Introduction to Flexible Manufacturing System (FMS)

Shazwan Halim

4 Jan 201818:41

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

00:00

🛠️ 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.

05:03

🔍 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.

10:11

🏭 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.

15:11

📊 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)

A Flexible Manufacturing System (FMS) is defined in the script as a highly automated group technology machine cell, which includes one or more processing stations, typically CNC machines, interconnected by automated material handling and storage systems, and controlled by a distributed computer system. It is designed to handle a mix of part types and varying production volumes, making it highly adaptable to changes in customer demand. The video emphasizes FMS's ability to process different part styles simultaneously and adjust production quantities quickly, which is crucial for meeting the fluctuating demands of the market.

💡CNC Machining Station

CNC, or Computer Numerical Control, machining stations are integral to FMS as they are the workstations that process workpieces into the desired shape. These stations are automated and controlled by computers, allowing for precision and efficiency in manufacturing. The script mentions that FMS typically includes CNC machines, highlighting their role in the automated and flexible production process.

💡Automated Material Handling and Storage System

This system is responsible for the movement of workpieces between workstations, handling various workpiece configurations, and providing temporary storage. It is a critical component of FMS, ensuring that workpieces are transported efficiently to the appropriate workstations. The script describes how material is usually transported via conveyor systems, expandable rail systems, overhead gantry systems, robotic arms, or automated guided vehicles, showcasing the variety of methods used in FMS for material handling.

💡Distributed Computer System

The distributed computer system in FMS serves as the control center, managing the operations of the workstations and the material handling system. It coordinates the input from human supervisors and controls the production flow to achieve the desired output. The script highlights the system's role in performance monitoring, reporting, and diagnostics, which are essential for maintaining the efficiency and reliability of the FMS.

💡Human Resources

Human resources play a vital role in managing, maintaining, and operating the FMS. They are involved in tasks that machines cannot perform, such as quality inspection and complex decision-making. The script mentions that human resources are also responsible for loading and unloading workpieces, as well as tool changing, emphasizing the continued importance of human involvement in an otherwise highly automated system.

💡Group Technology

Group technology is a manufacturing strategy that involves grouping similar parts together for efficient production. The script refers to FMS as a system suited for group technology, which means it can handle the production of parts that are similar in design or manufacturing process, thus optimizing the use of resources and machinery.

💡Industrial Revolution

The script provides a brief history of the Industrial Revolution, highlighting its impact on manufacturing advancements. The first Industrial Revolution is marked by the invention of the steam engine, the second by the discovery of electricity leading to mass production, and the third by the introduction of electronics, PLCs, and computers, which automated manufacturing lines. FMS is a product of these advancements, particularly the third Industrial Revolution, where automation and computerization became integral to manufacturing.

💡Toyota Manufacturing System

The Toyota Manufacturing System is mentioned in the script as a famous system during the third Industrial Revolution. It is known for its emphasis on lean manufacturing principles, such as just-in-time production and continuous improvement. While the script does not delve deeply into the Toyota system, it serves as a context for the evolution of manufacturing practices that led to the development of FMS.

💡Cyber-Physical System

The script mentions the fourth Industrial Revolution, characterized by cyber-physical systems, smart factories, and artificial intelligence. FMS is positioned as a precursor to these advanced manufacturing concepts, suggesting that its automation and flexibility are in line with the trends towards greater integration of digital and physical systems in manufacturing.

💡Layout Configurations

The script outlines various FMS layout configurations, including linear, loop, letter, open field, and robot-centered types. Each configuration has its advantages and is suited to different production requirements. The layout determines how workpieces move through the system, affecting efficiency and flexibility. The video discusses how these configurations influence the system's ability to handle different production volumes and part types.

💡Adaptability

Adaptability is a key feature of FMS, as it allows the system to adjust to changes in production schedules, volumes, and the introduction of new part designs. The script emphasizes that FMS can quickly react to both predictable and unpredictable changes, which is essential for maintaining competitiveness in a dynamic market. Adaptability is a core concept in the video, illustrating the system's flexibility and responsiveness.

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.