The flexible manufacturing system can produce many products without any issues. It also responds smoothly to changing demands and needs. Businesses can manufacture a large number of products easily. The FMS can help in making all kinds of cars, gadgets, and more.
The FMS's ability to be flexible means a lot of cost savings and quicker production. This is a perfect combination for manufacturers.
Flexible Manufacturing System Definition
A flexible manufacturing system is a combination of electronic systems and machines. These machines are designed to adjust to different production levels. This means they can handle both low and high amounts of work. The flexibility of this system also allows the business to offer personalized services so that they meet each customer's requirements and needs.
What is FMS?
In today's fast-paced world, production managers need to be updated with the current market trends. A flexible manufacturing system is important to meet customer demands and make modern approaches.
Flexible Manufacturing Systems has a lot of machines working together or individually. This is connected by computers. They handle things such as:
- Unloading materials
- Making the product
- Testing materials
- Storing them for the next step
The FMS can also switch between making different products automatically. Nowadays, being flexible and automated is very important. This allows businesses to create unique items and stay competitive.
Objectives of FMS
The main goal of flexible manufacturing systems is to improve cost savings and productivity. This process is exactly like big amounts of production. But they should also be able to handle smaller production quantities.
The principle objectives of a flexible manufacturing system include the following components:
1. To enhance operational control by
- Reducing the amount of uncontrollable variables
- Reducing the reliance on human communication
- Providing instruments to identify and respond to changes in the manufacturing plans swiftly.
2. To implement the reduction of direct labor work by
- Eliminating operators from the machine site
- Ending reliance on highly trained machines (whose manufacturing abilities could be better applied to manufacturing engineering tasks).
- Introducing and supporting unsupervised or lightly monitored machining operations by acting as a catalyst.
3. To increase short-run responsiveness, which includes
- Engineering modifications
- Processing changes
- Machine downtime or unavailability
- Cutting tool failure
- Delayed material delivery
4. To improve long-run accommodations by more quickly and easily assimilating
- Changing product volumes
- New product additions and introductions
- Differentiation part mixes
- Increasing machine utilization by -
i. Eliminating machine setup Ii. Using automated features to replace manual interventions iii. Providing rapid transfer equipment to keep machines in the cutting cycle
- Reducing inventories by
i. Reducing lot sizes ii. Increasing the turnover of inventors iii. Providing the necessary manufacturing tools
Types of Flexible Manufacturing Systems
Flexible manufacturing systems have many types. They have been used everywhere in the world. These, along with their unique subdivisions, are mentioned below:
FMS based on Operation
Based on the different kinds of operations, the FMS can be divided further into five categories as follows:
- Progressive: This production includes machines that are set up in a line.
- Loop: This production includes machines that have materials moving in circles. This helps in transferring them to different stations.
- Ladder: This kind of operation includes stations that look like a ladder. Along with the materials moving forward from one 'leg' to another.
- Open Field: This operation includes the materials moving to various stations. With the layout being more open and moving in different directions. This supports more difficult and modern production.
- Robot-centered: This one involves the stations being controlled by robots. These robots are placed at specific spots to help feed the materials. They also help to transport them to different stations.
FMS based on Machine Numbers
- Single: This setup uses only one machine for production.
- Dual or Triple: This setup uses two or three machines. Plus loading as well as unloading workstations.
- Flexible Manufacturing: This setup uses a total of four or more machines. These connect to the main distribution system.
FMS based on Flexibility Level
- Random: This setup uses a modern system. It is capable of handling major changes in the making of different parts.
- Dedicated: This setup includes a fixed product design with a specific part arrangement feature.
- Engineered: When manufacturers need the same arrangement for every batch.
- Modular: This setup can be used to fit the flexibility needs accordingly by adding parts.
Benefits of Flexibility Manufacturing System
Like all systems, the Flexibility Manufacturing System has many attractive benefits. Among those, the most important ones are listed below:
- Less downtime
- Fewer workstations
- Reduced requirements for labor
- Decreased work-in-progress stock
- Enhanced production flexibility
- Minimized wastage of materials
- Swift changes in dies, stamping, and tools
Levels of Manufacturing Flexibility
Businesses nowadays face a lot of unstable market trends. This demands having a strong hold on global competition. Hence, having flexibility in manufacturing levels is very important. Especially for manufacturing firms to suit customer demands in high-quality production. The following are the three most prominent levels of flexibility management:
- Basic Flexibility
- Basic Flexibility includes the flexibility of material handling. This considers how simple it is to place and move a lot of pieces within the system.
- Operation flexibility- It involves using different sequences for different sections.
- Machine flexibility- focuses on the smooth working of different machines.
- Aggregate Flexibility
- Aggregate Flexibility is about how easily a system can grow over time.
- Processing flexibility- measures the system's ability to create various part types without configurations.
- Routing flexibility - counts how many ways a part can efficiently move through the system.
- Volume flexibility - checks how it can benefit the system at different production levels for existing parts.
- System Flexibility
System flexibility is an umbrella term and has the following types:
- Product flexibility - the variety of parts and components that can be produced in an arrangement with a minimal amount of setup.
- Process flexibility - the variety of component types that a system is capable of manufacturing without the need for extensive setup.
- Routing flexibility- a part's flexibility to take a different route through a system while still effectively completing a process plan.
- Volume flexibility- the ability of a system to run profitably at various columns of an existing part type.
- Expansion flexibility- the capacity to create and grow a system.
Process of Flexibility Manufacturing System
A Flexible Manufacturing System is a complete manufacturing setup controlled by large computers. It includes handling systems and transportation of materials to stations. All of this takes place through computer-controlled machines. The important components of a flexible manufacturing system are three essential systems for easy production - workstation systems, systems for storage and handling materials, as well as the central control computer. The processing of the FMS takes place in the following manner:
- The key elements work together in synchronization to create a smooth production process.
- At the middle of the system, processing stations are present. The stations are composed of automated CNC machines that are capable of precise and accurate work.
- The advanced machines in FMS handle many tasks with accuracy, reliability, and speed.
- This system connects with the processing stations. They are responsible for delivering materials when and where they are needed.
- The central control computer is responsible for controlling the entire operation.
It is a hi-tech unit that regulates the movement of machines and materials within the FMS flexible manufacturing System.
Limitations of Flexibility Manufacturing System
Alongside its many advantages, the application of a flexible manufacturing system has its limitations as well. Let us look below for reference.
1. Still Technology
In some cases, firms don't need to change their technology levels. This was shown by IBM's success with manual assembly when adopting FMS components.
2. Costly Investment
Higher maintenance, training, and energy costs are needed. Rapid technology changes may make capital equipment outdated faster.
3. Restricted Ability
Limited capacity for adapting to modifications in products or mixtures of products. For example, Different tools are needed for making various products. Sometimes, even tools that belong to the same group might not work well in a specific manufacturing system.
4. Weak Structure
Firms with weak infrastructure and fewer resources struggle with the flexibility of manufacturing system implementation.
5. Flexibility as Center
FMS is valuable for quick product changes and competition when cost or quality isn't the main concern.
6. Non-cooperating Workers
Workers might not want to work sometimes. Job replacement can stress the company's FMS installation.
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FAQs on Flexible Manufacturing System
1. What is a Flexible Manufacturing System?
FMS is a uniquely made manufacturing setup controlled by computers. It consists of the following:
- Automated machines
- Material handling systems
- A central control computer
2. How does the FMS work?
It uses computer-controlled machines and automatic material handling. It can produce a wide range of products. The central control computer controls the flow of materials. It also coordinates the movements of machines.
3. What are the benefits of implementing a Flexible Manufacturing System?
FMS offers numerous advantages that make it making it highly beneficial for businesses:
- Reduced downtime
- Increased production flexibility
- Minimised waste
- Improved quality control
- Enables cost savings
4. Is a Flexible Manufacturing System suitable for all types of products?
Yes. FMS is most effective for producing a family of parts with similar processing requirements. It's really good at handling these parts because it can adjust easily to their common manufacturing needs. This makes everything smoother and saves money, too.
5. How long does it take to set up a Flexible Manufacturing System?
Setting up a Flexible Manufacturing System (FMS) takes different amounts of time, depending on how complex and big the system is. Usually, making an FMS needs more time for designing and planning because it's a bit more involved.
6. Can a Flexible Manufacturing System handle different production volumes?
Yes, FMS is designed to handle various production volumes. It is capable of quickly adjusting to:
- High-mix production
- Low-volume productions
- Mass production.
