Fms m6uo

Content: Introduction  Component of F.M.S

Processing Station Material Handling Computer Control  Types of F.M.S Layout  Objectives of F.M.S

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

In manufacturing, flexibility meansThe Capability of Producing Different parts without

major retooling. A measure of how fast the company converts its process(es) From making an old line of product to produce a new product. The ability to change a production schedule ,to modify a part or to handle multiple parts. So a flexible manufacturing system is a manufacturing system in which there is some amount of flexibility that allows the system to react in the case of changes whether predicted or unpredicted.

Levels of Flexibilities:There are three levels of manufacturing flexibilities-

1.Basic Flexibilities Machine flexibility - the ease with which a machine can process various operations Material handling flexibility -a measure of the ease with which different part types can be transported and properly positioned at the various machine tools in a system Operation flexibility - a measure of the ease with which alternative operation sequences can be used for processing a part type

2. System Flexibilities Volume flexibility - a measure of a system’s capability to be operated profitably at different volumes of the existing part types Expansion flexibility - the ability to build a system and expand it incrementally Routing flexibility - a measure of the alternative paths that a part can effectively follow through a system for a given process plan Process flexibility - a measure of the volume of the set of part types that a system can produce without incurring any setup Product flexibility - the volume of the set of part types that can be manufactured in a system with minor setup

3. Aggregate flexibilities Program flexibility - the ability of a system to run for reasonably long periods without external intervention Production flexibility - the volume of the set of part types that a system can produce without major investment in capital equipment Market flexibility - the ability of a system to efficiently adapt to changing market conditions

Distinguishing An automatic materials handling subsystem links machines in the system and provides for Characteristics: automatic interchange of work pieces in each machine. Automatic continuous cycling of individual machines. Complete control of the manufacturing system by the host computer. Lightly manned, or possibly unmanned.

FMS Example:

Types of FMS: Based on the number of machines Based on the number of kinds

A) Based on the number of machines Flexible manufacturing systems can be distinguished according to the number of machines in the system. The following are typical categories:  Single machine cell (Type I A)  Flexible manufacturing cell (usually type II A,

sometimes type III A)  Flexible manufacturing system (usually Type II A, sometimes type III A) [email protected] (NIT Jalandhar)

Single Machine Cell (SMC)  A single machine cell consists of one CNC machining

center combined with a parts storage system for unattended operation.  Completed parts are periodically unloaded from the parts storage unit, and raw work parts are loaded into it

Flexible Manufacturing Cell (FMC)

 A flexible manufacturing cell consists of two or three

processing workstations (typically CNC machining centers) plus a part handling system.  The part handling system is connected to a load/unload station.

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Flexible Manufacturing System (FMS)

 A flexible manufacturing system has four or more

processing workstations connected mechanically by a common part handling system and electronically by a distributed computer system.

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B) Based on number of kinds  Sequential FMS  Random FMS  Dedicated FMS  Engineered FMS  Modular FMS

Sequential FMS: It manufactures one-piece part batch type and then planning and preparation is carried out for the next piece part batch type to be manufactured. It operates like a small batch flexible transfer line. Random FMS: It manufactures any random mix of piece part types at any one time. Dedicated FMS: It continually manufactures, for extended periods, the same but limited mix of piece part batch types. Engineered FMS: It manufactures the same mix of part types throughout its lifetime. Modular FMS: A modular FMS, with a sophisticated FMS host, enables and FMS to expand their FMS capabilities in a stepwise fashion into any of the previous four types of FMS.

Basic component of F.M.SWork stations or Processing Stations Automated material handling Computer control system

1. Workstations Workstations are typically computer numerical control (CNC) with machine flexibility. Following are the types of workstations typically found in an FMS: Load/Unload Stations. Machining Stations. Other processing Stations. (punching, shearing, welding, etc.) Assembly Station. Other Stations and Equipment. (Inspection, Vision, etc)

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

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

Machining Center

Indexing plate

Industrial Robots assembling the Car:-

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2. Material Handling and Storage System The various Automated material handling system are used to transport work parts and subassembly parts between the processing station . Functions of the Handling System  Independent movement of workparts between stations.  Handle a variety of workpart configurations.  Temporary storage.  Convenient access for loading and unloading workparts.  Compatible w ith computer control

Material Handling Equipment The material handling function in an FMS is often shared between two systems: Primary handling system establishes the basic layout of the FMS and is responsible for moving workparts between stations in the system. (Conveyor). Secondary handling system consists of transfer devices, automatic pallet changing, and similar mechanisms located at the workstations in the FMS. The function of the secondary handling system is to transfer work from the primary system to the machine tool or other processing station and to position the parts with sufficient accuracy and repeatability to perform the process or assembly operation.

Tow Type A.G.V:-

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Unit Load A.G.V:-

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3. Computer Control System It is used to co-ordinate the activities of processing station and material handling System in the F.M.S. A typical FMS computer system consists of a central computer and microcomputers.  Microcomputers controlling the individual machines and other components.  The central computer coordinates the activities of the components to achieve smooth overall operation of the system

The various function of computer control system are: Control of each work station.  Distribution of control instruction to work station.  Production control.  Traffic control.  Shuttle control.  Work handling system and monitoring.  System performance monitoring and reporting.

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

2. Loop Type: The basic loop configuration is as shown in Fig.. The parts usually move in one direction around the loop, with the capability to stop and be transferred to any station. The loading and unloading station are typically located at one end of the loop Fig. 3. Ladder Type: The configuration is as shown in Fig. The loading and unloading station is typically located at the same end. The sequence to the operation/transfer of parts from one machine tool to another is in the form of ladder steps as shown in Fig. [email protected] (NIT

Progressive type Type

Ladder type

Loop

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

Fig: Robot Centered cell

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