Flexible Manufacturing Systems Tom T Foster Boise State University

Transcription

1 Flexible Manufacturing Systems Tom Foster Boise State University

2 Flexible Manufacturing Systems (FMS) An FMS is a reprogrammable manufacturing system capable of producing a variety of products automatically. Conventional manufacturing systems have been marked by one of two distinct features: The capability of producing a variety of different product types, but at a high cost (e.g., job shops). The capability of producing large volumes of a product at a lower cost, but very inflexible in terms of the product types which can be produced (e.g., transfer lines). An FMS is designed to provide both of these features.

3 FMS Components Numerical Control (NC) machine tools Automated material handling system (AMHS) Automated guided vehicles (AGV) Conveyors Automated storage and retrieval systems (AS/RS) Industrial Robots Control Software

4 Flexible Manufacturing System Tools Computer control room Conveyor Machine Machine Pallet Load Unload Parts Terminal Finished goods

5 Classification of FMS- related Problems Strategic analysis and economic justification, which provides long-range, strategic business plans. Facility design, in which strategic business plans are integrated into a specific facility design to accomplish long-term managerial objectives. Intermediate-range planning, which encompasses decisions related to master production scheduling and deals with a planning horizon from several days to several months in duration. Dynamic operations planning, which is concerned with the dynamic, minute-to-minute operations of FMS.

6 FMS Problems Pa rt t ype sele ct ion (Askin) - selecting parts that will be produced in the FMS over some relatively long planning horizon. Pa rt s ele ctio n (Stecke) - from the set of parts that have current production requirements and have been selected for processing in the FMS, select a subset for immediate and simultaneous processing. Mac hi ne gro upi ng (Stecke) - partition machines into groups where each machine in a group can perform the same set of operations. Lo adi ng (Stecke) - allocate the operations and required tools of the selected part types among the machine groups. Con trol - provide instructions for, and monitor the equipment in the FMS so that the production goals identified by the above problems are met.

7 Information Technology Management information system (MIS) move large amounts of data Decision support system (DSS) add decision making support Expert system recommend decision based on expert knowledge

8 Decision Support System Decision Support System Management Personnel Management Information System Accounting Data Computer system: data processing Information: reports model results what if? analysis Production Marketing Decisions Distribution Other areas Quantitative techniques What -if? analysis

9 Artificial Intelligence Neural networks emulate interconnections in brain Genetic algorithms based on adaptive capabilities in nature Fuzzy logic simulate human ability to deal with ambiguity

10 Advanced Communications Electronic data interchange (EDI) Internet Wireless communications Teleconferencing & telecommuting Bar coding Virtual reality

11 Manufacturing Technology Numerically controlled (NC) machines controlled by punched tape Computer numerical controlled (CNC) controlled by attached computer Direct numerical control (DNC) several NC machines controlled by single computer

12 Automated Material Handling Conveyors Automated guided vehicle (AGV) Automated storage & retrieval system (ASRS)

13 Flexible Manufacturing Systems (FMS) Programmable machine tools Controlled by common computer network Combines flexibility with efficiency Reduces setup & queue times

14 Robotics Programmable manipulators Follow specified path Better than humans with respect to hostile environments long hours consistency

15 Robot Parts Controller hardware, software, power source Manipulator robot arm End-effector hand

16 Computer Integrated Manufacturing (CIM) Integration of design, manufacture & delivery via computer technology CAD - uses software to create & modify designs CAM - uses programmable automation in manufacturing CAE - links functional design to CAD form design CAPP - creates processing instructions for CAM GT- classifies designs to benefit from prior experience

17 Components Of CIM CAD CAE GT DFM IGES, PDES, DMIS TQM Bar codes, EDI Product design CAD/CAM MRP JIT/ kanban DSS/ES/ AI LAN, TOP, satellites Systems management CIM Manufacture Process planning CAPP Cellular manufacturing MAP, STEP NC/CNC/ DNC FMS Robotics AGV, ASRS Automated inspection Cells and centers

18 Adoption Of Technology Technology Readiness Need well-designed products & efficient processes Technology Design Know what to automate Technology Selection Choose the right level Technology Integration Have a strategy for incremental automation