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Different facilities are required for each of the three quantity ranges
Low Production:
Job shop is the term used for this type of production facility
Medium Production:
Batch production
Cellular manufacturing
High Production:
Quantity production
Quantity Production:
Typical layouts used in quantity production are process layout and cellular
layout
Product is complex
Work units are physically moved through the sequence to complete the
product
Cell Layout
Product Layout:
Group machines in a line to make a certain product - Assembly line
Ex-rim wheel manufacturer
Functional layout:
A company must organize itself to design the processes and equipment, plan
and control production, and satisfy product quality requirements
Typical departments:
1. Manufacturing engineering
2. Production planning and control
3. Quality control
Flexible Manufacturing:
Schedule production
Quality control (detect and reject defective work units produced by the
system)
Three cases:
1. Single-model case - all parts or products are identical (sufficient
demand/fixed automation)
2. Batch-model case - different parts or products are produced by the
system, but they are produced in batches because changeovers are
required (hard product variety)
3. Mixed-model case - different parts or products are produced by the
system, but the system can handle the differences without the need
for time-consuming changes in setup (soft product variety)
Enablers of Flexibility:
System must be able to change over the fixtures and tools required for
the next work unit in minimum time
Automation:
Flexibility:
Flexible Automation:
Fms
ManufacturersConsidera
tions (Maleki, 1991)
According to Hoeffer, the change in manufacturing over time was due to
several factors. (Hoeffer, 1986)
Short-term Changes
Engineering changes,
Processing changes,
For these benefits to work for the manufacture there are two characteristics
that the FMS should have. These are:
Equipment of FMS:
Primary equipment
work centers
Grinding machines
Process centers
Wash machines
Manual workstations
Secondary equipment
Support stations
Support equipment
Robots
Pallet/fixture/stillage stores
Tools stores
Transport system(AGVs,RGVs,robots)
Transport units(pallets/stillages)
Early FMSs were large and very complex, consisting of dozens of CNCs and
sophisticated material handling systems. They were very automated, very
expensive and controlled by incredibly complex software. There were only a
Currently, the trend in FMS is toward small versions of the traditional FMS,
called flexible manufacturing cells (FMC).
Today two or more CNC machines are considered a flexible cell and two
more more cells are considered a flexible manufacturing system.
The functions of the cell controller include work load balancing, part
scheduling, and material flow control.
In many applications, the cell robot also performs tool changing and
housekeeping functions such as chip removal, staging of tools in the tool
changer, and inspection of tools for breakage or expressive wear. When
necessary, the robot can also initiate emergency procedures such as system
shut-down.
FMS Goals:
Advantages of FMS:
Faster, lower- cost changes from one part to another which will improve
capital utilization
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
Application of FMS:
Metal-cutting machining
Metal forming
Assembly
Surface treatment
Inspection
Testing
A measure of how fast the company converts its process/es from making an
old line of products to produce a new product
Development of FMS:
Several actions must be decided on before you can have a have a FMS.
These actions include.
Example of a FMS:
FMS Layouts:
Progressive Layout:
Ladder Layout:
Parts can be sent to any machine in any sequence
Parts not limited to particular part families
Open Field Layout:
Most complex FMS layout