FMS
Vimal KEK
Types of Layout
The layout of the FMS is established
by the material handling system
Five basic types of FMS layouts
In-line
Loop
Ladder
Open field
Robot-centered cell
Inline Layout
Loop Layout
One direction flow, but variations in processing
sequence possible for different part types
Secondary handling system at each
workstation
Rectangular Layout
Rectangular
layout
allows
recirculation of pallets back to the first
station
in
the
sequence
after
unloading at the final station
FMS Ladder Layout
Loop with rungs to allow greater
variation in processing sequence
FMS Open Field Layout
FMS Computer Functions
Workstation control
Individual stations require controls, usually
computerized
Distribution of control instructions to
workstations
Central intelligence required to coordinate
processing at individual stations
Production control
Product mix, machine scheduling, and other
planning functions
FMS Computer Functions
Traffic control
Management of the primary handling
system to move parts between workstations
Shuttle control
Coordination of secondary handling system
with primary handling system
Workpiece monitoring
Monitoring the status of each part in the
system
FMS Computer Functions
Tool control
Tool location
Keeping track of each tool in the system
Tool life monitoring
Monitoring usage of each cutting tool and
determining when to replace worn tools
Performance monitoring and reporting
Availability, utilization, production piece counts, etc.
Diagnostics
Diagnose malfunction causes and recommend
repairs
Duties Performed by Human
Labor
Loading and unloading parts from the
system
Changing and setting cutting tools
Maintenance and repair of equipment
NC part programming
Programming and operating the
computer system
Overall management of the system
FMS Applications
Machining most common
application of FMS technology
Assembly
Inspection
Sheet metal processing (punching,
shearing, bending, and forming)
Forging
FMS at Chance-Vought
Aircraft
FMS for Sheet Metal
Fabrication
FMS Benefits
Increased machine utilization
Reasons:
24 hour operation likely to justify investment
Automatic tool changing
Automatic pallet changing at stations
Queues of parts at stations to maximize utilization
Dynamic scheduling of production to account for
changes in demand
Fewer machines required
Reduction in factory floor space required
FMS Benefits
Greater responsiveness to change
Reduced inventory requirements
Different parts produced continuously rather
than in batches
Lower manufacturing lead times
Reduced labor requirements
Higher productivity
Opportunity for unattended production
Machines run overnight ("lights out operation")
FMS Planning and Design
Issues
Part family considerations
Defining the part family of families to be
processed
Based on part similarity
Based on product commonality
Processing requirements
Determine types of processing equipment
required
Physical characteristics of workparts
Size and weight determine size of processing
equipment and material handling equipment
FMS Planning and Design
Issues
Production volume
Annual quantities determined number of
machines required
Types of workstations
Variations in process routings
Work-in-process and storage capacity
Tooling
Pallet fixtures
FMS Operational Issues
Scheduling and dispatching
Launching parts into the system at
appropriate times
Machine loading
Deciding what operations and
associated tooling at each workstation
Part routing
Selecting routes to be followed by each
part
FMS Operational Issues
Part grouping
Which parts should be on the system at
one time
Tool management
When to change tools
Pallet and fixture allocation
Limits on fixture types may limit part
types that can be processed
FMS Reports
Availability uptime proportion of
station
Utilization utilization of station
Production daily and weekly
quantities of
different parts
produced
Tooling aspects of tools, control, life
status
Status present condition of FMS,
Trouble
spots