cell, and 3) Flexible manufacturing system.
What are the key differences between the three types of FMS?
-The key differences between the three types of FMS are the number of machines, adaptability to change, ability to recover from breakdowns, and the ease of introducing new parts. The more machines a system has, the faster the cycle time and the higher the total volume of product that can be produced, but this also leads to higher investment costs.
What are the five categories of FMS layout?
-The five categories of FMS layout are: 1) Linear type or progressive type, 2) Loop type, 3) Letter type, 4) Open field type, and 5) Robot-centered type.
What are the benefits of using an FMS?
-Benefits of using an FMS include maximizing machine utilization, reducing factory workspace, increased responsiveness to changes, reduced inventory requirements, fewer machines needed for production, lower manufacturing lead time, reduced labor requirements, and the opportunity for unattended production.
What are the factors to consider when implementing an FMS?
-Factors to consider when implementing an FMS include the high capital investment required, the need for substantial pre-planning, the necessity for highly skilled labor for setup and maintenance, and the suitability of the system for group technology products.
Outlines
🛠️ Introduction to Flexible Manufacturing Systems (FMS)
Shallon introduces the concept of Flexible Manufacturing Systems (FMS), defining it as an automated group technology machine cell that includes one or more processing stations, typically CNC machines, interconnected by automated material handling and storage systems, all controlled by a distributed computer system. FMS is designed for medium volume production, capable of processing from 100 to 10,000 units per year. The system's flexibility allows it to handle different part styles simultaneously and adjust production quantities according to customer demand. It can quickly adapt to changes in design, schedule, or volume. The four basic components of FMS are workstations, automated material handling systems, human resources, and computer control systems. Workstations can include machining, assembly, or inspection stations. The material handling system moves workpieces between workstations, while human resources manage, maintain, and perform tasks that require complex decision-making. The computer control system acts as an interface and coordinator for the entire system.
🔍 Assessing Flexibility in Manufacturing Systems
The script outlines four key tests to determine if a system qualifies as a flexible manufacturing system: the popularity test, which checks if the system can process different part styles in mixed model mode; the shadow change test, assessing the system's ability to accept changes in production schedules and quantities; the public test, which evaluates the system's recovery from equipment malfunctions without disrupting production; and the new path test, determining if new parts can be introduced alongside existing ones. If a system passes all four tests, it is deemed flexible. The history of FMS is briefly touched upon, starting with the Industrial Revolution in 1784, leading to the current era of Industry 4.0, characterized by cyber-physical systems, smart factories, and artificial intelligence. FMS was introduced in the 1960s to meet the need for efficient, around-the-clock operation, with the first system patented in 1966. The implementation of FMS in various countries followed, with Germany starting in 1969 and Japan and Russia in 1972.
🏭 Types and Layouts of Flexible Manufacturing Systems
Three types of FMS are described based on the number of machines: single machine cell, flexible manufacturing cell, and flexible manufacturing system. The single machine cell consists of one machining center connected to a material handling system, designed for batch or flexible mode operation. The flexible manufacturing cell includes two or three processing workstations with a material handling system, adaptable to changing production schedules and volumes. The flexible manufacturing system comprises four or more stations connected by a common material handling and computer system, offering advanced control and support systems. The benefits of FMS include increased machine utilization, reduced factory workspace, greater responsiveness to changes, reduced inventory requirements, fewer machines needed for production, lower manufacturing lead times, reduced labor requirements, and opportunities for unattended production. However, the implementation of FMS requires high capital investment, pre-planning, skilled labor, and is most suitable for group technology products.
📊 Benefits and Considerations of Implementing FMS
The benefits of FMS are highlighted, including maximizing machine utilization, reducing factory workspace, increasing responsiveness to changes, reducing inventory requirements, minimizing the number of machines needed, lowering manufacturing lead times, reducing labor requirements, and enabling unattended production. However, the decision to implement FMS must consider the high costs, the need for substantial pre-planning, and the requirement for highly skilled labor. FMS is ideal for manufacturers seeking high efficiency and mid-volume production with the need for flexibility. The script concludes by positioning FMS as a solution fitting the modern manufacturing world's move towards Industry 4.0, which demands high efficiency and greater automation in production.
Mindmap
Keywords
💡Flexible Manufacturing System (FMS)
💡CNC Machining Station
💡Automated Material Handling and Storage System
💡Distributed Computer System
💡Human Resources
💡Group Technology
💡Industrial Revolution
💡Toyota Manufacturing System
💡Cyber-Physical System
💡Layout Configurations
💡Adaptability
Highlights
Introduction to Flexible Manufacturing Systems (FMS).
Definition of FMS as a highly automated group technology machine cell.
FMS is suited for mixed and medium volume production.
Flexibility allows for processing different part styles simultaneously.
FMS can adjust to customer demand patterns and react to changes in design, schedule, or volume.
Four basic components of FMS: workstations, automated material handling, human resources, and computer control system.
Workstations in FMS typically include CNC machines for machining operations.
Material handling and storage system functions and capabilities.
Human resources' role in managing, maintaining, and performing tasks that machines cannot do.
Computer control system as an interface and coordinator for FMS components.
Criteria for qualifying a system as FMS: popularity test, shadow change test, very public test, and new path test.
Historical context of FMS within the Industrial Revolutions.
FMS introduced in 1960s due to market competition and the need for efficient systems.
Types of FMS: single machine cell, flexible manufacturing cell, and flexible manufacturing system.
Key differences between FMS types based on the number of machines and their capabilities.
FMS layout configurations: linear, loop, letter, open field, and robot-centered.
Benefits of FMS: increased machine utilization, reduced factory workspace, responsiveness to changes, reduced inventory, and lower manufacturing lead time.
Challenges in implementing FMS: high capital investment, need for skilled labor, and suitability for group technology products.
FMS as an ideal solution for manufacturers seeking high efficiency and flexibility in mid-volume production.
Modern manufacturing's shift towards Industry 4.0 and the role of FMS in this evolution.
Transcripts
hey my name is Shallon and this video is
an introduction to flexible
manufacturing system also known as FMS
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you
can be defined as a highly automated
group technology machine cell which
causes one or more processing station
usually CNC machining station and it is
interconnected by automated material
handling and storage system and it is
controlled by distributed computer
system
what may
flexible so basically FMS is suited for
meet where IT and meet volume production
which ranging from 100 unique to 10,000
unit per year we call it flexible system
because it is able to process different
paths style simultaneously at various
workstation and the design and
quantities of production can be adjusted
according to the demand pattern of the
customer and it is able to react quickly
to the predictable and unpredictable
changes be changes in the design changes
in the schedule or changes in the
production volume
there are four basic components of
flexible manufacturing system first
workstation second automated material
handling system the human resources and
finally computer control system
the first
component of emesis workstations type of
workstation typically found in an FM
system machining station which usually
CNC machines which process the workpiece
into desired shape lot and understand
Shinzon which the workpiece enter and
exit the machines assembly stations or
welding station which join together the
process workpiece and the last one at
the station such as cleaning inspection
and painting station material handling
and storage system is the second basic
component of FMS function of material
handling and storage system are to
provide movement of peace between
workstation handle variety of work
configuration function as a temporary
storage system and also to provide
convenient access to load and unload
station material is usually transported
to the workstation via conveyor system
expandable rail system overhead gantry
system robotic arm system and automated
guided vehicle or also known as a DV
Human Resources is the third basic
components of FMS it plan manage and
provides the maintenance for the whole
FMS system it also perform the tasks
that cannot be done by Machine and
required complex decision which can be
handled by the computer system in
example quality inspection Human
Resources also provides the programming
and plan for the operation of the whole
system other than that human is also
required to load and unload the
workpiece from the machine and perform
the tool changing process the final
basic components of a families computer
control system it function as an
interface between human and other
components of FMS which is workstations
and material handling and storage system
it also coordinate letters input by
human supervisor the computer system
also controls the production traffic and
movement of the shuttle to achieve
desirable output it also provides tempo
formance monitoring and reporting the
computer control system also capable to
conduct full diagnostic for the system
qualified a manufacturing system to be
defined as flexible manufacturing system
there are four questions that need to be
asked the first question is on the
popularity test can the system process
different part of product styles in a
mixed model mode and the second question
is shadow change test can the system
readily accept changes in production
schedule and production quantities the
third question is a very public test can
the system recover a breast fully from
equipment malfunction or breakdowns so
that the production not completely
disrupted by the breakdowns and the
final question that need to be asked is
the new path test can the new part
introduce into existing parts with
relatively is if we answer all the four
question yes then we can define the
system as flexible manufacturing system
if there is one no so it is not
fulfilling the requirement was flexible
manufacturing system
before we discuss on the history of FMS
as a part of manufacturing advancement
let us go through briefly on the history
of Industrial Revolution first
Industrial Revolution happened in 1784
when James Watt founded steam engine and
mechanization is happening around Europe
during that time Second Industrial
Revolution happened in 1870 when
electricity was found this lead to mass
production and division of level
according to a specific skill set the
Industrial Revolution happened in 1969
when Electronics PLC and computer was
founded this little automation of
manufacturing line and utilization of
robot in production line Toyota
manufacturing system is the famous
system during this time and now we are
the brain of first Industrial Revolution
which characterized by cyber-physical
system smart factory and artificial
intelligence
FMS was introduced in 1960 when intense
market competition in the industrial
world required a system that is more
efficient and that can operate 24 hours
without human operator first SMS was
patented in 1966 by David Williamson a
British engineer working for a company
called volume first concept was
initially called system 24 due to its
capability to run 24 hours a day on
which 16 hours it can run by itself due
to its advantages the concept later on
adopted by many companies like Ingersoll
Rand caterpillar Cincinnati mellotron
and General Electric's Germany's start
implementing FMEA in 1969 while Japan
and Russia start implementing it in 1972
there are three types of FMS which
categorized by the number of machine in
the system first single machine cell
second flexible manufacturing cell and
the flexible manufacturing system single
machine cell consists one machining
center which connected to pastoral
system and it can load and unload path
to and from the storage system it is
designed to operate in batch mode
flexible mode or combination of both
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flexible manufacturing cell contains two
or three processing workstation + fat
handling system which connected to load
and under station it is readily
adaptable to changing production
schedule and volumes new path designs
can be introduced to the system with
relative ease
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flexible manufacturing system contains
four or more manufacturing station
connected mechanically by common pot
handling system and electronically by a
distributed computer system it includes
advanced computer control system and
supporting systems such as measuring
machine storage station and tool
monitoring system
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you
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key differences between the three FMS
systems on the number of machines in
short the more machines that the system
have the faster the cycle time of the
product can be completed and the higher
the total volume of product that can be
produced however this also lead to
higher investment to set up the system
second table shows the differences
between the three systems in terms of
variety adaptability to shadow change
ability to recover from machine
breakdowns and errors and ability to
introduce new paths to the system our
system shows that it is able to perform
various part at the same time except for
a single manufacturing cell which can
only produce different part in
sequential mode and not simultaneously
all system also able to adapt to shed
will change and able to produce new
parts with new designs in term of
recovery from breakdowns and error only
flexible manufacturing system is able to
recover immediately FMS sits in the
middle line compared to other
manufacturing system in term of ability
to produce various product and volume of
production
FMS can be concluded as the most ideal
manufacturing system to get the
production they require a mid volume and
mid variety of product design
we can classify FMS layout into five
categories first linear type or also
known as progressive type ii Luke type
that letter type first open field type
and finally robot Center type linear
type or progressive type is the simplest
form of FMS layout configuration the
machine and handling system are arranged
in a straight line where putt progress
from one workstation to the network
station in a well-defined sequence what
piece always moving in one direction and
knowable flow in the system the second
type of FMS layout configuration is loop
lay out where the workstation organized
around on the a system or a pot handling
system in a loop form but usually flow
in one direction around the loop with
capability to stop and be transferred to
any station within the loop
the SMS the up configuration is letter
type layout where the workstation
located around a look with cross section
between the straight section of the loop
the cross section increased the possible
path for the piece to move between the
workstations and also reduce the travel
distance of the workpiece the system
proved to be more flexible than looked
at a linear time
upon filling out is the most complex FMS
layup configuration it was these
multiple loops and let us organize to
achieve processing requirements this
configuration usually used for
processing large family paths routing of
peace is in multi direction and complex
sequence what piece usually move between
the workstations by using automated
guided vehicle the final FMS layout
configuration is robot centered cell
where it used one or more robot as
material handler to load and unload the
workpiece into the processing machines
endlessly
out the machine usually arranged in
circular layout around the robot so it
is easy for the robot to load and unload
their workpiece to and from the machine
FMS benefits it's used in many ways
first seven ages of sms's it will
maximize the machine utilization as it
is a fully automated system so the
machine can run 24 hours even with the
human attention second FMS can reduce
the factory workspace as last floor area
is required in the system compared to
the traditional batch production that
the system has greater responsiveness to
predictable and unpredictable changes
first smsql reduce inventory requirement
through a more efficient management of
stock level fifth fewer machine is
required to run production as one
machine is capable or doing multiple
processes 6 this system can lower the
manufacturing lead time as this system
minimize the waiting time for the part
to be processed at the machine and since
the material handling is automated the
pub is transferred faster from the
warehouse to the processing machine 7th
FMS proof to reduce the level
requirement through utilization of robot
and automated system and finally FMS
create an opportunity for unattended
production as the system is fully
automated and it allowed the system to
run over period of time without human
attention
although FMS have many advantages there
are a few factors that need to be
considered when we decide to implement
FMS first factor that need to be
considered is the costs as FMS require
high capital investment to set the
system FMS also requires substantial and
tedious pre-planning to run the system
and the system also require highly
skilled labor to set up and also
maintain the system and FMS is only
suitable for group technology product
as for the conclusion FMS is an ideal
solution for the manufacturers who
looking for high efficiency and mid
volume production but requires some sort
of flexibility in its production if the
cost is justified FMS will benefit
manufacturers in many ways modern
manufacturing world is moving toward the
next step of Industrial Revolution which
is industrial 4.0 this concept demand
high efficiency and greater automation
in production and FMS seems to suit the
concept very well thank you very much
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