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ME 2402 – COMPUTER INTEGRATED
MANUFACTURING (CIM)
YEAR/SEMESTER : IV/VII
UNIT IV SHOP FLOOR CONTROL AND
INTRODUCTION TO FM...
UNIT IV SHOP FLOOR CONTROL AND INTRODUCTION TO
FMS
Shop floor control – phases – factory data collection
system – automati...
SHOP FLOOR CONTROL
A shop floor control system is defined as a system for utilizing
data from as well as data processing f...
Function of SFC
Scheduling
Dispatching
Follow-up
Providing output data
Providing efficiency
1/25/2016 M.MANIMARAN KRC...
Phases of SFC
1. Order release
phase provides the documentation needed to process a production
order through the factory.
...
Phases of SFC
2. Order scheduling
order scheduling executes the dispatching function in production planning and control.
T...
Phases of SFC
3. Order progress
The order progress phase monitors the status of the various orders
in the plant, work-in-p...
Factory data collection system
Several data collection techniques used to collect data from the shop
floor. These techniqu...
Types of data collection system
1. On-line data collection system
The data are entered directly into the plant computer sy...
Automatic identification method
It refers to various technologies used in automatic (or) semi-
automatic acquisition of pr...
Types of Automated Identification Technology
Bar codes
Radio frequency systems
Magnetic stripe
Optical character recog...
Application
1. Material handling
– Shipping and receiving and Storage
– Sortation
– Order picking
– Parts for assembly
2. ...
BAR CODE TECHNOLOGY
• It is most the most popular method of automatic identification
in factory data collection.
• Bar cod...
BAR CODES TECHNOLOGY
1/25/2016 M.MANIMARAN KRCE TRICHY 14
Bar codes technology
Commonly used bar codes are:
Code 39 interleaved two-of-five(ITF)
Universal product code code 93
Code...
Radio frequency identification
1/25/2016 M.MANIMARAN KRCE TRICHY 16
AUTOMATED DATA COLLECTION SYSTEM
Computer process monitoring involves the use of the computer
to observe the process and a...
Flexible manufacturing system
DEFINITION
• FMS is highly automated GT Machine cell, consisting of group of
processing stat...
TYPES OF FLEXIBILITY
There are three levels of manufacturing flexibility.
a) Basic flexibilities
1.Machine flexibility: Th...
b) System flexibilities
1.Volume flexibility
2.Expansion flexibility
3.Routing flexibility
4.Process flexibility
5.Product...
TESTS OF FLEXIBILITY
The following are four reasonable tests of flexibility in an
automated manufacturing system :
 Part ...
COMPONENTS OF FMS
FMS has the following components.
Workstation
Material Handling and Storage System
Computer Control S...
WORKSTATION
Following are the types of workstations typically found in an FMS
1. Load/Unload Stations.
2. Machining Statio...
MATERIAL HANDLING SYSTEM
The various automated material handling systems are used to
transport work parts and subassembly ...
COMPUTER CONTROL SYSTEM
1. Production Control
2. Workstation Control
3. Quality Control
4. Failure diagnosis
5. Safety Mon...
HUMAN RESOURCES
Human are needed to manage the operations of the FMS.
Functions typically performed by human includes:
1. ...
FMS LAYOUT CONFIGURATION
These are different types of layout:
1. Inline or progressive layout
2. Loop Layout
3. Ladder Lay...
INLINE LAYOUT
1/25/2016 M.MANIMARAN KRCE TRICHY 28
Loop Layout
1/25/2016 M.MANIMARAN KRCE TRICHY 29
LADDER LAYOUT
1/25/2016 M.MANIMARAN KRCE TRICHY 30
TYPES OF MATERIAL HANDLING SYSTEM
1. Conveyor
2. Cranes and Hoists
3. Industrial Trucks
4. Monorails
5. AGV’s
6. Industria...
Conveyor
1/25/2016 M.MANIMARAN KRCE TRICHY 32
Cranes
1/25/2016 M.MANIMARAN KRCE TRICHY 33
Hoists
1/25/2016 M.MANIMARAN KRCE TRICHY 34
Trucks
1/25/2016 M.MANIMARAN KRCE TRICHY 35
RGV and AGV
1/25/2016 M.MANIMARAN KRCE TRICHY 36
FMS APPLICATION
1. Machining
2. Sheet metal working
3. Plastic Injection Moulding
4. Forging
5. Welding
6. Textile Machine...
ADVANTAGE OF FMS
1. Increased machine utilization
2. Reduced Inventory
3. Reduced Lead times
4. Greater Flexibility in pro...
DISADVANTAGES OF FMS
1. High Capital Investment is required
2. Training and Maintaining knowledge labor is difficult
3. Co...
THANK YOU!!
1/25/2016 M.MANIMARAN KRCE TRICHY 40
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Unit iv Shop floor control and FMS Slide 1 Unit iv Shop floor control and FMS Slide 2 Unit iv Shop floor control and FMS Slide 3 Unit iv Shop floor control and FMS Slide 4 Unit iv Shop floor control and FMS Slide 5 Unit iv Shop floor control and FMS Slide 6 Unit iv Shop floor control and FMS Slide 7 Unit iv Shop floor control and FMS Slide 8 Unit iv Shop floor control and FMS Slide 9 Unit iv Shop floor control and FMS Slide 10 Unit iv Shop floor control and FMS Slide 11 Unit iv Shop floor control and FMS Slide 12 Unit iv Shop floor control and FMS Slide 13 Unit iv Shop floor control and FMS Slide 14 Unit iv Shop floor control and FMS Slide 15 Unit iv Shop floor control and FMS Slide 16 Unit iv Shop floor control and FMS Slide 17 Unit iv Shop floor control and FMS Slide 18 Unit iv Shop floor control and FMS Slide 19 Unit iv Shop floor control and FMS Slide 20 Unit iv Shop floor control and FMS Slide 21 Unit iv Shop floor control and FMS Slide 22 Unit iv Shop floor control and FMS Slide 23 Unit iv Shop floor control and FMS Slide 24 Unit iv Shop floor control and FMS Slide 25 Unit iv Shop floor control and FMS Slide 26 Unit iv Shop floor control and FMS Slide 27 Unit iv Shop floor control and FMS Slide 28 Unit iv Shop floor control and FMS Slide 29 Unit iv Shop floor control and FMS Slide 30 Unit iv Shop floor control and FMS Slide 31 Unit iv Shop floor control and FMS Slide 32 Unit iv Shop floor control and FMS Slide 33 Unit iv Shop floor control and FMS Slide 34 Unit iv Shop floor control and FMS Slide 35 Unit iv Shop floor control and FMS Slide 36 Unit iv Shop floor control and FMS Slide 37 Unit iv Shop floor control and FMS Slide 38 Unit iv Shop floor control and FMS Slide 39 Unit iv Shop floor control and FMS Slide 40
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ME 2402 COMPUTER INTEGRATED MANUFACTURING

Unit iv Shop floor control and FMS

  1. 1. ME 2402 – COMPUTER INTEGRATED MANUFACTURING (CIM) YEAR/SEMESTER : IV/VII UNIT IV SHOP FLOOR CONTROL AND INTRODUCTION TO FMS Prepared By MANIMARAN.M ASSISTANT PROFESSOR K.RAMAKRISHNAN COLLEGE OF ENGINEERING TRICHY 1/25/2016 1M.MANIMARAN KRCE TRICHY
  2. 2. UNIT IV SHOP FLOOR CONTROL AND INTRODUCTION TO FMS Shop floor control – phases – factory data collection system – automatic identification methods – Bar code technology – automated data collection system. FMS – components of FMS – types – FMS workstation – material handling and storage system –FMS layout- computer control systems – applications and benefits. 1/25/2016 M.MANIMARAN KRCE TRICHY 2
  3. 3. SHOP FLOOR CONTROL A shop floor control system is defined as a system for utilizing data from as well as data processing files to maintain and communicate information on shop orders and work centers. It also known as Production Activity Control (PAC). 1/25/2016 M.MANIMARAN KRCE TRICHY 3
  4. 4. Function of SFC Scheduling Dispatching Follow-up Providing output data Providing efficiency 1/25/2016 M.MANIMARAN KRCE TRICHY 4
  5. 5. Phases of SFC 1. Order release phase provides the documentation needed to process a production order through the factory. The collection of document is called as shop packet. Route sheet Material requisitions Job cards Move tickets Part list 1/25/2016 M.MANIMARAN KRCE TRICHY 5
  6. 6. Phases of SFC 2. Order scheduling order scheduling executes the dispatching function in production planning and control. Two elements of order scheduling • Machine loading • Job sequencing Priority sequencing rules (or)Dispatching rules SOT (shortest operating time) Earliest due date STR (slack time remaining) = time remaining before due date-remaining process time STR/OP = STR/No.of. Remaining operations Critical ratio (CR) = Due date – Current date/No.of remaining working days Queue ratio (QR) = slack time remaining in the schedule /planned remaining queue time First – come, first served Last – come, last served1/25/2016 M.MANIMARAN KRCE TRICHY 6
  7. 7. Phases of SFC 3. Order progress The order progress phase monitors the status of the various orders in the plant, work-in-progress and other characteristics that indicate the progress and performance of production. Three forms of order progress report as follow as Work order status report Progress report Exception report 1/25/2016 M.MANIMARAN KRCE TRICHY 7
  8. 8. Factory data collection system Several data collection techniques used to collect data from the shop floor. These techniques require the employees to gather the data and later the data are gathered on a fully automated systems that requires no human participation. Types of data collected by FDC – List number of parts that are scraped – List number of parts requiring rework – Equipment downtime – Time clock by employees for punch in and out. – Time taken at each work Centre – Labor time in each work order Factory data collection system 1/25/2016 M.MANIMARAN KRCE TRICHY 8
  9. 9. Types of data collection system 1. On-line data collection system The data are entered directly into the plant computer system and are immediately available to the order progress 2. Off-line data collection system the data are collected temporarily in a storage device to be entered and processed by plant computer in a batch mode 1/25/2016 M.MANIMARAN KRCE TRICHY 9
  10. 10. Automatic identification method It refers to various technologies used in automatic (or) semi- automatic acquisition of product data entry into a computer system. Basic components • Encoded data • Machine reader (or) scanner • Decoder 1/25/2016 M.MANIMARAN KRCE TRICHY 10
  11. 11. Types of Automated Identification Technology Bar codes Radio frequency systems Magnetic stripe Optical character recognition Machine vision 1/25/2016 M.MANIMARAN KRCE TRICHY 11
  12. 12. Application 1. Material handling – Shipping and receiving and Storage – Sortation – Order picking – Parts for assembly 2. Manufacturing – Order processing – Work-in-process – Machine utilization and Worker attendance 3. Retails sales and inventory 4. Ware housing and distribution center operations 5. Mail and parcel handling 6. Patient identification in hospitals 7. Cheque processing in banks1/25/2016 M.MANIMARAN KRCE TRICHY 12
  13. 13. BAR CODE TECHNOLOGY • It is most the most popular method of automatic identification in factory data collection. • Bar code technology was invented in 1949 by Norman J. Woodland and Bernard silver of USA. 1/25/2016 M.MANIMARAN KRCE TRICHY 13
  14. 14. BAR CODES TECHNOLOGY 1/25/2016 M.MANIMARAN KRCE TRICHY 14
  15. 15. Bar codes technology Commonly used bar codes are: Code 39 interleaved two-of-five(ITF) Universal product code code 93 Code 128 Codabar 1/25/2016 M.MANIMARAN KRCE TRICHY 15
  16. 16. Radio frequency identification 1/25/2016 M.MANIMARAN KRCE TRICHY 16
  17. 17. AUTOMATED DATA COLLECTION SYSTEM Computer process monitoring involves the use of the computer to observe the process and associated equipment and to collect and record data from the operation. • Data acquisition system • Data collection system • Multi level scanning 1/25/2016 M.MANIMARAN KRCE TRICHY 17
  18. 18. Flexible manufacturing system DEFINITION • FMS is highly automated GT Machine cell, consisting of group of processing stations interconnected by automated material handling system and controlled by computer system. • or • A flexible manufacturing system (FMS) is a form of flexible automation in which several machine tools are linked together by a material- handling system, and all aspects of the system are controlled by a central computer. 1/25/2016 M.MANIMARAN KRCE TRICHY 18
  19. 19. TYPES OF FLEXIBILITY There are three levels of manufacturing flexibility. a) Basic flexibilities 1.Machine flexibility: The ease with which a machine can process various operations 2.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 3.Operation flexibility: A measure of the ease with which alternative operation sequences can be used for processing a part type 1/25/2016 M.MANIMARAN KRCE TRICHY 19
  20. 20. b) System flexibilities 1.Volume flexibility 2.Expansion flexibility 3.Routing flexibility 4.Process flexibility 5.Product flexibility c) Aggregate flexibilities 1.Program Flexibility 2.Production Flexibility 3.Market Flexibility 1/25/2016 M.MANIMARAN KRCE TRICHY 20
  21. 21. TESTS OF FLEXIBILITY The following are four reasonable tests of flexibility in an automated manufacturing system :  Part variety test. Can the system process different part styles in a non batch mode?.  Schedule change test. Can the system readily accept changes in production schedule, and changes in either part mix or production quantity.  Error recovery test. Can the system recover quickly from equipment breakdowns, so that the production is not completely disrupted.  New part test. Can new part designs be introduced into the existing product mix with relative ease. 1/25/2016 M.MANIMARAN KRCE TRICHY 21
  22. 22. COMPONENTS OF FMS FMS has the following components. Workstation Material Handling and Storage System Computer Control System Human Resources 1/25/2016 M.MANIMARAN KRCE TRICHY 22
  23. 23. WORKSTATION Following are the types of workstations typically found in an FMS 1. Load/Unload Stations. 2. Machining Stations. 3. Other processing Stations. (punching, shearing, welding, etc.) 4. Assembly Station. 5. Inspection station. 6. Other Stations and Equipment. (Inspection, Vision, etc) 1/25/2016 M.MANIMARAN KRCE TRICHY 23
  24. 24. MATERIAL HANDLING SYSTEM The various automated material handling systems are used to transport work parts and subassembly parts between the processing stations. Functions: 1. Random, Independent movement of work piece between stations. 2. Handle variety of Parts 3. Temporary storage 4. Convenient access for loading and unloading 5. Compatible with computer control. 1/25/2016 M.MANIMARAN KRCE TRICHY 24
  25. 25. COMPUTER CONTROL SYSTEM 1. Production Control 2. Workstation Control 3. Quality Control 4. Failure diagnosis 5. Safety Monitoring 6. Work piece Monitoring 7. Performance Monitoring and Reporting 1/25/2016 M.MANIMARAN KRCE TRICHY 25
  26. 26. HUMAN RESOURCES Human are needed to manage the operations of the FMS. Functions typically performed by human includes: 1. Loading raw work parts into the system, 2. Unloading finished parts (or assemblies) from the system, 3. Changing and setting tools, 4. Equipment maintenance and repair, 5. NC part programming in a machining system, and 6. Programming and operation the computer system. 1/25/2016 M.MANIMARAN KRCE TRICHY 26
  27. 27. FMS LAYOUT CONFIGURATION These are different types of layout: 1. Inline or progressive layout 2. Loop Layout 3. Ladder Layout 4. Open-field Layout 5. Robot Centered Layout 1/25/2016 M.MANIMARAN KRCE TRICHY 27
  28. 28. INLINE LAYOUT 1/25/2016 M.MANIMARAN KRCE TRICHY 28
  29. 29. Loop Layout 1/25/2016 M.MANIMARAN KRCE TRICHY 29
  30. 30. LADDER LAYOUT 1/25/2016 M.MANIMARAN KRCE TRICHY 30
  31. 31. TYPES OF MATERIAL HANDLING SYSTEM 1. Conveyor 2. Cranes and Hoists 3. Industrial Trucks 4. Monorails 5. AGV’s 6. Industrial Robots 1/25/2016 M.MANIMARAN KRCE TRICHY 31
  32. 32. Conveyor 1/25/2016 M.MANIMARAN KRCE TRICHY 32
  33. 33. Cranes 1/25/2016 M.MANIMARAN KRCE TRICHY 33
  34. 34. Hoists 1/25/2016 M.MANIMARAN KRCE TRICHY 34
  35. 35. Trucks 1/25/2016 M.MANIMARAN KRCE TRICHY 35
  36. 36. RGV and AGV 1/25/2016 M.MANIMARAN KRCE TRICHY 36
  37. 37. FMS APPLICATION 1. Machining 2. Sheet metal working 3. Plastic Injection Moulding 4. Forging 5. Welding 6. Textile Machinery manufacture 7. Semiconductor Manufacture 1/25/2016 M.MANIMARAN KRCE TRICHY 37
  38. 38. ADVANTAGE OF FMS 1. Increased machine utilization 2. Reduced Inventory 3. Reduced Lead times 4. Greater Flexibility in production scheduling 5. Reduced direct labor cost 6. Increased Labor productivity 7. Consistent quality 1/25/2016 M.MANIMARAN KRCE TRICHY 38
  39. 39. DISADVANTAGES OF FMS 1. High Capital Investment is required 2. Training and Maintaining knowledge labor is difficult 3. Cost of Fixture 4. Conditioning Monitoring is expensive 5. Sophisticated manufacturing systems 6. Limited ability to adapt to changes in product or product mix. 1/25/2016 M.MANIMARAN KRCE TRICHY 39
  40. 40. THANK YOU!! 1/25/2016 M.MANIMARAN KRCE TRICHY 40
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