Flexible Manufacturing System

Early automation systems consisted of a transfer line, which was a fixed-path conveyor with single-purpose equipment installed on either side of it. The conveyor moved the parts to each workstation where the machines performed a predetermined task. This automation was economical only for those organizations, which were involved in the production of large volumes of a single product or similar products.

To overcome these inefficiencies, Flexible Manufacturing Systems (FMS) were introduced in production lines. FMS is a form of flexible automation in which several machine tools are linked to the material-handling system. A central computer controls all aspects of the system. This system is effective in producing different items that have similar processing requirements. Figure shows the layout of a typical FMS. The components that make up a typical FMS are:

• An automated loading system to load materials

• Two or more machining centers, which are automated to change tools by themselves

• A system to move materials in between machining centers

• An unloading system

• A central computer that integrates the whole process

Figure: Layout of a Typical FMS

In a flexible manufacturing system, the automated material handling equipment moves the requisite materials to the appropriate work-center.  Machines at these centers are pre-programmed to select, position and perform specific operations with many tool options. Once the machine processes a particular batch, the central computer signals the details of the next job and each machine repositions and retools accordingly. In the meantime, the processed parts are automatically transferred to the next machining center in its route. Different FMS layouts are possible, based on the production requirements. These layouts include progressive layout, closed loop layouts, ladder layout and open field layout.

In comparison with the traditional automated systems, the flexible manufacturing system offers many advantages such as reduced direct labor, shorter response time, consistent quality of products and better control over the manufacturing processes. However, these benefits do not come cheap. FMS requires huge capital investments in equipment, and planning and control systems. Hence, they are employed only by those production organizations in which all the products produced utilize similar components or different products manufactured are variations of the same basic design.              

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