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Hybrid Layouts

Hybrid Layouts. Flexible Manufacturing Systems (FMS). Flexible Manufacturing Systems. Manufacturing system that can produce a large variety of items Low quantity automated manufacturing Group of machines Capable of a variety of operations Integrated by an automatic transport facility

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Hybrid Layouts

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  1. Hybrid Layouts Flexible Manufacturing Systems (FMS)

  2. Flexible Manufacturing Systems • Manufacturing system that can produce a large variety of items • Low quantity automated manufacturing • Group of machines • Capable of a variety of operations • Integrated by an automatic transport facility • Automatic tool changing

  3. FMS The Beginning • Proposed in England 1960s: “System 24” • Automation vs. Reorganization • Early FMS • Large & Complex • Expensive • Unpractical

  4. FMS Current Trends • Smaller version of traditional FMS • As few as 2 CNC machines

  5. FMS In Depth • Mass production vs. Small batches • Machines • Capable of a variety of operations • Automatic transport facility • Automatic tool changing mechanisms • Built in sensing capabilities

  6. FMS Constraints • Variances • Task execution times • Undeterminable arrival times • Organization of multiple machines

  7. Hierarchical Production Scheduling Model

  8. Master Production Plan • Specifies the set of products to be manufactured • Considers worst case production times in order to guarantee requests • Conservative capacity analysis • No sequencing

  9. Production Flow Planner • Distributes subassembly requests • Requests material from storage • Handles feedback from scheduling level • Controls part routing • Monitors and adjust flow rates • Compensates for free time

  10. Workstation Scheduler • Distributed among workcells • Real time operation decisions • Available parts • Priority • Uncertainties handled through gained time of over conservative estimates • Feed back • Performance • Produced subassemblies • Gained time

  11. FMS Layouts

  12. Progressive FMS • Parts follow identical progression • Used for processing related parts

  13. Closed-loop FMS • Arranged in a general order • Used for a large variety of parts • Able to skip stations • Able to move around the loop in order to alternate sequence

  14. FMS Ladder Layout • Processed parts are not limited to part families • Parts can move through machines in any sequence

  15. Open Field Layout • Most complex FMS layout • Material is routed in any order • Typically includes support stations • Tool interchange • Pallet • Inspections • Chip/Coolant collection systems

  16. Mitsubishi • M-H4B Horizontal Machining Center • Minimum cycle time for job completion • Adaptive • Mass production • Design changes in mid-production • Quick automatic tool changer (ATC) • Simplistic programming centers • Machine Flexibility

  17. Mitsubishi • Flexible Mass Production System (FMPS) • Same workpiece production runs from 750-12,000 units/month • Runs 15 different workpiece families on same production line • ATC swaps tools in 1.33 sec. • 6 sec. pallet changes

  18. Mixed-Model Assembly Lines • Problem • Higher demand • Lower demand • Solutions • Sophisticated forecasting techniques • Mixed-Model Assembly Lines • Process more than one product model

  19. Important Factors • Line balancing • U-shaped lines • Flexible workforce • Model sequencing

  20. Line Balancing • Variances in model completion time • Average time from all models • Averages create periods of spare-time • (Flexible workforce)

  21. U-Shaped Lines • Workers assist other stations • Communication • Down time

  22. Flexible Workforce • Employees trained on multiple machines • Advantages • “Bottle Neck” can catch up • Different model use different machines • Helps line adapt to varied task lenghths

  23. Model Sequencing • Strategically ordering models sent through the line • Large runtime followed by shorter runtime • Uniform production

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