1. Flexible Manufacturing Systems
Principles of EngineeringTM
Lesson 4.5 – Control Systems
Forging new generations of engineers
Project Lead The Way, Inc.
Copyright 2007

2. Flexible Manufacturing Systems
Principles of EngineeringTM
Lesson 4.5 – Control Systems
Flexible Manufacturing Systems
Introduction to FMS/FAS
Project Lead The Way, Inc.
Copyright 2007

3. Conventional Manufacturing
Consisted of 2 varieties
Job Shop type systems were capable of large variety of product, but at a high cost.
Transfer lines could produce large volumes of a product at a reasonable cost, but were limited to the production of one, two, or very few different parts.
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4. Flexible Manufacturing Systems (0617-850)
What is FMS/FAS?
A FMS/FAS is one manufacturing machine, or multiple machines that are integrated by an automated material handling system, whose operation is managed by a computerized control system. An FMS can be reconfigured by computer control to manufacture various products.
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5. Flexible Manufacturing Systems (0617-850)
What is CIM?
CIM is the integration of the total manufacturing enterprise through the use of integrated systems and data communications coupled with new managerial philosophies that improve organizational and personal efficiency.
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6. What is a manufacturing Cell?
A manufacturing cell usually consists of two or three processing workstations (typically CNC Machining or turning centers) plus a part handling system.
The following two slides contain a CAD layout and picture of the RIT Mfg Eng Tech Class of 2000’s manufacturing work cell.
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7. Manufacturing Workcell (CAD)
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8. Manufacturing Workcell
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9. Manufacturing Cells VS FMS
A FMS/FAS is a manufacturing cell, but a cell is not necessarily a FMS/FAS
A FMS/FAS is a complete system that runs automatically
A manufacturing cell has some or most of the components of a FMS/FAS, but not all of them.
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10. Flexible Manufacturing Systems (0617-850)
History of FMS
1950’s NC machines first appear
1960’s Computers appear in industry
Later 1960’s Flexible Manufacturing Systems first appeared in the U.S.A. at companies like Ingersoll-Rand, Caterpillar, John Deere, and General Electric Co.
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11. Volume Vs Variety

12. Flexibility in a FMS/FAS
Machine flexibility
Production flexibility
Mix flexibility
Product flexibility
Routing flexibility
Volume flexibility
Expansion flexibility
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13. Components of an FMS/FAS
Workstations
Material handling and storage system
Computer control system
People to manage and operate the system
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14. Flexible Manufacturing Systems (0617-850)
Types of Workstations
Load/unload Stations
Machining Stations
Other Processing Stations
Assembly
Other Stations and Equipment (like Inspection)
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15. Layout Configurations for Material Handling System
In-line layout
In-line Transfer
Conveyor
Rail guided vehicle
Loop layout
Conveyor system
In-Floor towline carts
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16. Flexible Manufacturing Systems (0617-850)
Layouts Continued
Ladder layout
Conveyor System
Automated Guided Vehicle (AGV)
Rail guided Vehicle
Open field layout
AGV
In-line towline carts
Robot-centered layout
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17. Computer Control Systems
Workstation
Distribution of control instructions to workstations
Production control
Traffic control
Shuttle control
Workpiece monitoring
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18. Computer Controls (cont)
Tool control
Tool locations
Tool life monitoring
Performance monitoring and reporting
Diagnostics
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19. Why Implement a FMS/FAS?
Increased machine utilization
Fewer machines required
Reduction in factory floor space required
Greater responsiveness to change
Reduced inventory requirements
Lower manufacturing lead times
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20. Why Implement a FMS/FAS? (continued)
Reduced direct labor requirements and higher labor productivity
Opportunity for unattended production
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21. FMS Implementation Issues
Part family considerations
Processing requirements
Physical characteristics or workparts
Production volume
Scheduling and dispatching
Machine loading
Part routing
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22. Flexible Manufacturing Systems (0617-850)
FMS Issues (cont)
Part grouping
Tool management
Pallet and fixture allocation
Requires management commitment and planning
Major invest of time and money
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