FLEXIBLE MANUFACTURING SYSTEM

Flexible Manufacturing
System
FLEXIBLE MANUFACTURING
SYSTEM
SUBMITTED TO:
SUBMITTED BY:
Mrs. SHIPRA
RANJIT PASWAN
(Assit. Professor)
RAVI YADAV
NIFT, BLORE
AMIT-VII
NIFT, BLORE
System
FLEXIBLE MANUFACTURING SYSTEM

IN CONTEX OF ANY INDUSTRY
FMS CONCEPT
System
Today flexibility means to produce reasonably priced customized

products
of high quality that can be quickly delivered to customers.
A flexible manufacturing system (FMS) is a manufacturing
system in which
there is some amount of flexibility that allows the system to react
in the case
of changes, whether predicted or unpredicted.
FMS CONCEPT CONTIUED.
System
what is flexibility in manufacturing?

(A)BASIC FLEXIBILITIES
Machine flexibility - the ease with which a machine can process
various
operations
Material handling flexibility - a measure of the ease with which
different
part types can be transported and properly positioned at the
various machine
tools in a system
Operation flexibility - a measure of the ease with which
alternative
System
(B) SYSTEM FLEXIBILITIES

Volume flexibility - a measure of a systems capability to be
operated
profitably at different volumes of the existing part types
Expansion flexibility - the ability to build a system and expand it
incrementally
Routing flexibility - a measure of the alternative paths that a
part can
effectively follow through a system for a given process plan
Process flexibility - a measure of the volume of the set of part
types that a
System
Product flexibility - the volume of the set of part types that can
be
manufactured in a system with minor setup
(C) AGGREGATE FLEXIBILITIES
Program flexibility - the ability of a system to run for reasonably
long periods
without external intervention
Production flexibility - the volume of the set of part types that a
system can
produce without major investment in capital equipment
Market flexibility - the ability of a system to efficiently adapt to
changing
market conditions
DIFFERENT APPROACHES OF FMS
APPROACH
MANUFACTURING
System
FLEXIBILITY MEANING
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 multiple parts
OPERATIONAL
The ability to efficiently produce highly customized and

unique products
The ability to exploit various dimension of speed of delivery
CUSTOMER
STRATEGIC
CAPACITY
The ability of a company to offer a wide variety of products

to its customers
The ability to rapidly increase or decrease production levels
or to shift
capacity quickly from one product or service to another
DIFFERENT LEVEL OF FMS
System
Flexible Manufacturing Module (FMM).
Example : a NC machine, a pallet
changer and a part buffer;
Flexible Manufacturing (Assembly) Cell (F(M/A)C).
Example : Four
FMMs and an AGV (automated guided vehicle);
Flexible Manufacturing Group (FMG).
Example : Two FMCs, a FMM and

two AGVs which will transport parts from a Part Loading area, through machines, to
a Part Unloading Area;
Flexible Production Systems (FPS).
Example : A FMG and a FAC, two

AGVs, an Automated Tool Storage, and an Automated Part/assembly Storage;
Flexible Manufacturing Line (FML).

layout and AGVs.
Example : multiple stations in a line
ADVANTAGE OF IMPLEMENTATION
System
Faster, lower- cost changes from one part to another which will
improve
capital utilization
Lower direct labor cost, due to the reduction in number of
workers
Reduced inventory, due to the planning and programming
precision
Consistent and better quality, due to the automated control
Lower cost/unit of output, due to the greater productivity using
the same number of workers
Savings from the indirect labor, from reduced errors, rework,
repairs and rejects
DISADVANTAGE OF IMPLEMENTATION Flexible Manufacturing

System
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
CONCLUSION
System
FMSs complexity and cost are reasons for their slow

acceptance
by industry. In most of the cases FMCs are favored.
System
FLEXIBLE MANUFACTURING SYSTEM

IN CONTEX OF APPAREL INDUSTRY
NEED OF FMS IN APPAREL INDUSTRY
System
Global market (European,US), which is known for its small

sized orders and even shorter lead times
Small orders as the start up losses and frequent changes make
it difficult
for a factory to run cost effectively with progressive bundle
system
The need of the hour is of flexible manufacturing systems that
provide
high performance and quick response in a cost effective manner.
Flexible manufacturing System helps a company in :
Developing a quick response system.
Developing human capital with decision making power and collaborative capabilities.
Reduction of work in progress.
Utilizing work areas more effectively.
INTRODUCTION
System
It is a contained, manageable work unit that includes an
empowered work
team, equipment, and work to be executed. Modules frequently
operate as
mini factories with teams responsible for group goals and selfmanagement.
The number of teams in a plant varies with the size and needs
of the firm
and product line
Different names used to identify FMS apparel production
systems,
Modular manufacturing
Cellular manufacturing units
Compact work teams
Flexible work groups,
INTRODUCTION
contued..
System
Teams may be used to perform all the operations or a certain

portion of
the assembly operations depending on the organization of the
module and
processes required.
A team-based system operators are given the responsibility for
operating
their module to meet goals for throughput and quality.
A FMS System operates as a Pull System, with demand for work
coming
from the next operator in line to process the garment.
Teams usually operate as Stand-up or Sit-down units.
INTRODUCTION
contued..
System
A module may be divided into several work zones based on the

sequence
of operations and the time required for each operation
A general thumb rule to determine the no. of operator required
is,
average number of operations required for a style being
produced and divide by three
Work flow within a module may one of the following:
Single-piece hand-off,
Kanban
Bump-back system
SINGLE-PIECE HAND-OFF
System
Machines are arranged in a very tight configuration

As soon as an operation is completed the part is handed to the
next operator
Operations need to be well balanced, usually only one garment
component between each operation
If a small bundle is used between operation, an operator will
complete the operation on the entire bundle and carry the bundle
to the next operation
An operator may follow a component or bundle for as many
operations as they have been trained or until the adjacent
operator is ready to assume work on the bundle.
KANBAN
System
Uses a designated work space between operations to balance

supply with demand
The designated space will hold a limited number of completed
components (two or three) in queue for the next operation
If the designated space is full, there is no need to produce more
until it is needed or the space empties.
When the space is full the operator can assist with other
operations that may be slow.
BUMP-BACK
SYSTEM
It was developed
by (TSS)
the Toyota Sewn Product Management
System
System
Probably the
manufacturing
most
widely
used
type
of
team-based
It is a stand-up module with flexible work zones and crosstrained operators

Operators may be cross-trained on up to four different
successive operations
Operators shift from operation to operation until the next
operator is ready
to begin work on the garment.
BUMP-BACK SYSTEM (TSS) contued..
System
The operator who has been relieved of the garment will then
move back to
the beginning of the work zone and take over work on another
garment
This approach enables continuous work on a garment and
allows each
operator to perform several different operations
This arrangement frequently uses a 4-to-l ratio of machines to
operators
ADVANTAGES OF FMS
System
High flexibility
Fast throughput times
Low wastages
Reduced Absenteeism
Low work in process
Increased employee ownership of the production process
Empowered employees
Improved Quality
DISADVANTAGES OF FMS
A high capital investment in equipment.
High investment in initial training.
High cost incurred in continued training
System
DETERMINATION OF TEAM SIZE
System
The Key points that should taken care of while deciding upon the number of operators are:
The technical characteristics of the product, that is the S.A.M

and
complexity
Expected Production Capacity.
Poly Functionality requirements.
Module continuity and stability in important to adapt with its
flexibility
requirements so no changes should be made to the team after
setting it up
DETERMINATION OF TEAM SIZE contued.. Flexible Manufacturing

System
The team has to be self managed and identification between

the team
members is a must to develop the team spirit. So, the team size
should not
be exceed a certain limit.
The level of flexibility expected would also be a critical issue
since more
number of workers would bring down the flexibility by reducing
the poly
functionality requirements.
Module team Size =
Expected Production Capacity * S.A.M of Garment/
Working
MACHINE REQUIREMENT
System
The total machine requirement for the Module will have the
total number of
work stations along with all the attachments, work aids and
auxiliary
equipment requirements.
Number of SNLS machines required for the Module =
Expected Production Capacity*Total SNLS S.A.M /
Hours per day
Working
CONCLUSION
System
Modular production system is a new concept which has evolved

as natural
progression in accordance to the apparel market needs
Modular Production System brings along with itself benefits like
Low
inventory, quick response through reduced throughput time and
flexibility to
style changes.
This brings a feeling of self belief and belongingness to the
employee
towards the company.
BIBLIOGRAPHY
1) Flexible manufacturing system
By: DR. Rajesh Bheda
2) Graduation project
BY: Abhinay Shrivastava at Lagoona Clothings
3) www.Apparelsearch.com
4) www.apparelkey.com
5) www.epnet.com
System
System
THANK YOU

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Flexible Manufacturing

Today flexibility means to produce reasonably priced customized

FMS CONCEPT CONTIUED.

what is flexibility in manufacturing?

FMS CONCEPT CONTIUED.

(B) SYSTEM FLEXIBILITIES

FMS CONCEPT CONTIUED.

DIFFERENT APPROACHES OF FMS

The ability to efficiently produce highly customized and

The ability of a company to offer a wide variety of products

DIFFERENT LEVEL OF FMS

Flexible Manufacturing Module (FMM).

Example : a NC machine, a pallet

changer and a part buffer;

Flexible Manufacturing (Assembly) Cell (F(M/A)C).

FMMs and an AGV (automated guided vehicle);

Flexible Manufacturing Group (FMG).

Example : Two FMCs, a FMM and

Flexible Production Systems (FPS).

Example : A FMG and a FAC, two

Flexible Manufacturing Line (FML).

Example : multiple stations in a line

DISADVANTAGE OF IMPLEMENTATION Flexible Manufacturing

Limited ability to adapt to changes in product or product mix

FMSs complexity and cost are reasons for their slow

FLEXIBLE MANUFACTURING SYSTEM

NEED OF FMS IN APPAREL INDUSTRY

Global market (European,US), which is known for its small

It is a contained, manageable work unit that includes an

Teams may be used to perform all the operations or a certain

A module may be divided into several work zones based on the

Machines are arranged in a very tight configuration

Uses a designated work space between operations to balance

It is a stand-up module with flexible work zones and crosstrained operators

BUMP-BACK SYSTEM (TSS) contued..

DETERMINATION OF TEAM SIZE

The technical characteristics of the product, that is the S.A.M

DETERMINATION OF TEAM SIZE contued.. Flexible Manufacturing

The team has to be self managed and identification between

Modular production system is a new concept which has evolved

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