Flexible Manufacturing Systems

Definition of Flexible Manufacturing Systems (FMS)

  • A Flexible Manufacturing System (FMS) is a type of advanced production system that allows for automated production of a variety of products with different specifications, in random order, and in varying volumes.

  • The flexibility comes from its capabilities to manage changes within the production environment, such as changes in product design, production volume, or manufacturing sequence.

  • It typically consists of several interconnected machines which are controlled by a central computer system, ensuring the whole production process runs smoothly and efficiently.

Components of a FMS

  • Common components include: automated machines, such as Computer Numerical Control (CNC) machines, robots, or coordinate-measuring machines (CMMs); material handling systems, like automated guided vehicles (AGVs) or conveyors; computer control systems; and human operators for supervision, maintenance and exception handling.

  • These components are typically integrated through a combination of hardware and software, allowing the system to adapt to changes quickly and efficiently.

Benefits of a FMS

  • Adaptability: A FMS can be quickly adapted to produce a new type of product, or to change the specifications of an existing product. This is essential in industries where product life cycles are short and demand is unpredictable.

  • Efficiency and Economies of Scale: In a FMS, production can be efficiently managed to match demand, reducing the costs associated with keeping large inventories. By optimising production schedules, it can also increase machine utilisation and reduce waste.

  • Quality: As many of the steps in the production process are automated, the possibility of human error is reduced, which can lead to improvements in product quality.

Challenges within a FMS

  • Initial Investment and Maintenance Costs: A FMS requires a substantial initial investment in machinery, control systems, training, and set-up. Maintenance costs can also be high, particularly where specialist technicians are required.

  • Complexity: The design and management of a FMS can be complex and require specialised skills. For this reason, its implementation is often only justifiable for companies with high production volume and product variation.

  • Dependence on Technology: Given a FMS relies heavily on technology, any technical glitches or breakdowns can seriously affect production flow and output.

FMS in Practice

  • FMSs are used in a range of industries, particularly those with high product diversification and variable demand, such as automotive, electronic device manufacturing, and aerospace industries.

  • The concepts at the core of FMSs like multi-function machining, automation, computer control, and adaptability are becoming increasingly important with the rise of Industry 4.0 — the fourth industrial revolution characterised by smart factories, artificial intelligence, and the Internet of Things.