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Essay on Flexible Manufacturing System

Essay Contents:

  1. Essay on the Definition of Flexible Manufacturing System
  2. Essay on the Characteristics of Flexible Manufacturing System
  3. Essay on the Need for Flexible Manufacturing System
  4. Essay on the Requirements for Flexible Manufacturing Systems
  5. Essay on the Development of Flexible Manufacturing System
  6. Essay on the Advances in Flexible Manufacturing System
  7. Essay on the Decision Making in Flexible Manufacturing System
  8. Essay on the Problems in Implementing Flexible Manufacturing System
  9. Essay on the Areas of Flexible Manufacturing System
  10. Essay on Flexible Manufacturing System (FMS) Communications
  11. Essay on the Intelligent Control of Flexible Manufacturing System
  12. Essay on the Limitations of Flexible Manufacturing System (FMS)

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Essay # 1. Definition of Flexible Manufacturing System (FMS):

Flexible Manufacturing System (FMS) could be defined as a set of machines in which parts are automatically transported under computer control from one machine to another for processing. Flexibility refers to the ability to respond effectively to changing circumstances. A flexible system is one which is able to respond to change.

A flexible manufacturing system (FMS) should be capable of coping with both external changes (i.e. changes in the type, mix, processing requirements and quantity of job allocated to the system, changes in the training and skill of operators assigned to the system), as well as internal changes or disturbances (i.e. machine and material handling system breakdowns, variability in processing time, operator absences, quality problems, etc.).

Essay # 2. Characteristics of Flexible Manufacturing System (FMS):

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1. A major portion of the output of the engineering sector involves batch production and flexible manufacturing system (FMS) offers immense cost and quality benefits for such requirements.

2. A batch production with conventional machine tools calls for some minimum number of similar components to be produced to distribute the cost of setting up machines and tools and thus be economical. For flexible manufacturing system (FMS), minimum batch of a given type of components can be one even.

Thus there is no need of locking up the money in extensive stocks of finished parts due to production of a minimum batch of components in order to be economical. The work-in- progress is reduced considerably.

3. It is possible to produce at random all the variants and series of a product planned to be manufactured by a firm.

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4. Flexible manufacturing system (FMS) has the capability to quickly respond to any design changes in the product. It has inherent flexibility to cater to new models of the product in pipeline without major modification.

5. Flexible manufacturing system (FMS) utilises several machining centres arranged one after the other with robots and proper automatic material handling equipment. Software is developed to integrate the machine CNC control and the handling system. Each machining centre is equipped with several tool magazines. All the tools required to complete each operation on each model of the product can be stored in the magazine.

6. All the part programs for the different models are stored in the memory. System has only to identify the model of the product presented to a machine in order to complete the machining operations. Thus it is possible to have totally random mixes of models of a product proceeding down the line at any one time.

7. The system can be conceived in multiples of 15-20 minutes operations. If certain operations take longer, then multiples of similar machines can be installed in the line. Sometimes identical machines are introduced for each operation so that production can continue even if one machine goes down.

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8. Components are loaded on to a pallet. Means are provided to identify the exact model. Loaded pallets enter the line and wait at the start of the line until a signal that one of the first operation machines is vacant is obtained. The handling system automatically directs the pallet to the first vacant machine for first operation. The pallets are loaded on a fixture.

The fixture is designed so that it permits access to all four sides and end faces and wherever machining operation is required. The pallets are designed to have windows where access for machining is required. As the pallet enters the machining area, air blast first clears both the fixture and pallet locations. The fixture is then properly clamped and supported. Touch trigger probes are used to check its location in the pallet.

Probes also identify the exact model of the component and signals from the probes activate master calling program which selects the appropriate part program and sub-routines from the control memory.

An overhead cascade coolant wash is provided to clear away swarf before the pallet is located. All coolant and swarf is carried away via underground ducts to a central separation and coolant filteration plant.

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9. After the first operation is completed, a tool in the spindle pushes in one of the coding pins and proximity switches in the line can then identify this as a first operation completed pallet. This pallet is then directed to second machine for second operation. If all the second machines are loaded this pallet may have to wait for some-time.

10. At the end of the line the pallet is unloaded and returned via an overhead conveyor that runs above the centre track, to the start of the line.

11. To minimise operator intervention in the line, extensive use of touch trigger probes is made.

12. In flexible manufacturing systems (FMS), industrial robots can be used for material handling (loading/unloading), inspection activities, and assembly operation.

Essay # 3. Need for Flexible Manufacturing System (FMS):

In today’s competitive global market, manufacturers have to modify their operations to ensure a better and faster response to needs of customers, ever higher quality of products, and increased flexibility and faster response in introduction of new products to respond to the needs of market place. The conventional manufacturing relied on economies of scale. In such systems, change can’t be tolerated as it leads to loss in production.

In the present new manufacturing environment, the stress is on small batch manufacturing, larger product variety, production on demand with low lend times, and to be agile all the time. FMS system and CIM systems provide answer for changing needs. The use of computers in manufacturing has advanced the flexibility of manufacturing environments.

The computerised FMS would gain popularity but it is important that cost to develop, implement and maintain such system should be lowered so that their use is not restricted for large volumes only. Greater flexibility is needed in system so that changes due to smaller sizes can be easily taken care of.

The necessity in today’s environment is for open architecture with well-defined modules and application interfaces so that different functional modules can work together with other modules in an integrated manner.

Further keeping the requirement for accommodating frequent changes, both hardware and software would need to be designed with their reuse in mind. The need for reconfiguration can be met by moduler system that can be easily put together and taken apart and reused when need to reconfigure arises.

Essay # 4. Requirements for Flexible Manufacturing Systems:

On the other hand the transfer line is very productive but is suitable for one or two component types. The flexible manufacturing systems provide compromise for above two cases. The FMS not only improves productivity but also provides the required flexibility enabling the factories to become more reactive to market demands.

The various requirements for FMS are:

(i) Competitiveness/quality.

(ii) Trend towards smaller orders.

(iii) Reduction in stocks.

(iv) Greater variety of products and product versions.

(v) Better utilisation of resources.

(vi) Shorter throughput times from receipt of the order to delivery.

(vii) Shorter reaction times to market shifts.

For best results in factories, it is not sufficient only to automate the local environment of the machine tools, but also to automate the global environment which comprises the following main activities:

(i) Management and provision of resources.

(ii) Preparation and transport of work pieces.

(iii) Supply and evaluation of production data.

(iv) Inspection of work pieces and machine tools.

True flexibility is achieved when a computer is applied to control the above mentioned global environment of production.

Essay # 5. Development of Flexible Manufacturing System (FMS):

Flexible Manufacturing System (FMS) has been developed to provide some of the economies of mass production to small batch manufacturing. It has brought about radical changes in manufacturing.

Flexible Manufacturing System (FMS) could be considered integration of three areas, viz.:

(i) Flexible Manufacturing Module (FMM) which can be lathe with a robot,

(ii) Flexible Manufacturing Cell (FMC) which can be two or more machines tied together by a robotic system to manufacture group of designated parts, or a parts mix, and

(iii) FMS which is characterised by part movement from a loading station, through four, five, six or seven machines and to unloading station where a part emerges as a complete unit.

Thus, the flexibility in FMS is brought about by linking together the potentially independent NC machine tools, assembly machines, inspection machines, storage, transportation and orientation systems for parts and tooling’s resulting in an overall computer control system that coordinates all the functions.

FMS’s are essentially automated job shops but the problems associated with job shops, viz. dispatching work station assignment, load levelling and capacity utilisation, task sequencing etc. are automated and even human decisions are taken by computer.

In many machining operations, the machine tool works only for a short time and major time is spent in arranging for proper fixture; to hold the part, tools, and deciding the machining parameters, moving the part to the machine and properly position and set up; removing the part after machining to the next station etc.

FMS would automate all the above operations through direct numeric control of the machines (DNC), an automated material handling subsystem (MHS) which moves the parts about FMS on pallet, and computer algorithms which control both the DNC and MHS functions and also the management functions. DNC stores part program and uses them to drive the machine tools.

It is essential that FMS should incorporate features like adaptive feed-rate controls, tool breakage detectors, and tool life monitoring systems. The system should be capable of handling a variety of parts in an efficient way.

Such system is best suited where production has to be exactly to suit demand and there is no scope to warehouse the parts produced. The same machine should be able to produce several types of components over a period of month across the spindle at the same time keeping the set up times economical enough.

Flexible Manufacturing Systems (FMS) include automatic machine loading and transfer of in-process parts, from initial setup through all process steps, to maximise utilisation of every machining spindle.

Flexible manufacturing systems (FMS) typically provide:

(а) Concurrent manufacture of a wide range of part configuration, i.e., processes simultaneously a variety of work pieces in any order on any machine.

(b) The discipline of transfer line technology with the flexibility of CNC.

(c) The totally integrated process, starting with raw parts through finished parts ready for stocking.

(d) Output rate changes and random part mix to meet changing production schedules.

(e) A major reduction in or elimination of set up interference with machine production time.

(f) A throughput process, with major reductions of in- process inventory, lead time, and part handling.

In brief, FMS is an integrated system of computer controlled machine tools and other work stations with an automated flow of information, work pieces, tools, etc. These systems consist of machine tools and a material handling system in which normal operation is under computer control.

The control of FMS is achieved through computer implemented algorithms which make all the operational decisions. The complete system is so arranged that the automated production of a group of complex work pieces in any lot size, particularly small and medium batch is possible.

Such systems are usually complex and dynamic. The planning of such manufacturing system is usually highly complex and is the most important aspect for its success. The FMS is usually planned by simulation techniques, in which a model (an idealised representation of the components, inter­relations, and characteristics of real life system) is drawn. The analysis of model behaviour shows ways for improving the system by carrying out necessary changes.

FMS offers the advantages of reduction of cost per part, reduction of throughput times, and increasing flexibility towards changes of the product mix, reduced inventory and lead times, and increased productivity. One biggest drawback of this system is the unknown availability and reliability of the planned system.

Essay # 6. Advances in Flexible Manufacturing System (FMS):

Following developments in FMS technology will greatly revolutionaries and dramatically boost the capabilities of manufacturing systems:

(i) Laser checking for part location.

(ii) Special computerised tool setting station.

(iii) Establishment to tool information like tool lengths, offsets, etc. by LVDT (linear variable displacement trans­ducer).

(iv) Automatic tool changers.

(v) Tracking of tool life by tool control computers.

(vi) Tool compensation system and adaptive control.

(vii) Spindle probes to check work piece features like bore diameter, hole pattern location.

(viii) Laser and fibre optics technology to check bore diameters and part surface location.

(ix) Increased use of robots.

(x) Improved software.

(xi) Fault analysis (vision-system for on-line quality control).

(xii) Swarf and coolant control.

(xiii) Machine tool structure design.

(xiv) Work piece transport system.

(xv) Computerised simulation to establish efficiencies and programming facilities.

Essay # 7. Decision Making in Flexible Manufacturing System (FMS):

In view of complexity of FMS operations decision making is done at three levels:

(i) Long term decision making (month/year). These decisions are taken by upper management level and include strategic decisions (allocation of new part, addition of new machining centre, changing layout of material handling system), performance evaluation, ancillary support like preparation of part programmes for a new part.

(ii) Medium term decision making (days/weeks). Such decisions are taken at supervisor level and include dividing overall production targets into batches of parts, assigning system resources within each batch so as to achieve maximum resource utilisation, and responding to changes in upper level production plans or material availability.

(iii) Short-Term decision making (minute/hours). These decisions are taken by computers and include—which part to be taken up, allocation of machine and sequence of operation, tool management, system monitoring and diagnostics, reacting to disruptions.

Essay # 8. Problems in Implementing Flexible Manufacturing System (FMS):

Before adoption of FMS, one should consider the following problem areas:

(i) How does the FHS fit into the company’s long term manufacturing and marketing strategy ?

(ii) How the investment in FMS be justified ?

(iii) How the design and operation of the system be optimised ?

(iv) How the risks and costs associated with the development of control software be minimised ?

(v) How the multiple vendor’s devices be interfaced into one integrated system ?

(vi) How the components and process will be selected ?

It is important to find solution to these problems and probably the use of following technologies will be of great assistance:

(i) Computer simulation.

(ii) Group technology.

(iii) Broad-Based long term planning.

(iv) Integration of devices.

(v) Control software.

Transport Mechanisms:

An FMS can be considered to consist of a portfolio or processing machines, a means for physical transport, a communication system, and a control system.

Essay # 9. Areas of Flexible Manufacturing System (FMS):

The set of software procedure forming FMS control system generally cover following three areas:

I. Production Scheduling:

It handles the following problems:

(i) Part mix problem, comprising:

(a) Part type selection and

(b) Mix ratio selection.

(ii) Part flow problem, comprising:

(a) Part loading in an empty system,

(b) Part loading in a working system,

(c) Part loading between work stations (operations sequencing)

(iii) Process selection problems, i.e. the selection of alternative routes for manufacture of a work piece.

II. Process Planning:

It handles following problems:

(i) Part routing for each work piece, comprising:

(a) Number of clamping positions,

(b) Fixtures required, and

(c) Machines used (workstations), taking into account possible alternative routing.

(ii) Workstation configuration, comprising:

(a) Tools required and

(b) Part programs for the NC unit of the work station.

III. Real-Time process control and monitoring:

It handles following tasks:

(i) Interface with the production scheduling and process planning sections, whose activities are typically asynchronous.

(ii) FMS process control, comprising:

(a) Device status monitoring,

(b) Transfer of control programs to work station,

(c) Control of FMS subsystems,

(d) Overall supervisory system control.

(iii) System monitoring to allow for compilation of:

(a) Technical reports,

(b) Management reports (quality control),

(c) Accounting reports, and

(d) Diagnoses.

Essay # 10. Flexible Manufacturing System (FMS) Communications:

The main purpose of all FMS communications systems is to fulfil the following three requirements:

(i) To enable files to be sent and received from the devices within the FMS (part, programs, tool offset tables, robot parameter files, PLC recipes, etc.)

(ii) To carry control instructions to the devices (cycle start, enable optional stops, etc.)

(iii) To carry status information from the devices (device busy, device idle, alarm, etc.)

The main problem with FMS communications is with regard to the interfacing of many manufacturers device control equipment into one integrated system. The developing of Manufacturing Automation Protocol (MAP) will however resolve this problem because then every manufacturer will be following one identical, i.e. MAP protocol.

MAP standardised communications is based on the full (Open Systems Interconnection) OSI seven layer model. This is an established model which identifies generic communication requirements and provides a uniform nomenclature, thus facilitating comparison.

However the development and adoption of all the seven layers is found to result in quite complicated and expensive communication system. Thus alternative approaches to full MAP, frequently called MAP subnet (which of course are less generic but cheaper to implement and high in performance) are being developed.

The seven layers of the OSI model of MAP are as follows:

Sevel Layers of the OSI Model of MAP

Essay # 11. Intelligent Control of Flexible Manufacturing System (FMS):

Flexible manufacturing system (FMS) in addition to normal working may be required to handle events like failure of a robot or machine tool, and several normal events like completion of processing by a machine, downloading of a part program, etc.

FMS can thus be considered as a discrete event dynamical system and can be modelled using advanced techniques, queuing networks, Petri-net models, (to establish freedom from deadlocks in the system), discrete event simulation, perturbation analysis, and min-max algebra. Use can also be made of modelling techniques, operations research and artificial intelligence to control the different work cells based on the data acquired.

Intelligent control system of FMS incorporates following features:

(i) Receiving communication about failures and disruptions and decide suitably the further course of action after interaction at all levels.

(ii) Tool management.

(iii) Formulating plans for decision making at all levels, assisted by decision support systems.

(iv) Executing plans (task with structured environment).

(v) Reliability and availability studies in FMS System.

(vi) Monitoring and fault diagnostic system to draw attention of operator.

Essay # 12. Limitations of Flexible Manufacturing System (FMS):

The limitations of FMS are:

(i) High cost of programming,

(ii) Less degree of sophistication of fabrication,

(iii) Assembly processes,

(iv)Non-Availability of reliable feedback devices for tool wear,

(v) Breakage.

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