Flexible Manufacturing Systems
Definition of Flexible Manufacturing Systems (FMS)
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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.
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The flexibility comes from its capabilities to manage changes within the production environment, such as changes in product design, production volume, or manufacturing sequence.
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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
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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.
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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
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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.
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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.
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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
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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.
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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.
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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
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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.
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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.