Manufacturing Systems
Manufacturing systems are broadly classified based on
production volume, product variety, and flexibility.
Conventional systems: Job shop, batch, mass, continuous.
Modern/advanced systems:
Cellular manufacturing,
Flexible Manufacturing System (FMS), and finally
CIM.
Evolution of Manufacturing Systems
Era
Early Mass Production
1920s- (Ford Assembly Line)
Straight-line layout, manual
labor, very high volume, low
variety
1960s-Modern Mass
Production (Electronics
Line)
Straight-line, human +
machine, precision work,
high volume
Evolution of Manufacturing Systems
1990s- Automated Mass
Production (Automobile
Robots – Industry 4.0)
IoT-enabled, still low variety,
Highly efficient, Automated.
1960-70s-Group
Technology (Cellular
Manufacturing)
Machines grouped by part
families, medium volume &
variety, flexible, reduced
lead time
Lean U-Cell Implementation
Cellular manufacturing
• Cellular Manufacturing: An advanced production method in which machines are
grouped into cells to process a family of similar parts (based on shape, processing
requirements, or function).
• Each cell is like a “mini factory” dedicated to part families.
• These mini factories or cells organize similar workers and equipment close
together. This creates less travel time of products between departments.
• It is a key component of Lean Manufacturing and Group Technology (GT).
• GT = Identifying and grouping parts with similar design/manufacturing features.
• Cellular Manufacturing applies GT on the shop floor → machines are arranged
into cells to produce families of parts efficiently.
Common layouts in Cellular Manufacturing:
• Eliminates waste (WIP, setup time, transport).
•I-cell: Machines arranged in a straight line.
• Supports Just-In-Time (JIT) production. •U-cell: Machines in a U-shape (most popular in Lean).
•L-cell: Machines in an L-shape.
Depends on material flow, operator convenience, and available space.
Challenges / Limitations
Benefits of Cellular Manufacturing
• Reduced lead time. • Machine breakdown can stop the entire cell.
• Reduced material handling. • Balancing cells (equal load distribution) is
• Lower work-in-progress (WIP) inventory. difficult.
• Improved quality control. • Requires training & skilled workforce.
• Flexibility for product mix changes. • Initial implementation cost (cell redesign,
• Better worker involvement and ownership. coding system).
• Not always suitable for a very high variety &
very low volume.
Best suited
• Medium variety, medium volume production.
• Parts can be grouped into families.
• Not ideal for pure job shops (too much variety, low
repetition) or highly standardized mass production
(assembly lines better).
Flexible Manufacturing System (FMS)
• A Flexible Manufacturing System (FMS) is a computer-controlled manufacturing
system that can produce different products with minimal manual intervention,
while being able to adapt quickly to changes in product type, design, or production
volume.
• Batch Production and discrete part manufacturing. (can produce 50 engine blocks of
type A, then 30 of type B, using the same set of CNC machines.)
• It allows customization while maintaining efficiency. (Examples-Manufacturing gears,
shafts, or engine parts where each part is separate and countable.)
• Produces parts in batches.
• Manned GT cells to automated cells requires FMS.
• Part similarities in terms of design and manufacturing allow them to be processed on the
FMS workstations.
• Parts and products are in mid-volume, mid-variety production range.
Flexible Manufacturing System
• A highly automated GT machine cell,
consisting of a group of processing stations
(usually CNC machine tools),
interconnected by an automated material
handling and storage system, and controlled
by a central integrated computer system.
• The FMS relies on the principles of GT.
• No manufacturing system can produce an
unlimited range of products.
• An FMS is capable of producing a single
part family or a limited range of part
families.
Flexibility Tests in an Automated Manufacturing System
To qualify as being flexible, a manufacturing system should satisfy the following
criteria ("yes" answer for each question):
1. Can it process different part styles in a non-batch mode?
2. Can it accept changes in the production schedule?
3. Can it respond gracefully to equipment malfunctions and breakdowns?
4. Can it accommodate the introduction of new part designs?
Types of FMS
Kinds of operations: Number of machines (workstations):
• Processing vs. assembly • Single machine cell (n=1)
• Type of processing- rotational vs. non- • Flexible manufacturing cell (n=2 or 3)
rotational • Flexible manufacturing system (n=4 or
more)
Single Machine Manufacturing Cell
Flexible Manufacturing Cell
Flexible Manufacturing System
CIM
CIM = integration of the entire enterprise via computers.
• CIM is not a “type” of manufacturing system like FMS or mass production.
• It is an integration strategy: using computers to control all functions of
manufacturing — design (CAD), planning (CAPP), production (CAM, CNC,
robots, FMS), quality (CAQC), and management (ERP, MIS).
• CIM is a higher-level umbrella that can include FMS as a subsystem.
• CD/DVD factory layout (FMS) can be part of a CIM environment if it is
connected with CAD design, automated scheduling, quality control, and ERP.
Machine tools and related equipment
• Machine Tools: Power-driven machines used to shape or form parts made of
metal, plastic, composites, or other materials.
• In Computer Integrated Manufacturing (CIM), machine tools are computer-
controlled (CNC/NC) and integrated with CAD, CAM, and material handling
systems.
• Related equipment includes fixtures, tooling, inspection devices, robots, and
automated handling systems.
Classification of Machine Tools
Conventional Machine Tools
Lathe, milling, drilling, grinding, shaping, boring, etc.
Numerical Control (NC) & CNC Machine Tools
Programmed instructions control motion.
CNC (Computer Numerical Control): Microprocessor-based control for precision,
flexibility, and automation.
Types: Turning centers (CNC lathes), CNC milling, EDM, Laser, Waterjet machines, etc.
Flexible Manufacturing Cells/Systems (FMC/FMS)
Multiple CNC machines + robotic handling + tool changers.
Advanced Machine Tools
Additive Manufacturing (3D printing, metal AM).
Hybrid Machines
Multi-axis (5-axis, 7-axis) CNC.
Key Elements of Machine Tools in CIM
Cutting Tools
CNC Machines
Carbide, ceramic, CBN, diamond tools for
Automatically execute programs (G-codes,
high-speed machining.
M-codes).
Tool life monitoring integrated with CNC.
Interfaced with CAD/CAM for direct
Robots
manufacturing.
Used for loading/unloading, assembly,
Automatic Tool Changers (ATC)
welding, and inspection.
Enable multiple operations without manual
Integrated as part of related equipment in
intervention.
CIM.
Reduce setup time, improve flexibility.
Inspection Devices
Pallet Changers & Fixtures
On-machine probes, sensors.
Quick setup for batch jobs.
Coordinate Measuring Machines (CMM).
Allow unattended “lights-out” machining.
Non-contact laser/vision systems.
Rapid Manufacturing 3D printing/additive
manufacturing is the
Rapid manufacturing is defined as “the use of computer-aided process, and rapid
design-based automated additive manufacturing process to construct prototyping is the end
parts that are used directly as finished products or components.” result. Rapid
prototyping is one of
many applications
under the 3D
printing/additive
manufacturing
umbrella.
APPLICATION AREA OF AM: Complexity
APPLICATION AREA OF AM: Building
APPLICATION AREA OF AM : Medical