Define FMS. What is the general field of FMS application? Is the field of FMS application significant in terms of the potential market size for its capability? State with reference to any production unit.

Define FMS. What is the general field of FMS application? Is the field of FMS application significant in terms of the potential market size for its capability? State with reference to any production unit.

Answer. A flexible manufacturing system (FMS) is a manufacturing system in which there is some amount of flexibility which allows the system to react in the case of changes, whether predicted or unpredicted. This flexibility is generally considered to fall into two categories, within which are numerous other subcategories.

A Flexible Manufacturing System (FMS) consists of several machine tools along with part and tool handling devices such as robots, arranged so that it can handle any family of parts for which it has been designed and developed.

While variations abound in what specifically constitutes flexibility, there is a general consensus about the core elements. There are three levels of manufacturing flexibility.

(a) 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

(b) 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

(c) 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

Different FMSs levels are
• Flexible Manufacturing Module (FMM). Example : a NC machine, a pallet changer and a part buffer;
• Flexible Manufacturing (Assembly) Cell (F(M/A)C). Example : Four FMMs and an AGV(automated guided vehicle);
• Flexible Manufacturing Group (FMG). Example : Two FMCs, a FMM and two AGVs which will transport parts from a Part Loading area, through machines, to a Part Unloading Area;
• Flexible Production Systems (FPS). Example : A FMG and a FAC, two AGVs, an Automated Tool Storage, and an Automated Part/assembly Storage;
• Flexible Manufacturing Line (FML). Example : multiple stations in a line layout and AGVs.

FMS systems are intended to solve the following problems
• Production of families of workparts, often based on group technology
• Random launching of workparts into system is OK, because setup time is reduced with FMS.
• Reduced manufacturing lead time - this is possible because FMS has organization, and fast setup.
• Reduced work in process
• Increased machine utilization
• Reduced direct and indirect labor
• Better management control

The most common problems in an FMS are:
• Scheduled maintenance
• Scheduled tool changeovers
• Tooling problems (failures and adjustments)
• Electrical Failures
• Mechanical Problems (e.g., oil leaks)

ADVANTAGES AND DISADVANTAGES OF FMSS IMPLEMENTATION

Advantages
• Faster, lower- cost changes from one part to another which will improve capital utilization
• Lower direct labor cost, due to the reduction in number of workers
• Reduced inventory, due to the planning and programming precision
• Consistent and better quality, due to the automated control
• Lower cost/unit of output, due to the greater productivity using the same number of workers
• Savings from the indirect labor, from reduced errors, rework, repairs and rejects

Disadvantages
• Limited ability to adapt to changes in product or product mix (ex. machines are of limited capacity and the tooling necessary for products, even of the same family, is not always feasible in a given FMS)
• Substantial pre-planning activity
• Expensive, costing millions of dollars
• Technological problems of exact component positioning and precise timing necessary to process a component
• Sophisticated manufacturing systems