1- System Technology

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VII - Flexible Manufacturing Systems ????
??????? ?????
IE 469 Manufacturing Systems 469 ??? ??? ???????

• 1- System Technology
• ????? ??????

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1a- Introduction Single Station cell ????? ????
???????
A station contains of one machine and tooling and
positioning fixtures ?? ???? ????? ??? ??????
????? ?????? ??????? ? ????? It can be one of the
following ????? ?? ???? ??? ?????? ???????

• Labour carries out ???? ??????
• Machine operation ????? ????????
• Load/unload ????? ?????? ????????
• Tool change ????? ??????? ?????

Manual/ mechanized machine ?????? ????? ??
?????

• Machine automatically operate? for a work cycle
  ???? ???????? ???????? ?????????? ????? ??? ?????
  
• Operator carries out ???? ??????
• Load/unload ????? ?????? ????????
• Tool changes ????? ??????? ?????

Work station ???? ???????
Semi Automatic NC M/c ??? ????????? ???????
???? ????

• Machine operate automatically ???? ????????
  ???????
• For more than one cycle ??????? ?????? ?? ????
  ???
• Tool changes????? ???????
• Part presenter (Load/unload) ????? ????????
  ???????? ????????

Automatic CNC,AS/R, AH ?????? ???? ????? ?
????? ???????? ???????? ??????????
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1b- Introduction Single Station cell ????? ????
???????
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1c- Introduction Single Station cell ????? ????
???????
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1d- Introduction Single Station cell ????? ????
???????
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1e- Introduction Single Station cell ????? ????
???????
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1f- Introduction Single Station cell ????? ????
???????
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1g- Introduction Single Station cell ????? ????
???????
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2a- Flexible system Defined ????? ???? ???????
?????
It is production line consisting of workstations
with CNC M/c connected with automated handling
system and operates with computer controllers.
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???????? ????? ?????? ?????????? ??????? , ???
??? ?????? ???????-
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2b- Flexible system Defined ????? ???? ???????
?????
Group of products are produces with stable rate
as demand requires. The following can be
achieved. ??? ??????? ??????? ?? ???????? ?????
?????? ??????? ????? ????? ??? ???? ??????-

• labour cost reduction ??? ?? ????? ???????
• WIP reduction ??? ??????? ??? ????????
• High production Rate ?????? ????? ?????
• Operation standardization ?????? ????????
  ????????
• Integration between operations ??????? ???
  ????????

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2c- Flexible system Defined ????? ???? ???????
?????
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2d- Flexible system Defined ????? ???? ???????
?????
Work station
Terminal
Robot
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2e- Flexible system Defined ????? ???? ???????
?????
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2f- Flexible system Defined ????? ???? ???????
?????
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3a- Meaning of flexibility ???? ??????? ?????
??????? ?????
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3b- Meaning of flexibility ???? ??????? ?????
??????? ?????
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3c- Meaning of flexibility ???? ??????? ?????
??????? ?????
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3d- Meaning of flexibility ???? ??????? ?????
??????? ?????
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3e- Meaning of flexibility ???? ??????? ?????
??????? ?????
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3f- Meaning of flexibility ???? ??????? ?????
??????? ?????

• Flexibility test criteria
• Part variety test Can the system process
  different parts in a non-batch mode? Test of
  machine flexibility production flexibility,
  etc.
• Schedule change test Can the system readily
  accept changes in production (quantities or mix)?
  test of volume flexibility expansion
  flexibility mix flexibility,..
• New part test Can new part designs be introduced
  into the existing product mix easily? test of
  routing flexibility mix flexibility,..
• Error recovery test Can the system recover from
  malfunctions and breakdown without disruption of
  production? test of product flexibility
  production flexibility,..

• ????? ?????? ???????
• ?????? ???? ???????- ?? ???? ?????? ?????? ?????
  ?????? ?? ??? ??? ????? ?????? ????? ???????
  ????? ????????.....
• ?????? ???? ???????- ?? ???? ?????? ??????? ????
  ??????? (???? ?????)? ?????? ????? ??? ????????
  ????? ??????? ????? ???????.....
• ?????? ????? ?????- ?? ???? ?????? ???? ??????
  ?? ???? ??????? ??????? ??????? ???? ???????
  (???? ?????)? ?????? ????? ???????????? ?????
  ???????..
• ?????? ???? ?????? ?? ?????- ?? ???? ??????
  ??????? ?? ????? ???? ???? ??? ???????? ??????
  ????? ??????? ????? ????????.....

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4a- classification of flexible manufacturing
????? ??? ??????? ?????

• Classification according to type Group of
  Products and operations can be classified using
  group technology to find the type of system such
  as
• Automated Flexible system containing CNC M/c,
  automated Handling, and control.
• Flexible cell containing limited number of M/cs
  automated or not and connected to by suitable
  handling system.
• Classification according Geometry This is relate
  to shape to be processed (Round or prismatic)

• ????? ???? ????? ???? ??????? ???? ???? ??????
  ??????? ????????? ??? ????? ??? ??????? ?????
  ????????? ???????? ?????
• ?????? ?????- ????? ?????? ????????? ????? ??
  ????????? ?????? ???????? ?????? ??????.
• ?????? ??????- ???? ???? ?????? ???? ??? ???
  ????? ?? ????????? ???? ????????? ?? ?????
  ??????? ?? ????? ?????? ????? ?????? ??????.
• ????? ???? ????? ??? ????? ????? ???????
  ??????? , ??? ???? ??????? ?????????? ?? ????
  ??????? ????????? .

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4b- classification of flexible manufacturing
????? ??? ??????? ?????

• ????? ???? ?????Order Type ??? ????? ?????
  ????? ??????? ?????? ???????? ?????
• ?????? ?????? - ??? ???? ???? ??? ????? ??
  ?????? ?????? ?????? ?? ?????? ???? ????????
  ???????? ??? ???? ????? ?????? ???? ??????
  ???????? ???????? ??????? ??????
• ?????? ????? ???????? - ??? ???? ???? ??? ??
  ?????? ?????? ?? ?????? ?? ?????? ????????
  ???????? ??? ???? ????? ?????? ???????? ???????
  ???? (???? ????? ???? ???????).

• Classification according to Order Type This is
  related the production quantities and product
  varieties.
• Dedicated system It is a system produce a
  limited number of products and has manufacturing
  similarities. This means that the system is
  designed according operation sequence.
• Random-order system it is system produces
  variety of products are different in design and
  operations. This means system with higher
  flexibility.

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4c- classification of flexible manufacturing
????? ??? ??????? ?????
??? ?????? Random Order
???? Dedicated
FMS System Type Flexibility Criteria Flexibility Criteria Flexibility Criteria Flexibility Criteria
FMS System Type Part Variety Schedule Change Error Recovery New Part
Dedicated Limited Limited Limited NO
Random Order Possible Frequent Minimized YES
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5a- examples for flexible system ????? ??????
????? ??? ??????? ?????
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5b- examples for flexible system ????? ??????
????? ??? ??????? ?????
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5c- examples for flexible system ????? ??????
????? ??? ??????? ?????
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5d- examples for flexible system ????? ??????
????? ??? ??????? ?????
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5e- examples for flexible system ????? ??????
????? ??? ??????? ?????
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5f- examples for flexible system ????? ??????
????? ??? ??????? ?????
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6a- Flexible system configuration ????? ??????
??? ??????? ?????
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6b- Flexible system configuration ????? ??????
??? ??????? ?????
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6c- Flexible system configuration ????? ??????
??? ??????? ?????
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6d- Flexible system configuration ????? ??????
??? ??????? ?????
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6e- Flexible system configuration ????? ??????
??? ??????? ?????
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6f- Flexible system configuration ????? ??????
??? ??????? ?????
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7a- material handling functions ????? ?????
???????? ???? ??????? ?????

1. ??????? ?????????? ???? ????????? ??? ???????
   ?????? ????? ?????? ????????? ?????? ?????????
   ???????? ??????.
2. ?????? ????? ?????? ????????? ?????? ?????
   ??????? ??? ????? ??????? ??????? ????????.
3. ??????? ?????? ?????? ????????? ???? ??????
   ?????? ?????? ??????? ?????????.
4. ????? ??????? ???????? ??????? ??????? ???? ??
   ???? ?????? ????? ??????? ?? ???? ???????? ???
   ????? ???????.
5. ?????? ?? ?????? ??????? ?????? ??????? ??
   ?????? ?????? ??????? ????????.

1. Random, independent movement of work pieces
   between work-stations Routing and loading
   flexibilities.
2. Handling a variety of work pieces configurations
   fixture and product shape flexibilities
3. Temporary Storage Production flexibility
4. Convenient access for loading and unloading Use
   suitable station (s) for load/unload of parts
5. Compatible with computer ability to control from
   computers to direct to stations

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7b- material handling equipment ????? ?????
???????? ???? ??????? ?????
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8a- Control functions ????? ????? ?????? ????
??????? ?????

1. ?????? ?? ???? ????? ?????? ?????? ????? ?????
   ?????? ????????? ???? ???????? ?????????
2. ????? ????? ?????? ??????? ????? ????? ?????????
   ??? ???????.
3. ?????? ??????? ??? ?????? ????? ?????????
   ???????? ??????? ?? ?????? ???? ???????? ???????
   ??? ?????? ??????? ??? ??? , ??????? ???????
   ??????? , ?????? ??????? ??????? ????????.
4. ?????? ????? ?????? ???? ??? ????????? ???
   ??????? ?????? ???? ??????? ???????? ???????
   ???????.

1. Control of each work station execute operating
   program as required.
2. Distribution of control instruction to work
   stations
3. Production control decision on product mix
   according required production such as production
   rate, availability of material, and fixture
   pallets, etc.
4. Traffic control Monitoring the parts moves
   between stations and preparing routing of pallets
   movement to required areas.

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8b- Control functions ????? ????? ?????? ????
??????? ?????

• ?????? ???? ??????? ?????? ????? ???? ?????????
  ???? ?????? ?????? ?????? ?????? ?????? ?????????
  ?? ?????? ?????? ??? ??????? ?? ???????? ???????.
• ?????? ???????? ??? ?????? ???? ???????
  ???????? ?? ????? ???????? ???????? ?????????
  ????????? ????????? ????????
• ?????? ?????? ?????? ?????? ??????
• ?????? ???? ?????? ????????? ?? ?? ???????
  ??????? ???????
• ????? ??????? ??????????
• ??????? ???????? ??????? ??????? ???????? ??
  ??????
• ?????? ????? ??????? ?????? ??? ???????

• Shuttle control parts frequency in a station
  Control organise and coordinate total move of
  parts and synchronize them with station
  operation
• Work-piece Monitoring Monitoring the vehicles
  condition in material handling
• Tool Monitoring To manage two conditions
• Monitoring tool slots availability at all
  stations and carry out
• Monitor Tools slot availability
• Report Loading requirement the tools at slots
• Tool life monitoring and determining tool
  changing time

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8c- Control functions ????? ????? ?????? ????
??????? ?????

• ?????? ???? ?????? ???????? ??? ????????? ?????
  ?? ?????? ?? ?????? ?????
• ?????? ??????? ????? ????? ??????? ??????
• ?????? ????????? ????? ????? ??????? ??????
• ?????? ??????? ????? ?? ???? ??????? ??????
• ?????? ?????? ????? ?? ?????? ??????? ???????
  ????????? ???????? ????????
• ?????? ?????? ????? ?? ??????? ???????
• ??????? ?????? ????? ??????? ???? ??????
  ???????? ???????? ?????? ????? ????????.

• System Performance Monitoring and Reporting
  Periodical collection of information and
  include
• Availability Reports operation and breakdown
  times
• Utilization Reports station and system
  utilization
• Production Reports Production quantities
  produced daily
• Status reportThe instantaneous conditions of
  M/c tools pallets vehicles, etc.
• Tool reportsTool reporting
• Diagnostic finding the cause and effect of
  problems and determine treatment methods.

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8d- Control functions ????? ????? ?????? ????
??????? ?????

• The system files ????? ??? ??????
• Part program file ??? ?????? ???????
• Routing files ??? ???? ????????
• Part Production File ??? ????? ???????
• Pallet reference file ??? ??????? ???????
• Station Tool file ??? ???? ??????
• Tool life file ??? ??? ??????

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9a- flexible system plan ???? ???? ??????? ?????
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9b- flexible system scheduling ????? ????? ?????
??????? ?????
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9c- flexible system work time ??? ????? ?????
??????? ?????
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9d- flexible system work time ??? ????? ?????
??????? ?????
Time to change tools and work holders(Perform
Setup) is not shown
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10a- comparison between MFG systems ??????
??????? ???? ??????? ?????
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10b- comparison between MFG systems ??????
??????? ???? ??????? ?????
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11a- control frame work ?????? ?????? ????
??????? ?????
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11b- control frame work ?????? ?????? ????
??????? ?????
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11c- control frame work ?????? ?????? ????
??????? ?????
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12- benefits of Flexible manufacturing ????? ????
??????? ?????

1. Increased machine utilization ????? ???????
   ?????????
2. Automatic changes of tooling and pallets ??????
   ?????????? ??????? ????????
3. Use of dynamic scheduling of production (consider
   variation of demand, operation, and waiting at
   stations) ??????? ??????????? ??????? ???? ????
   ?? ???????? ???????? ?? ???????? ???????? ?
   ?????? ????????? ??? ???????
4. Fewer machines required ??? ??? ?? ?????????
5. Reduction of factory floor space ??????? ?? ?????
   ??????
6. Greater responsiveness to change ????????? ??????
   ??????
7. Reduced inventory requirements ??????? ?? ???????
   ???????
8. Lower manufacturing lead times ??? ????? ???
9. Reduced labor requirements with increase in
   productivity ??????? ?? ??????? ??????? ????
   ???????
10. Opportunity for unattended production ???? ???
    ??????? ???????