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Flexible Manufacturing Systems

Flexible Manufacturing Systems. Tom Foster Boise State University. Flexible Manufacturing Systems (FMS).

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Flexible Manufacturing Systems

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  1. Flexible Manufacturing Systems Tom Foster Boise State University

  2. Flexible Manufacturing Systems (FMS) • An FMS is a “reprogrammable” manufacturing system capable of producing a variety of products automatically. Conventional manufacturing systems have been marked by one of two distinct features: • The capability of producing a variety of different product types, but at a high cost (e.g., job shops). • The capability of producing large volumes of a product at a lower cost, but very inflexible in terms of the product types which can be produced (e.g., transfer lines). • An FMS is designed to provide both of these features.

  3. FMS Components • Numerical Control (NC) machine tools • Automated material handling system (AMHS) • Automated guided vehicles (AGV) • Conveyors • Automated storage and retrieval systems (AS/RS) • Industrial Robots • Control Software

  4. Flexible Manufacturing System Computer control room Tools Conveyor Machine Machine Pallet Load Unload Parts Finished goods Terminal

  5. Classification of FMS-related Problems • Strategic analysis and economic justification, which provides long-range, strategic business plans. • Facility design, in which strategic business plans are integrated into a specific facility design to accomplish long-term managerial objectives. • Intermediate-range planning, which encompasses decisions related to master production scheduling and deals with a planning horizon from several days to several months in duration. • Dynamic operations planning, which is concerned with the dynamic, minute-to-minute operations of FMS.

  6. FMS Problems • Part type selection (Askin) - selecting parts that will be produced in the FMS over some relatively long planning horizon. • Part selection (Stecke) - from the set of parts that have current production requirements and have been selected for processing in the FMS, select a subset for immediate and simultaneous processing. • Machine grouping (Stecke) - partition machines into groups where each machine in a group can perform the same set of operations. • Loading (Stecke) - allocate the operations and required tools of the selected part types among the machine groups. • Control - provide instructions for, and monitor the equipment in the FMS so that the production goals identified by the above problems are met.

  7. Information Technology • Management information system (MIS) • move large amounts of data • Decision support system (DSS) • add decision making support • Expert system • recommend decision based on expert knowledge

  8. Personnel Accounting Information: Computer Production reports system: Data model results Decisions data what if? processing Marketing analysis Distribution Other areas Quantitative techniques Decision Support System Management Decision Support System Management Information System What -if? analysis

  9. Artificial Intelligence • Neural networks • emulate interconnections in brain • Genetic algorithms • based on adaptive capabilities in nature • Fuzzy logic • simulate human ability to deal with ambiguity

  10. Advanced Communications • Electronic data interchange (EDI) • Internet • Wireless communications • Teleconferencing & telecommuting • Bar coding • Virtual reality

  11. Manufacturing Technology • Numerically controlled (NC) machines • controlled by punched tape • Computer numerical controlled (CNC) • controlled by attached computer • Direct numerical control (DNC) • several NC machines controlled by single computer

  12. Automated Material Handling • Conveyors • Automated guided vehicle (AGV) • Automated storage & retrieval system (ASRS)

  13. Flexible Manufacturing Systems (FMS) • Programmable machine tools • Controlled by common computer network • Combines flexibility with efficiency • Reduces setup & queue times

  14. Robotics • Programmable manipulators • Follow specified path • Better than humans with respect to • hostile environments • long hours • consistency

  15. Robot Parts • Controller • hardware, software, power source • Manipulator • robot arm • End-effector • “hand”

  16. Computer Integrated Manufacturing (CIM) • Integration of design, manufacture & delivery via computer technology • CAD - uses software to create & modify designs • CAM - uses programmable automation in manufacturing • CAE - links functional design to CAD form design • CAPP - creates processing instructions for CAM • GT- classifies designs to benefit from prior experience

  17. CAD CAE GT DFM IGES, PDES, DMIS TQM Product design CAD/CAM Bar codes, EDI CAPP MRP CIM Systems management Process planning JIT/ kanban Cellular manufacturing DSS/ES/ AI MAP, STEP Manufacture LAN, TOP, satellites NC/CNC/ DNC FMS Robotics AGV, ASRS Automated inspection Cells and centers Components Of CIM

  18. Adoption Of Technology • Technology Readiness • Need well-designed products & efficient processes • Technology Design • Know what to automate • Technology Selection • Choose the right level • Technology Integration • Have a strategy for incremental automation

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