NPTEL : OPERATIONS MANAGEMENT

DEPARTMENT OF MANAGEMENT STUDIES

INDIAN INSTITUTE OF TECHNOLOGY DELHI

LECTURE 10
Module 3 : Systems Design
Module 3.2Group Technology & Flexible Manufacturing Systems
(Duration: 1 Hour)

Discussant

Professor D.K.Banwet
B.E. (Mech.),M.E. (Indl. Engg.),Ph.D. (Indl. Engg./ Production Operations Mgt.) [ IITD], FIE

Group Chair (Operations & Supply Chain Management)

Former HOD DMS , Dalmia Chair Professor
Former Coordinators ASRP & Entrepreneurship Programme
Email : dkbanwet@dms.iitd.ac.in

GROUP TECHNOLOGY
GROUP TECHNOLOGY IS A MANUFACTURING
TECHNIQUE AND PHILOSOPHY TO INCREASE
PRODUCTION EFFICIENCY BY EXPLOITING THE
UNDERLYING SAMENESS OF COMPONENT
SHAPE, DIMENSIONS, PROCESS ROUTE, ETC.

Group Technology is the

realization that many problems
are similar, and that by grouping
similar problems, a single
solution can be found to a set of
problems thus saving time and
effort.

Why Group Technology?

Average lot size decreasing
Part variety increasing
Increased variety of materials
With diverse properties
Requirements for closer
tolerances

HIGH

VOLUME

TRANSFER
LINE
SPECIAL
SYSTEM

PR
OD
UC
T

FL
E
ION
C

X IB

IL I
TY

AP
AC
IT

FLEXIBLE
MANUFACTURING
SYSTEM
MANUFACTURING
Cells
STD. AND GEN.
MACHINERY

LOW

VARIETY

HIGH

Hybrid Layout
Cellular layouts
Group machines into machining cells
Flexible manufacturing systems
Automated machining & material handling
systems

Mixed-model assembly lines

Produce variety of models on one line

Hybrid Layout: Group Technology

One Worker, Multiple Machines

Machine
2

Machine
1

Machine
3

Materials in

Finished
goods out

Machine
5

Machine
4
7

Group Technology
Lathing

Milling

Drilling

M
Grinding

Receiving and
shipping

Assembly
A

(a) Jumbled flows in a job shop without GT cells

Group Technology
L

Assembly
area
A

Cell 2

Cell 1
Receiving

Cell 3
L

(b) Line flows in a job shop with three GT cells

Shipping

Group Layout
Advantages:
1. By grouping products, higher
machine utilization can result.
2. Smoother flow lines & shorter travel
distances are expected than for
process layouts.
3. Team atmosphere & job
enlargement benefits often result.
4. Has some of the benefits of product
layouts & process layouts; it is a

Group Layout

Limitations:
1. General supervision required.
2. Greater labour skills reqd. for team members to be
skilled on all operations.
3. Critically dependent on production control balancing
the flows three individual cells.
4. If slow is not balanced in each cell, buffers & WIP
storage are reqd. in the cell to eliminate need for
added material handling to 8 from the cell.
5. Has some of disadvantages of product & process
layouts(compromise between the two)
6. Decreases opportunity to use special purpose
equipment.

Group Technology:
Benefits
1. Better human relations
2. Improved operator expertise
3. Less in-process inventory and material
handling
4. Faster production setup

Group Technology:
Transition from Process Layout

1. Grouping parts into families that follow

a common sequence of steps
2. Identifying dominant flow patterns of
parts families as a basis for location or
relocation of processes
3. Physically grouping machines and
processes into cells

Everyday Examples
1. Fast food chains
2. Doctors, dentists and also manufacturing

A FAMILY OF PARTS

Production Family

 Lack Of Common Database For

Mfg., Design...
Dont redesign the wheel
Automated process planning
Database to drive the
automated factory

Benefits Of Group Technology

Reductions in
Throughput time
Set-up time
Overdue orders
Production floor space
Raw material stocks
In-process inventory
Capital expenditures
Tooling costs
Engineering time and costs
New parts design
New shop drawings
Total number of drawings
Contd

Other Benefits Of Group Technology

Easier to justify automation
Standardization in design
Data retrieval
Easier, more standardized process plans
Increases in quality

Gt affects most every operating and staff function.

It is more than merely a technique, but a total
Manufacturing philosophy.
DATA
PROCESSING

DESIGN
ENGINEERING

MAINTENANCE

SALES
INVENTORY

TOOL
ENGINEERING

PLANNING

ESTIMATING

PURCHASING

INDUSTRIAL
RELATIONS

ASSEMBLY

QUALITY
CONTROL

MANAGEMENT

R&D

MFG.
ENGINEERING

COST
ACCOUNTING

GT

SHIPPING &
RECEIVING

Clustering Techniques: the Fundamental

Issue in Cell Development
We cluster parts to build part families
Part Families visit cells
Part Families share set-up ideas and
equipment (Family Fixtures)
Part Families follow the same (or similar)
process routing
These are the ideas and activities that offer
reported benefits

Clustering Techniques: the Fundamental

Issue in Cell Development
We cluster Machines to build cells:

Cells lead to Flow Mathematics

Cells contain all equipment needed to produce a part family
Cells allow development of Multi-functional workers
Cells hold work teams responsible for production and quality
They Empower the workers

Empowered to set internal schedules

Empowered to assign tasks
Empowered to train and rotate jobs
Etc, etc, etc

Building the CMS Facility

Before
Clustering

After
Clustering

Clustering Methods
Using Process Similarity methods:
Create Machine Part Matrices
Compute machine pairwise Similarity
Coefficient comparisons:

Sij

ij

xij

x jj

here:
xij is # of parts (in matrix) visiting
both machines of the pair
x

jj

is # of parts visiting one but not both machines

Example:
Part Number
X

Mach B
ine
C
ID
D

1
1

1
1

Computing Similarity
Coefficients:
Total Number is:
[(N-1)N]/2 = [(5-1)5]/2 = 10
For 25 machines (typical number in a small Job
Shop): 300 Sijs

Here they are:

1
S AB
.33
1 2
0
S AC
0
04
2
S AD
.67
2 1

Continuing:
0
0
05
0
S BC
0
04
2
S BD
.67
2 1
0
S BE
0
05
0
SCD
0
05
2
SCE
.67
2 1
0
S DE
0
06
S AE

Here, if the similarity

coefficient is .33
consider clustering
This criteria means
clustering:
A&D, A&B, B&D
C&E

Declustering:
A&C, A&E, B&C, B&E
and C&D, D&E

Continuing:
Examining our Matrix and our freshly clustered machine
cells, we develop 2 part families:
For the Cell A/D/B: Part Numbers 2, 3 & 5
For the Cell C/E: Part Numbers 1, 4 & 6

Care must be taken (in most cases) to assure that each

cell has all the machines it needs sometimes a couple
of families need a key machine
In this case, the manager must decide to either replicate the
common machine or share it between the cells creating a bottleneck
and scheduling problem for each cell
This is typically one of the cost problems in CMS systems

Summarizing:

Make Machine/Part Matrix

Compute Similarity Coefficients
Cluster Machines with positive ( .33) Sijs
Determine Part Families for the clusters (cells)
Decide if machine replication is cost effective
Re-layout facility and Cross Train workforce
Start counting your new found cash
Court customers to grow part families on Cell-by-Cell
basis

Other Clustering Methods:

Rank order Clustering
This method automates the cluster study by computing Binary
weights from a machine part matrix
It orders parts and machine cells automatically by structuring
and computing the matrix with binary weights
It implies a computer algorithm for solving the clustering problem
It may not solve if machines are needed by more than one family
forces intelligence in application and hand scanning after
several ordering iterations

Rank Order Clustering Method:

1.
2.
3.
4.
5.

For each row of the machine/part matrix (M/P/M) read the pattern
of cell entries as a binary word. Rank the rows by decreasing
binary value. Equal values stay in same order.
Ask if newly ranked rows in the matrix are the same as previous
order? Yes (STOP) No (continue)
Re-form the M/P/M with rows in new descending order. Now rank
the columns by decreasing binary word weight. Columns of equal
weight are left where they are
Are current column weights the same as current column order?
Yes (STOP), No (continue)
Re-form the matrix column order per rank order (highest to left)
and return to #1.

RANK ORDER CLUSTERING FOR CELL

FORMATION

STEP 1:
Parts

16 8
24 23

4
22

2
21

1
20

Machines

III

IV

16 A

24

23

22

21

II

Rank

Dec
Low
Equipment

16 + 4 + 1 = 21

8 + 2 +1 = 11

8 + 2 + 1 = 11

16 + 4 = 20

1 E rows
20 as per
1 rank of
1 decimal
1 8 + 2row
+ 1 euipment.
= 11
5
Arrange

 STEP 2:
I
16
8
4
2

A
B
C
D

1
E
Dec. Col.
Equivalent
Rank

24
23
22
21

II

1
1

III

IV

1
1

V
1

1
1

1
1

1
1

24

1
7

24

1
7

1
23

20

 STEP 3:
A
B
C
D
E

I
1
1

II
1
1

III
1

IV

1
1
1

1
1
1

1
1
1

I
Cell formed A 1III 1
D 1 1

V
B IV
1
C 1
D 1

II
1 1
1 1
1 1

Lets try it with our earlier

problem:
Part Number
X

Mach B
ine
C
ID
D

1
1

1
1

Step 1:
Part Numbers
B. Wt:

Ma
chi
ne
ID

25

24

23

22

21

20

B
C

1
1

Step 2: Must Reorder!

1
1

D. Equiv

Rank

23+21 = 10

24+23 = 24

25+22=36

24+23+21 =
26

25+22+20=
37

Step 3:
Part Number

Machi
ne ID

B. WT.

24

23

22

21

20

6
1

D. Equiv

24+23
= 24

22+21=
6

22+21+
20=7

24+23=
24

22+20=
5

24=16

Rank

Step 4: Must Reorder

Back at Step 1:

Great
Cluster
Result!

Part Number
B Wt:
E

Mac
hine
ID

25

24

23

22

21

20

Order stays the same: STOP!

D. Eqv

Rank

25+24+
23=56

25+24=
48

22+21+
20 = 7

22+21=6

22+20=5

Issues in Clustering:
R/O clustering oscillations indicating need of machine
replication (happens often!)
Presence of Outliers and/or Voids in the finished
clusters
Outliers indicate the need of machine replication
Voids indicate skipped machines in a cell

Generally speaking, these clustering algorithms are

designed to convert existing routes for facility reorganization
They require a previous engineering study to be performed to
develop a series of routers on a core sample of parts that
represent most of the production in the shop

Reduction Of Mfg. Costs By Various

Steps Of Group Technology Applications
Not All Cost Savings Are Immediate...
Improvements in Engineering Design
Materials Management & Purchasing Benefits
Production Control Benefits
Manufacturing Engineering Benefits
Tooling & Setup Benefits
Management Benefits
Overall Cost Reduction &
Increased Productivity

12 18 24
Time (months)

36

Flexible Manufacturing
Systems (FMS)

What Will Be Covered

Definition
History of FMS
FMS equipment
Types of FMS
Applications of FMS
FSM different approaches
Advantages
Disadvantage

Development of FMS
Nuts and Bolts
How FMS works
A real world example
Summary

Definition
A Flexible Manufacturing System (FMS)
is a production system consisting of a set of
identical and/or complementary numerically
controlled machine which are connected
through an automated transportation
system.
Each process in FMS is controlled by a
dedicated computer (FMS cell computer).

History of FMS
At the turn of the century FMS did not exist. There was not a big enough need for
efficiency because the markets were national and there was no foreign
competition. Manufacturers could tell the consumers what to buy. Henry Ford is
quoted as saying people can order any color of car as long as it is black.
This was the thinking of many big manufacturers of the time.
After the Second World War a new era in manufacturing was to come. The
discovery of new materials and production techniques increased quality and
productivity. The wars end opened foreign markets and new competition. Now the
market focused on consumer and not the manufacturer.
The first FMS was patent in 1965 by Theo Williamson who made numerically
controlled equipment. Examples of numerically controlled equipment are like a
CNC lathes or mills which is called varying types of FMS.
In the 70 s manufacturers could not stay to date with the ever-growing
technological knowledge manufacturers competitors have, so FMS became
mainstream in manufacturing.
In the 80 s for the first time manufacturers had to take in consideration efficiency,
quality, and flexibility to stay in business.

Equipment of FMS
Primary equipment
Work centers
Universal machining centers (prismatic FMSs)
Turning centers (rotational FMSs)
Grinding machines

Process centers

Wash machines
Coordinate measuring machines
Robotic work stations
Manual workstations

Equipment of FMS
Secondary equipment
Support stations
Pallet/fixture load/unload stations
Tool commissioning/setting area

Support equipment

Robots
Pallet/fixture/stillage stores
Pallet buffer stations
Tools stores
Raw material stores
Transport system(AGVs,,robots)
Transport units(pallets/stillages)

Types of FMS

Sequential FMS
Random FMS
Dedicated FMS
Engineered FMS
Modular FMS

Applications of FMS

Metal-cutting machining
Metal forming
Assembly
Joining-welding (arc , spot), glueing
Surface treatment
Inspection
Testing

Why do we need flexibility in manufacturing systems?

Variety in products thus options for the consumers

Optimizing the manufacturing cycle time
Reduced production costs
Overcoming internal changes like failure, breakdowns, limited
sources, etc.
External changes such as change in product design and
production system.

Flexibility in Manufacturing System:

?
Flexibility can be defined as collection of properties of a
manufacturing system that support changes in production
activities or capabilities (Carter,1986).
Ability of the manufacturing system to respond effectively to
both internal and external changes by having built-in
redundancy of versatile equipments.

Various types of flexibility?

Machine flexibility
Capability of a machine to perform a variety of operations on a variety
of part types and sizes

Routing flexibility
Alternative machines, sequences or resources can be used for
manufacturing a part for changes resulting from equipment
breakdowns, tool breakages, controller failures, etc.

Process flexibility
Ability to absorb changes in the product mix by performing similar
operations, producing similar products or parts.

Product flexibility
Ability to change over to a new set of products economically and
quickly in response to markets

Production flexibility
Ability to produce a range of products without adding capital
equipment

Expansion flexibility
Ability to change a manufacturing system with a view to
accommodating a changed product envelope

Volume-variety relationship

FMS different approaches

The capability of producing different parts
without major retooling

A measure of how fast the company

converts its process/es from making an
old line of products to produce a new
product

The ability to change a production

schedule, to modify a part, or to handle

Advantages of using FMS

To reduce set up and queue times

Improve efficiency
Reduce time for product completion
Utilize human workers better
Improve product routing
Produce a variety of Items under one roof
Improve product quality
Serve a variety of vendors simultaneously
Produce more product more quickly

Disadvantage of using FMS

Limited ability to adapt to changes in
product or product mix (ex:machines are of limited capacity and
the tooling necessary for products, even of the same family, is not always feasible in a
given FMS)

Substantial pre-planning activity

Expensive, costing millions of dollars
Technological problems of exact
component positioning and precise timing
necessary to process a component
Sophisticated manufacturing systems

Development of FMS
Several actions must be decided on before you can
have a have a FMS. These actions include.
Selecting operations needed to make the product.
Putting the operations in a logical order.
Selecting equipment to make the product.
Arranging the equipment for efficient use.
Designing special devices to help build the product.
Developing ways to control product quality.
Testing the manufacturing system.

Illustration example of a FMS

Nuts and Bolts of FMS

FMS Layouts
Progressive Layout:
Best for producing a variety of parts

Closed Loop Layout:

Parts can skip stations for flexibility
Used for large part sizes
Best for long process times

FMS Layouts Continued

Ladder Layout:

Parts can be sent to any machine in any sequence

Parts not limited to particular part families

Open Field Layout:

Most complex FMS layout

Includes several support stations

Flexible Automation
Ability to adapt to
engineering changes in
parts
Increase in number of
similar parts produced on
the system

Ability to accommodate
routing changes
Ability to rapidly change
production set up

Challenges with FMS

Determining if FMS the best production system for your
company (economically and socially)
Possible expansion costs associated with implementing
FMS
Day to day maintenance of FMS operations

Flexible Manufacturing
system
How Does It Work ?

Making FMS Work

By implementing the components of robotics,
manufacturing technology and computer
integrated manufacturing in a correct order
one can achieve a successful Flexible
Manufacturing System

An outline for Mechanical Engineering

CAD/CAM laboratory Integrated System

How does it work?

ROBOTS
First 5 axis robot is in charge of picking and placing parts which are scanned by the
barcode reader, and transfer them to the left side for machining or throw it to the
conveyor for the other operations.
This robot utilizes a vacuum gripper to pick the parts.
Pneumatic Robot which contained a few reed sensors, used to set the limits for the
pneumatic cylinder motion. This robot is using a general griper which can be close or
open in each time.
This robot just picks the parts which are detected by the Metal Detector sensor,
placed before it.
Hence, the duty of this robot is to pick the Metal-Coated parts, chosen by the sensor
placed near it.
Second Five axis robot which has the same specifications as the former one, used to
pick the Non-Metal parts (which are detected by non-metal detector sensor on the big
conveyor) from the flexible conveyor and place them into a rail way for the next
defined operations.
This robot placed on a special Nut and Screw system which is connected to a Motor
using to turning the screw in case of moving the robot across the Big conveyor .

First robot

second robot

pneumatic robot

COMPUTERS AND SOFTWARES

First Robot is controlled by a General PC, using a visual basic program
to read the barcodes and also control the robots motion. For each
part the program decide Where to be placed according to the parts
barcode
The second 5-axis robot is controlled by a PC using special software
which is named Robotica.
Generally, this software has a GIU (Graphical User Interface) which
can be used for programming the robot remotely. After writing the
program, by pressing the Run Button on the program screen, each
line transferred to the robot using a general RS-232 cable.
Also we have another PC which is used to monitor the Main PlC ,
placed in an anti dust cabin for safety.

CONVEYORS
We have 2 Conveyors, one general belt conveyor and one big flexible
conveyor which are driven by two different Motors . The specifications of
these two conveyors are as below:

63C
63C
m
m

11C
11C
m
m

97Cm
97Cm

176C
176C
m
m

PLCs
We have two different PLC devices :
A Siemens S7-200 PLC with 5 inputs and 5 outputs , which is used as
secondary plc device , just to transfer the fire signal to the second
five axis robot.
A Telemeqanic
PLC with inputs and output , used as main PLC
device for controlling the motors, conveyors, sensors and all other
feedback signals.

Telemeqanic Micro TSX PLC

SIEMENS S7-200 PLC

REVIEWING THE SCENARIO

To run the system three parts are designed for three different operations. At
the first cell the scenario is collaboration of the barcode reader and the
first robot. After inserting the part in the input place , the small conveyor
start switch pushed down and the small conveyor runs.
After this the parts moves across the barcode reader for reading the
parts barcode, after that the conveyor stopped when the part reached
the optical sensor on the belt conveyor.

The Barcode reader Device

3 parts(1 Metal and 2 Non-metal with different barcodes)

The non-metal parts continue their route until they reach the non-metal
sensor, at this time, the sensor send a signal to the main PLC and the
main PLC send the required signal to the robot and also to the screw
motion control, so the screw starts turning and the robot get close to
the part which is in the conveyor waiting to be caught by the robot.
During this operation, the PC which is used to control the second
robot must be run and ready to send the program to the robot.
The robot catches the part and after that the signal from the non-metal
sensor goes off, so the screw starts in reverse direction by receiving a
signal from the main PLC , and the robot throws the parts into a
special rail at the end of the rout.

Metal Detector
Sensor

Non-Metal
Detector
Sensor

Computer integrated manufacturing and PLC

In todays manufacturing units several PLCs are used to switch on
or off robots ,conveyer belts and other part of manufacturing
systems. The advantages of PLC in automated systems made PLC
one of the main component of any Manufacturing unit.

An example of a simple and modern

manufacturing
Swarf
disposal
Universal Machining Center

Raw
Materials
Area

AGV transport system 2

AGV transport system 1

Host
computer
Universal Machining Center

Coordinate
Measuring
Machine

Head
Indexing
Machines
Wash
Machine

1
Piecepart
Buffer
Area

Assembly
Cells
1&2

Finish
Machine
Cell

FMS Example
One Design + One Assembly Process = Multiple Models

When different models are designed to be assembled in the same sequence they can be built in the same
plant.
This maximizes efficiency and allows the company to respond quickly to changing customer

FMS Example
Through the use of reprogrammable tooling in the body shop, standardized equipment in the
paint shop and common build sequence in final assembly, Ford can build multiple models on
one or more platforms in one plant.

Body Shop

In the body shop, where

the sheet metal comes
together to form the
vehicles body, flexibility
means more than 80
percent of the tooling is
not specific to one model.
It can be reprogrammed to
weld a car or a truck or a
crossover of similar size.

Paint Shop

In the paint shop, flexibility

means robotic applicators
are programmed to cover
various body styles as
they move through the
paint booth with equal
precision. This results in
minimizing waste and
environmental impact
while maximizing quality.

Final Assembly

In the final assembly

area, flexibility means
the build sequence is the
same among multiple
models on one or more
platforms allowing for
efficient utilization of
people and equipment.

FMS Example
Virtual Verification
Virtual manufacturing technology allows Ford to quickly add
various models into an existing facility or to reconfigure an
existing facility to produce a new model. In the virtual world,
manufacturing engineers and plant operators evaluate tooling and
product interfaces before costly installations are made on the plant
floor. This method of collaboration improves launch quality and
enables speed of execution.

Classification of the manufacturing system based on Volume-variety

considerations:
Transfer Line (High-Volume, Low-Variety Production system, H-L)

Machines dedicated to manufacture of one or 2 product types.

Nearly no flexibility
Maximum utilization and high production volume
Direct labor cost is minimal
Low per unit cost

Stand Alone NC machines / Flexible Manufacturing module

(Low-Volume High-Variety Production system, L-H)
Highest level of flexibility
Low utilization and low production volume
Very high per unit cost

What is FMS?
an automated, mid-volume, mid-variety, central computercontrolled manufacturing system
Activities covered: machining, sheet metal working, welding,
fabricating, assembly
Physical components:
Potentially independent NC machine tools capable of
performing multiple functions and having automated tool
interchange capabilities
Automated material handling system to move parts
between machine tools and fixturing stations
All the components are hierarchically computer controlled
Equipment such as coordinate measuring machines and
part-washing devices

A FMS consists of:

Physical subsystem
-Workstations: NC machine tools, inspection equipment,
part-washing devices, load & unload area.
-Storage-retrieval systems
-Material handling systems
Control subsystem
-Control hardware
-Control software

NC machine tools:
The major building blocks of an FMS,
determine the degree of flexibility,
determine the capabilities.
Machining centers with numerical control of movements in up to five axes.
Spindle movement in x, y and z directions, rotation of table, and tilting of table.

Workholding and Tooling considerations

Fixtures and pallets must be designed to minimize part-handling time
Strategies required for storage/retrieval of different fixtures
Integration with AS/RS and material handling system
Machining centers are equipped with tool storage known as tool
magazine.

Control systems in FMS

Work-order processing and part control system
Part process planning module, part routing module, part setup module,
etc.

Machine tool control system

DNC transmitter control module, NC editor, machine monitor and
control module

Tool management and control system

To control the processing of parts and enhance the flexibility to
manufacturing variety of parts. Tool identification, tool setup, tool
routing, tool replacement strategies are accomplished by the system

Traffic management control system

Material handling and storage control system coordinates part routing,
fixtures, pallets and tool modules

Quality control management system

Maintenance control system (service control system)

On-line help, alarms due to problems, etc.

Management control system

Capabilities include collection, storage, retrieval, and achieving of

work-piece inspection data.

Provides the management status of output performance.

Interfacing of these subsystems with the central computer

FMS Architecture
An FMS is a complex network of equipment and processes that must be controlled
via a computer or network of computers.
System is usually divided into a task-based hierarchy.
One of the standard hierarchies that have evolved is the National Institute of
Standards and Technology (NIST) factory-control hierarchy.
This hierarchy consists of five levels and is illustrated in Figures.

Operational Problems in FMS

Part selection and tool management

Fixture and pallet selection
Machine grouping and loading, considering part and tool assignments

Part Selection

Batching approach
-

Part types are partitioned into separate sets called batches. The selected part
types in a particular batch are manufactured continuously until all the
production requirements are completed. Then processing the next batch,
removing all the tools, loading new tools for the new batch.

Flexible approach
-

When the production requirements of some part types are finished, space
becomes available in the tool magazine. New part types may be introduced
into the system for immediate and simultaneous processing if this input can
help increase utilization of the system. This requires more frequent tool
changes.

Layout Considerations

Layout is one of the important design characteristics of FMS

design.
The layout of machines to process part families in an FMS is
determined by the type of material handling equipment used.

Fixed Product Layout

Limitations:
1. Personal & equipment movement is
increased.
2. May result in duplicate equipment.
3. Requires greater skill for personnel.
4. Requires general supervision.
5. May result in increased space &
greater WIP.
6. Requires close control &

Fixed Product Layout

Advantages:
1. Material movement is reduced.
2. When a team approach is used,
continuity of operations &
responsibility results.
3. Provides job enrichment
opportunities.
4. Provides & promotes pride & quality
because an individual can complete
the whole job

Algorithm:Step 0: Calculate = 2 + 4
Step 1: Calculate max {a, b}, then T2 is optimal. Calculate T2 and stop.
Otherwise go to step 2.
Step 2: If > max {a, b} and 2 a + b, then T2 is optimal. Calculate T2 and stop.
Otherwise go to step 3.
Step 3: If > max {a, b} and 2 > a + b, then T1 is optimal. Calculate T1 and stop.
Example: Determine the optimal cycle time and corresponding robot sequences in a twomachine robotic cell with the following data:
Processing time of Machine M1
=11.00 min
Processing time of Machine M2
=09.00 min
Robot gripper pickup
= 0.16 min
Robot gripper release time
= 0.16 min
Robot move time between the two machines = 0.24 min
Solution:
Step 0:
= 2 + 4
= 2(0.16) + 4(0.24) = 1.28 min
Step 1:
max {a, b}
1.28 max {11, 9}, i.e.1.28 < 11. Therefore, T2 is optimal.
T2 = + max {, a, b}
T2 = [4 + 4] + max {1.28, 11, 9} = [4(0.16) + 4(0.24)] + 11
T2 = 1.6 + 11 = 12.6 min
The optimal cycle time is 12.6 min and the optimal robot is given by fig (b) as shown in the
previous slide.

FMS Scheduling and Control

Flexible manufacturing systems can differ significantly in complexity.
Complexity is determined by:
The number of machines and the number of parts resident in the system.
The complexity of parts and control requirements of the specific equipment.
Example 1: The most simple FMS consists of a processing machine, a load/unload
area, and a material handler (a one-machine system is the most simple FMS that
can be constructed).
Operation of this system consists of loading the part/parts that move down a
conveyor to the machine.
Once the part is loaded onto the machine, the robot is retracted to a "safe position"
and the machining begins.
For a single part is to be processed in the system, a minimum number of switches
and sensors required are:
Parts on the conveyor all have to be oriented in the same way.
Robot can pick up the part and deliver it to the NC machine in the same
orientation.
Proximity switch or micro-switch is required at the end of the conveyor to

The logic for the system is as follows:

1. If a part is resident at the end of the
conveyor (switch 1 is on) and no part is
on the NC machine (switch 2 is off),
then pick up the part on the conveyor
and move it to the NC machine and
retract the robot to a safe point (run
robot program I). After the program is
complete and switch 2 senses that the
part is correctly positioned, start the
NC machine (turn on relay M,). While
the machine is running, a switch signal
from the NC machine, switch #2, will
be ON.
2. If switch 11 is off and switch # 2 is on
(the NC machine has completed
processing a part), take the part off the
NC machine and move it to the output
bin (run robot program 2).