Group Members

Sana Ch 61
M.Imran Sharif 76
Marina Sabir 57
Umair Riaz 99
M.Rehman Azmat 79
 Flexible
Manufacturing
System
 What is FMS

A flexible manufacturing system is a automated machine cell,

consisting of a group of processing workstations, interconnected
with automated material handling and storage system.
 What makes it flexible
Three capabilities that a manufacturing system must possess to
be a flexible.

1. The ability to identify and distinguish among the different

part styles processed by the system.

2. Quick change over of operating instructions.

3. Quick change over of physical setup.

 Classification of FMS…

Flexible manufacturing systems can be distinguished according to

the number of machines in the system. The following are typical
categories:

 Single machine cell

 Flexible manufacturing cell
 Single Machine Cell (SMC)

A single machine cell consists of one CNC machining

center combined with a parts storage system for
unattended operation.
 Flexible Manufacturing Cell (FMC)

A flexible manufacturing cell consists of two or three

processing workstations (typically CNC machining
centers) plus a part handling system
 FMS
A flexible manufacturing system has four or more processing
workstations connected mechanically by a common part handling
system and electronically by a distributed computer system.
 Advantages of FMS
Reduce time for product completion.

Produce a variety of Items under one roof.

Improve product quality.

Serve a variety of vendors simultaneously.

Produce more product more quickly.

 Disadvantages of FMS
Expensive.

FMS is a complex system.

Requires highly skilled technicians.

Needs high level of planning.

Demands high initial investment.

 Material Resource Planning
MRP is a production planning, scheduling, and inventory
control system used to manage manufacturing processes.
 MPS is the plan that a company has developed for
production, inventory, staffing, etc.
 MRP is a mean for determining the number of parts,
components, and materials needed to produce a product.
 MRP is a planning technique which converts master
production schedule of end products into detailed schedule
for raw materials and parts used in those end products.
 Master Production Schedule
Based on actual customers orders and predicted demand.
Indicates when each ordered item will be produced in coming
weeks, and in how much quantity.
MPS inputs comes from sales and marketing.
 BILL OF MATERIALS (BOM)

o A listing of all of the raw materials, parts, subassemblies, and

assemblies needed to produce one unit of a product .
o A BOM explains what to buy, how to buy and where to buy, and
includes instructions for how to assemble the product.
o A BOM may be used for communication between manufacturing
partners.
 Inventory Status File

Inventory status file keeps an up-to-date record of each item in

the inventory. Information such as, item identification number,
quantity on hand and safety stock level is recorded in this file.
 Functions of MRP
The basic functions of an MRP system include:

 Inventory control, bill of material processing, and elementary scheduling.

 MRP helps organizations to maintain low inventory levels.

 Companies need to control the types and quantities of materials they purchase,
plan which products are to be produced and in what quantities and ensure that
they are able to meet current and future customer demand, all at the lowest
possible cost.
 Advantages of MRP
 Keep inventory levels to a minimum.

 Keeps track of inventory that is used.

 Tracks the amount of material that is required.

 Set safety stock levels for emergencies.

 Plan for future needs of raw materials or components.

 Disadvantages of MRP

 Inaccurate information can result in miss-planning , overstock,

under-stock, or lack of appropriate resources.

 The inaccurate master schedule will provide wrong lengths of

time for production . Hence affecting planning.

 MRP systems can be costly and time-consuming to set up.

JITMANUFACTURING
 WHAT IS JIT
A highly coordinated processing system in which goods move
through the system, and services are performed, just as they
need.

Just-in-time (JIT) is an inventory strategy companies

employ to increase efficiency and decrease waste by receiving
goods only as they are needed in the production process.
 HISTORY

 Evolved in Japan after World War II, as a result of their

diminishing market share in the auto industry.

 Founded by Taiichi Ohno, a vice president of Toyota.

 Basically implemented in Toyota plant 1950, well

established after 1970.
 Functioning of JIT

 Involves keeping stock levels to a minimum.

 Stock arrives just in time to be used in production.
 Works best where there is a close relationship between
manufacturer and suppliers.
 Goods not produced unless firm has an order from a customer.
 Aims to get highest volume of output at the lowest unit cost.
 PULL TYPE SYSTEM
JIT IS based on pull type production control.
In the pull system production orders begin upon inventory reaching a
certain level
 Toyota uses kanban pull system.
 Kanban means signal card.
 A kanban is a visual signal that lets workers know that a supply of a
material needs to be replenished.
 ADVANTAGES OF JIT
 High quality
 Flexibility
 Reduced setup times
 Reduced need for indirect labor
 Less waste
 Low warehouse cost
 Synchronization between production
scheduling and work hour.
 DISADVANTAGES OF JIT
Time consuming

 No spare product to meet un expected order

 Supply Shock : If products do not reach on time

 High risk factor

High dependence on suppliers.