Introduction to Flexible
Manufacturing Systems
Manufacturing Flexibility
The topic of manufacturing flexibility was defined as the capability of a manufacturing
system to adapt to changes in operating requirements and variations in the parts or
products it produces. Such changes and variations might include production schedules,
part mixes, new part introductions, machine breakdowns, raw material deviations, and
so forth.
To qualify as being flexible, an automated manufacturing system should possess at
least some of the following types of manufacturing flexibility:
Part-variety flexibility, Part-mix flexibility, Volume flexibility, Routing flexibility.
Types of flexible manufacturing
systems
Flexible manufacturing cell
Flexible turning cell
Flexible transfer lines.
Flexible machining systems
Operational elements of a flexible
manufacturing cell
THE FMC SOFTWARE
TYPES OF DATA ASSOCIATED
JOB SCHEDULING
TOOL REQUIREMENTS
SETTING-UP WORK PIECE CARRIER
CLAMPING OR PALLETIZING
MATERIAL FLOW CONTROL
MACHINE TOOL PROGRAM
CELL MAGAZINE MANAGEMENT
FMS Layouts
Layouts of FMS
Material Handling systems
A great variety of material handling equipment is available commercially. The
equipment can be classified into five categories (1) transport equipment, (2)
positioning equipment, (3) unit load formation equipment, (4) storage equipment, and
(5) identification and control equipment.
The term unitizing equipment refers to (1) containers used to hold individual items
during handling and (2) equipment used to load and package the containers.
Containers include pallets, tote pans, boxes, baskets, barrels, and drums Pallets and
other containers that can be handled by forklift equipment are widely used in
production and distribution operations.
Automated Guided Vehicles
AGV Guidance and management
Conveyors
ASRS
• To increase storage capacity
• To increase storage density
• To recover factory floor space presently used for
storing work-in-process
• To improve security and reduce pilferage
• To improve safety in the storage function • To
reduce labor cost and/or increase labor
productivity in storage operations
• To improve control over inventories
• To improve stock rotation
• To improve customer service
• To increase throughput
Components of ASRS
The fixed-aisle automated storage/retrieval systems described earlier consist of the
following components: (1) storage structure, (2) S/R machine, (3) storage modules
(e.g., pallets for unit loads), and (4) one or more pickup-and-deposit stations
The storage structure is the rack framework, made of fabricated steel, which supports
the loads contained in the AS/RS. The individual storage compartments in the
structure must be designed to hold storage compartments.
The S/R machine is used to accomplish storage transactions, delivering loads from the
input station into storage, and retrieving loads from storage and delivering them to the
output station.
The pickup-and-deposit station is where loads are transferred into and out of the AS/
RS. It is generally located at the end of the aisle for access by the external handling
system that brings loads to the AS/RS and takes loads away.
Carousal storage systems
In process and post process
inspection
On-line/in-process inspection is achieved by performing the inspection procedure
during the manufacturing operation. As the parts are being made, the inspection
procedure simultaneously measures or gages their dimensions. The benefit of in-
process inspection is that it may be possible to influence the operation that is making
the current part, thereby correcting a potential quality problem before the part is
completed.
on-line/post-process inspection, the measurement or gaging procedure is
accomplished immediately following the production process. Even though it follows the
process, it is still considered an on-line method because it is integrated with the
manufacturing workstation, and the results of the inspection can immediately
influence the production operation.
Coordinate Measuring Machine
(CMM)
To accomplish measurements in three-dimensional space, the basic CMM consists of
the following components:
Probe head and probe to contact the work part surfaces
Mechanical structure that provides motion of the probe in three Cartesian axes
and displacement transducers to measure the coordinate values of each axis.
Drive system and control unit to move each of the three axes.
Digital computer system with application software
Rotary tables attached to the CMM worktable to reorient the part during the
measurement cycle.
Contact Probe
The contact probe indicates when contact has been made with the part surface during
measurement. Most probes today are touch-trigger probes, which actuate when the
probe makes contact with the part surface.
Immediately after contact is made between the probe and the surface of the object,
the coordinate positions of the probe are accurately measured by displacement
transducers associated with each of the three linear axes and recorded by the CMM
controller.
Types of Main structure
Arrangement
a. Cantilever
b. Moving bridge
c. Fixed bridge
d. Horizontal arm
e. Gantry
f. Column
Constructional features
Cantilever - the probe is attached to a vertical quill that moves in the z-axis direction
relative to a horizontal arm that overhangs a fixed worktable. The quill can also be moved
along the length of the arm to achieve y-axis motion, and the arm can be moved relative
to the worktable to achieve x-axis motion.
Moving bridge - The probe is mounted on a bridge that is translated relative to a stationary
table on which is positioned the part to be measured.
Fixed bridge - the bridge is attached to the CMM bed, and the worktable is moved in the x-
direction beneath the bridge.
Horizontal arm - The horizontal arm configuration consists of a cantilevered horizontal arm
mounted to a vertical column. The arm moves vertically and in and out to achieve y-axis
and z-axis motions. To achieve x-axis motion, either the column is moved horizontally past
the worktable (called the moving ram design), or the worktable is moved past the column.
Gantry - The probe quill (z-axis) moves relative to the horizontal arm extending between
the two rails of the gantry.
Column - It is similar to the construction of a vertical milling machine. The x- and y-axis
movements are achieved by moving the worktable, while the probe quill is moved
vertically along a rigid column to achieve z-axis motion
CMM operation
Positioning the probe relative to the part can be accomplished in several ways, ranging
from manual operation to direct computer control (DCC).
A CMM with manual drive and computer-assisted data processing provides some data
processing and computational capability for performing the calculations required to
evaluate a given part feature. The types of data processing and computations range
from simple conversions between U.S. customary units and metric to more complicated
geometry calculations, such as determining the angle between two planes.
A CMM with direct computer control (DCC) operates like a CNC machine tool. It is
motorized, and the movements of the coordinate axes are controlled by a dedicated
computer under program control. The computer also performs various data processing
and calculation functions and compiles a record of the measurements made during
inspection.
CMM software
CMM software is the set of programs and procedures used to operate the CMM and its
associated equipment. Core software consists of the minimum basic programs
required for the CMM to function, other than part programming software, which
applies only to DCC machines.
Probe calibration. This function is required to define the parameters of the probe
(such as tip radius, tip positions for a multi-tip probe, and elastic bending coefficients).
Probe calibration allows coordinate measurements to automatically compensate for
the probe dimensions when the tip contacts the part surface, avoiding the need for
the probe tip calculations.
Part coordinate system definition. This software permits measurements of the
part to be made without requiring a time-consuming part alignment procedure on the
CMM worktable.
Geometric feature construction. This software addresses the problems associated
with geometric features whose evaluation requires more than one point measurement.
These features include flatness, squareness, determining the centre of a hole or the
axis of a cylinder, and so on.
Machine vision