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

What is FMS ? What is the general field of FMS application?

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

An FMS is a totally automated manufacturing system that consists of machining centers with automated loading and unloading of parts, an automated guided vehicle system for moving parts between machines, and other automated elements to allow unattended production of parts. In a FMS, a comprehensive computer control system is used to run the entire system. A good example of an FMS is the Cincinnati Milacron facility in Mt. Grab, Ohio, which has been in operation for over 20 years. Exhibit SC.4 is a layout of this FMS. In this system, parts are loaded onto standardized fixtures (these are called ("risers"), which are mounted on pallets that can be moved by the AGVs. Workers load and unload tools and parts onto the standardized fixtures at the workstations. Most of this loading and unloading is done during a single shift. The system can operate virtually unattended for the other two shifts each day. Within the system there are areas for the storage of tools (area?) and for parts (areaS). This system is designed to machine large castings used in the production of the machine tools made by Cincinnati Milacron. The machining is done by the four CNC machining centers (areal). When the machining has been completed on a part, it is sent to the parts washing station (area 4) where it is cleaned. The part is then seen to the automated inspection station (area 6) for a quality check. The system is capable of producing hundreds of different parts.

Diagram exhibit SC.4.
Yes, the field of application is significant in terms of the potential market size for its capacity. The general field of applications are :
1: Although technological changes have occurred in almost every industry, many may be unique to an industry. For instance, a prestressed concrete block is a technological advance unique to the constructive industry. Major developments in the design of automobiles will result in cars that are made from recycle parts.
2: Some technological advances in recent decades have had a significant, widespread impact on manufacturing firms in many industries.
3: Hard ware technologies have generally resulted in greater automation of process; they perform labor-intensive tasks originally performed by humans, Example of these major types of hardware technologies are numerically controlled machine tools, maching centers, industrial robots, automated materials handling systems, and flexible manufacturing of systems. These are all computer- controlled devices that can be used in the manufacturing systems of products.
4: Software - based technologies aid in the design of manufacturing products and in the analysis and planning of manufacturing activities. These technologies include computer-aided design and automated manufacturing planning and control systems. And the reference to any production unit is:
Automated materials handling (AMH) system improve efficiency of transportation, storage, and retrieval of materials. Examples are computerized conveyers and automated storage and retrieval systems in which computers direct automatic loaders to pick and place items. Automated guided vehicle system use- embedded floor wires to direct driverless vehicles to various locations in the plant. Benefits of AMH systems include quicker material movement, lower inventories and storage space, reduced product damage, and higher labor productivity.