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Flexibility
The capability of the manufacturing system to

adapt successfully to changing environmental

conditions and process requirements.

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Definition of FMS

A flexible manufacturing system (FMS) is an

arrangement of machines.... interconnected by

a transport system. The transporter carries
work to the machines on pallets or other
interface units so that work-machine
registration is accurate, rapid and automatic. A
central computer controls both machines and
transport system...
It is a computer controlled process technology

suitable for producing a moderate variety of

products in moderate volumes.
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Characteristics of an FMS
All products are variations of a stable basic

design.
All products utilize the same family of
components.
The number of components is only moderate.
The volume of each component is moderate.

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Requirements for FMS with Automation

Machine Attachments
Computer Integrated Manufacturing (CIM)
Computer Aided Design (CAD)
Computer Aided Manufacturing (CAM)
Robotics and Robots
Group Technology
N/C Machines
Automated Quality Control Systems
Automatic Storage and Retrieval Systems (ASRS)
Automatic Identification Systems (AIS)
Automatic Assembly Systems
Automatic Process Control
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Machine Attachments
Attachments or inexpensive add-ons to machines

that reduce human effort and time required to

perform operations.
Eg: Magazine feed attachments, quick cutting and
grasping devices for lathes, strip feeders for
stamping machines etc.

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Numerically Controlled (N/C) Machines

Machines with control systems that read

instructions and translate them into machine

operations.
Eg: Lathes, boring mills, curing machines, weaving
machines etc.

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Robotics
Robot is a programmable machine that is capable

of moving materials and performing routine,

repetitive tasks which have manipulators and
possess human like physiological characteristics.
Robotics is the science of selecting Robots to
various applications.
Eg: Machines that weld, paint, assemble, inspect
for quality, grasp, transport and store.

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Automated QC Inspection
Automated machines that perform part or all of

the inspection process.

Eg: Electronic circuit checks, computer driven
function checks, weighting robots, flexible
inspection etc.

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Automatic Identification Systems (AIS)

Technologies used in automatic acquisition of

product data for entry into a computer.

Eg: Bar-Coding systems, inventory counting, data
entry for shop floor control etc.

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Automated Process Controls

Computer Systems that receive data on the

production process and send adjustments to

process settings.
Eg: Control Systems for rolling mills in
manufacturing etc.

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CAD/CAM
Computer Aided Design are the Computer

software programs that allow a designer to carry

out geometric transformations rapidly.
Computer Aided Manufacturing (CAM) are the
Manufacturing systems utilizing computer
software programs that control the actual machine
on the shop floor.

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Automated Storage and Retrieval Systems

ASRS are the systems meant for receiving orders

for materials from anywhere in operations,

collecting materials from locations within a
warehouse and delivering the materials to work
stations in operations.
Three major elements
Computer and communication Systems
Automated Material handling and Delivery

Systems
Storage and Retrieval Systems in warehouse
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Computer Integrated Manufacturing

Computer Information Systems utilizing a shared

manufacturing database for engineering design,

manufacturing engineering, factory production,
and information management.

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Group Technology
A way of organizing and using data for

components that have similar properties and

manufacturing requirements.
GT results in
Reduced item handling and movement times.
Reduced Change over times.
Reduced idle wait time of items at the machine.
Reduced work in process.

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Advantages
Increased output and enhanced productivity.
Improved and uniform quality.
Reduced cost.
Fewer accidents.
Better production control.
Lost Prerogatives gained.
Dangerous and unpleasant tasks.

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Advantages Contd
Reduced Inventories
Greater operating flexibility
Reduced lead time and scrap
Improved reliability
Design freedom

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Disadvantages
Heavy capital investment
Displacement of labour
Benefit of employee suggestion lost
Tighter specification may be needed
Costs of supply failure increases
Slack season would be disastrous
Dehumanization
Problems of developing countries

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Flexibility Without Automation

It is usually referred to as attaining the effect of
automation
without the expense
Preautomation
Modular Design
Standardization

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Preautomation
This attacks one of the Shingos 7 wastes, the

waste of processing itself.

It makes no sense in automating a stage of
production process when that stage adds no value
to the product.
Preautomation studies reveal unneeded
equipment and activities that can be eliminated
rather than automated.

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Modular Design:

The creation of products from some

combination of basic, preexisting subsystems.
Standardization:

Use of uniform standardized components in the

products. Eg: screws, spark plugs, nuts & bolts
etc.

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Industrial Examples
The General Motors Fairfax plant in Kansas city,

Missouri, produces Pontiac Grand Prixs.

Earlier, for producing cars with different colours it
took time for shutting down the painting area so
that it could be cleared of dust and scrubbed.
Today GM has reduced the production line delays
by using Technologies such as airtight chambers
and high powdered vacuum suctions.

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Industrial Examples Contd

General Motors, in a joint venture with Toyota at

the NUMMI (New United Motors Manufacturing

Inc.) plant outside San Francisco.
NUMMI has installed a new press line with
Exchange of die techniques like IED, OED, SMED
and OTED.
It has reduced the time taken for die exchange
from hours/days to minutes.

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Conclusion
Factories of the future will have stress on high
product quality, greater emphasis on flexibility,
fast delivery of customer orders, extensive use of
CAD/CAM for product design, structural changes
etc.
To fulfill all these requirements Flexible
Manufacturing Systems (FMS) has to play a very
important role

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