1. A MINI PROJECT
SUBMITTED
IN PARTIAL FULFILMENT OF THE REQUIREMENT
FOR THE DEGREE OF
MASTER OF BUSINESS ADMINISTRATION
IN
OPERATIONS MANAGEMENT
PRESENTED BY:
NEHA KHAN
MBA 2ND SEM
UNDER THE SUPERVISION OF:
DR. SWATI SRIVASTAVA
DEPARTMENT OF BUSINESS
ADMINISTRATION
TO STUDY FLEXIBLE MANUFACTURING SYSTEM
OF TOYOTA
2. TOYOTA
• A Japanese multinational automotive manufacturer.
• Founded by Kiichiro Toyoda on August 28, 1937.
• It is one of the most innovative car manufacturers
in terms of its production.
• They continue to evolve and revitalize their
production system.
• Toyota had a Flexible Body Line back in 1985.
• They have modified their production lines which
they now call the Global Body Line or GBL.
• GBL incorporates a completely different aspect of
flexibility.
3. FLEXIBLE MANUFACTURING SYSTEM
• A Flexible Manufacturing System (FMS) is a type of
industrial process that allows equipment to be used for
more than one purpose, or that may be related.
• Machines are often used to make customized parts, or
to make different parts of different product models.
• This type of system can be changed manually, but may
be controlled by a computer, and modified by a
completely automated process.
• A flexible manufacturing system is an automated
machine cell, consisting of a group of processing
workstations, interconnected with automated material
handling and storage systems.
4. OBJECTIVES
• To improve efficiency and economies of scale associated with mass
production.
• To maintain the flexibility in order to manufacture variety of products.
• Optimizing the manufacturing cycle time.
• To develop an automated material handling system.
• Reduce downtime and improve control over quality.
• Improve work-in-process inventory.
• Eliminate labour dependence on highly skilled machines.
• Reduce production costs.
• External changes such as change in product design and production system.
5. WHAT
MAKES IT
FLEXIBLE???
• Four capabilities that a manufacturing
system must possess to be a flexible.
– Process different part styles in a
non-batch mode.
– Accept changes in production
schedule.
– Respond gracefully to equipment
malfunctions and breakdowns in
the system.
– Accommodate the introduction of
new part designs.
6. CLASSIFICATION OF FMS
Based on the kinds of operations they perform-
• Processing operation
• Assembly operation
Based on the number of machines in the system-
• Single machine cell (SMC)
• Flexible machine cell (FMC)
• Flexible manufacturing system (FMS)
Based on the level of flexibility associated with the system-
• Dedicated FMS
• Random order FMS
7. BASIC COMPONENTS OF FMS
FLEXIBLE SYSTEM
WORKSTATION
CNC M/C
MATERIAL
HANDLING
ROBOT
TRANSFER
EQUIPMENT
AS/R EQUIPMENT
COMPUTER
CONTROL
REAL TIME CONTROL
(CONTROL DIFFERENT
ACTIVITIES)
9. ADVANTAGES OF 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
DISADVANTAGES OF FMS
• Expensive • Substantial pre-planning activity
10. FINDINGS
• Toyota has gained more productivity and profitability
• Computer controlled robots in the FMS enabled in achieving a mixed fund
of profits ranging from high usage to high production capacity.
• FMS has a great adaptability of changing the sequences of manufacturing
and utilize the idle time.
• Reduced the lead time by 40%, improved machine utilization by 30%,
reduced the labour times by 30%, and also reduced the direct and
indirect labour costs.
11. CONCLUSION
• Flexible manufacturing system has the ability to respond quickly to any design changes
in a product. It has the natural flexibility of finding new types of piped product without
major modifications.
• The Flexible Manufacturing System uses a number of robotic equipment and systems.
Software developed to integrate CNC control machine and management system.
• Flexibility in manufacturing has improved:
– Lower labor costs,
– Decreased inventory costs,
– Consistent and better quality,
– Low cost/output unit,
– Savings from indirect work, from reduced errors, recycling, repairs and disposal.
