Implementation Of Flexible Manufacturing Systems Research Articles

Implementation of flexible manufacturing systems in Africa: Multiple case studies in the Gambia and Ghana

In comparison to Europe, Asia, and America, the African manufacturing sector performs poorly. This is largely attributable in part to inadequate use of advanced manufacturing concepts and technologies, as well as the insufficiently skilled workforce. African manufacturing companies must adopt and implement advanced manufacturing technologies and concepts such as flexible manufacturing systems in order to boost growth and accelerate development in the sector. In this study, we conducted multi-case studies on the implementation of flexible manufacturing systems in the manufacturing sectors of two West African countries (The Gambia and Ghana). Six manufacturing companies from The Gambia and eight from Ghana were chosen. Many of the companies involved in the study are small businesses that specialize in mechanical parts/system production, welding, and fabrication. The findings revealed that the use of advanced manufacturing technologies and concepts, as well as the adoption of flexible manufacturing systems, is extremely low. The results also show that the major obstacles to the adoption and implementation of advanced manufacturing technologies are, cost and, lack of qualified personnel. Companies have agreed to adopt and implement advanced manufacturing technologies and concepts if the opportunity arises. They also require more information on some cutting-edge technologies before deciding whether to adopt and implement them. Some of the other major challenges faced by African manufacturing companies include, high energy costs and unstable power supply, poor transportation network, and, lack of adequate finance.

A Perspective of Flexible Manufacturing System in Manufacturing Sectors

The rapid changes in customer demand force manufacturers to develop new technologies for flexibility enhancement in the manufacturing system. Different kinds of literature are available to explain the issues in the Flexible manufacturing system (FMS) and different traditional techniques employed for solving such issues. However, several new techniques have emerged in the past 25 years and no literature reviews exist to differentiate such modern approaches from traditional ones. The core purpose of this review is to study and investigate different levels of techniques involved in the effective implementation of FMS. This paper serves with some reasonable investigation of flexible issues faced in manufacturing industries such as scheduling, machine loading, material handling, and decision-making stage. For each manufacturing issue, the emerged manufacturing techniques are described in this review. This will also help future researchers interested in doing their research work in the area of FMS. It provides information to develop the best model for solving issues of the observed FMS problem. This paper contains the details of issues related to flexibility in manufacturing sectors with its resolving techniques that are reviewed and symbolized between the years 2000 and 2021.

Evaluation of the technological effects of application of the FMS elements

Flexible manufacturing systems (FMS) represent complex systems with great technological capabilities that are able to simultaneously achieve high level of flexibility, cost effectiveness and productivity. However, due to high investment cost and cost of exploitation of the FMS elements, the conditions for their rational use are required. Taking into account the increasingly complex conditions of production and launch of products, a systematic approach in the planning and implementation of FMSs is needed, thereby including the most significant technological and economical characteristics. This paper introduces two methodologies for evaluating the technological effects of application of the FMS elements at the conceptual level along with their verification for a single family of rotational parts.

Multi-objective Production Planning for a Flexible Manufacturing System based on NSBBO Method

The dramatic expansion in the global manufacturing market has created a demand for small and medium enterprise (SME) to apply the advanced manufacturing technology (AMT). The flexible manufacturing system (FMS) is considered as a highly competitive manufacturing strategy to ensure the success of the enterprises in the developing countries. The implementation of FMS, however, is an intractable task that requires complete integration of numerous components from various vendors. This paper presents a multi-objective production planning model for selecting the most suitable combination of machines and operations in machining processes to simultaneously minimize the system unbalance, makespan (MK) and total flow time. The proposed model considered the capacity of machines, tool magazines, batch sizes, processing time and the time taken to transport machining parts. Moreover, it also considered the different allocation of each part of batch into various machines. The principle of biogeography-based optimization (BBO) is adapted to explore the possibilities of attaining feasible solutions for a formulated problem. The most appropriate solutions in selecting the machine and operation allocation were determined based on non-dominated sorting BBO procedure (NSBBO) and validated by FlexSim simulation environment. The obtained results highlighted the practical applicability in the implementation of FMS.

Introduction of Flexible Manufacturing Systems as a Necessary Measure for the Russian Industrial Development

With the onset of the Fourth Industrial Revolution, the business environment becomes inherent in changes that occur with maximum speed, as well as characterized by the systemic nature of the consequences. One of them is the transformation of operational management models in industrial enterprises. The modern manufacturing system should focus not only on speed of response and flexibility, but also on the cost and quality of products. Integration of effective models: agile manufacturing, quick response manufacturing and lean production, in order to extract the best from them is proposed. The purpose of this study is to analyze this flexible manufacturing system and to relate it to the current state of the Russian industrial development. Theoretical and practical aspects of this model are presented. The examples of the flexible models introduction in the Russian industrial sector is allocated. The conclusion about the necessity of the flexible manufacturing systems implementation for the Russian industrial development is drawn.

FLEXIBLE MANUFACTURING SYSTEMS: INDUSTRY 4.0 SOLUTION

The development of flexible manufacturing systems (FMSs) and solutions based on flexibility idea (flexible assembly systems, flexible selection and picking systems, automated warehouses) began in the eighties of the last century. The process of planning, designing and FMS implementation is not an easy in many traditional companies. The authors of this paper presented some remarks on conventional and flexible manufacturing systems, listing positive and negative premises and consequences of FMS implementation. The paper briefly discusses the idea of flexible manufacturing system and automation, as the solution typical for the Industry 4.0, recognizes the approach of polish enterprises towards the approach and some of the trends that seem to be the future of the FMS solutions.

AGV Controlled FMS

One of the key factors that prevent the implementation of Flexible Manufacturing Systems (FMS) is the elaborate cost associated with the control software. In a FMS there is often a wide range of equipment, such as personal computers, Programmable Logical Controllers (PLCs), CNC Machines or robots, each of these having their ownintelligence' and library of data. Providing a means of communication between these individual controllers has traditionally been achieved using a Local Area Network (LAN). This proves more expensive when traditional manual operated machines have to be integrated into the system. The model described in this paper provides an alternative to the con- ventional use of a LAN in a FMS environment. In the design solution, an Automatically Guided Vehicle (AGV) is used as both the materials handling unit and the communications line linking each station to the host controller. Communications between the AGV and peripheral equipment is achieved using a standard infrared data link, eliminating hard-wiring and network protocols. A simulation model has been developed to demonstrate the feasibility of such a system, using industrial data. The software package Witness is used to develop the simulation model. The objective from developing this simulation model is to test whether an AGV is capable of meeting the demands of such a scenario. The research undertaken aims to test this by modelling an existing factory layout. Using this layout and captured machining times and part routes, from the factory database, the feasibility of such AGV controlled production system is established. The model shows that such a system is plausible in a scenario where machine times are high and the distance between machines is large.

An Innovative Drive Train Design for Improved Dead Reckoning Accuracy in Automated Guided Vehicles

The automated guided vehicle (AGV) is a key component for the successful implementation of flexible manufacturing systems (FMS). AGVs are wheeled mobile robots (WMR) employed for material handling in the constantly evolving layouts of these modern factory shop floors. As such their ability to navigate autonomously is an equally important aspect to sustain an efficient manufacturing process. However, their mobility efficiency is inherently affected by the unproductive systematic and non-systematic odometry errors. Odometry errors mainly occur due to the mobility configuration of the AGV drive train and the surface characteristics the robot is interacting with. Odometry error accumulates over the distance traveled and leads to severe dead reckoning inaccuracy if the robot’s feedback control mechanism is unable to correct the error fast. This paper proposes an innovative drive train mechanism called dual planetary drive (DPD) that will minimize odometry errors without the need for complex electronic feedback control systems

Task scheduling of AGV in FMS using non-traditional optimization techniques

Flexible Manufacturing System (FMS), which is equipped with several CNC machines and Automated Guided Vehicle (AGV) based material handling system is designed and implemented to gain the flexibility and efficiency of production. After the implementation of FMS, in practice, the scheduling of the resources, such as frequent variation in the parts, tools, AGV routings, becomes a complex task. This is being done traditionally using various mathematical programming techniques. In recent years, random search algorithms have been attempted for scheduling. Most of the research has been emphasized only on single objective optimization. Multi objective problems in scheduling with conflicting objectives are more complex and combinatorial in nature and hardly have a unique solution. This paper addresses multi objective task scheduling of AGV in a flexible manufacturing environment using nontraditional optimization algorithms. In this paper the authors made an attempt to find the nearoptimum schedule for two AGVs based on the balanced workload and the minimum traveling time for maximum utilization. The proposed methods are exemplified with illustrations. (Received in March 2009, accepted in September 2009. This paper was with the authors 3 months for 1 revision.)

GTA‐based framework for evaluating the feasibility of transition to FMS

PurposeToday's volatile condition of the market is forcing the manufacturing organizations to adapt the flexible manufacturing systems (FMS) to meet the challenges imposed by international competition, ever‐changing customer demands, rapid delivery to market, and advancement in technology. There are certain enablers, which help in the implementation of FMS or in the transition process from traditional manufacturing system to FMS. The utmost need is to analyze the behavior of these enablers for their effective utilization in the implementation of FMS. This paper aims to address these issues.Design/methodology/approachThis paper presents a methodology based on graph theoretical approach for finding the feasibility of transition to FMS for any industry. A universal feasibility index of transition (FIT) is proposed that evaluates and ranks different organizations according to their capability to be converted into FMS. This FIT value is obtained from a permanent feasibility function obtained from an enablers' digraph of FMS.FindingsThe major finding of this paper is that one can judge whether a particular industry is fit for FMS or not by calculating its FIT value. This FIT value can also be utilized in ranking different industries for their possible transition to FMS.Practical implicationsThe FIT obtained from a permanent function indicates the strength of enablers and their inter‐relations. More is the value of this index; more will be suitability of that organization for FMS adoption. In this way, managers can judge that a particular organization is suitable or fit for FMS implementation or not, without making the huge investments for such a complex production system and thus, minimize their risks.Originality/valueIdentification, classification of enablers into some important categories, and their analysis is a unique and innovative effort in the area of FMS.

A graph-theoretic approach to evaluate the intensity of barriers in the implementation of FMSs

Manufacturing organisations adopt Flexible Manufacturing Systems (FMSs) to meet the challenges imposed by today's volatile market standards. But the implementation of FMSs is not an easy job. Various barriers are experienced in real-life cases during its implementation. It is very much necessary to analyse the nature and impact of these barriers so that production managers can think of some strategies to overcome these barriers. In the present work, a Graph-Theoretic Approach (GTA) has been utilised to find the intensity of these barriers through an index which is calculated through a permanent function obtained from the digraph of FMS barriers.

An ISM approach for modelling the enablers of flexible manufacturing system: the case for India

The volatile condition of today's market is forcing the manufacturing managers to adapt the flexible manufacturing systems (FMS) to meet the challenges imposed by international competition, ever changing customer demands, rapid delivery to market and advancement in technology. There are certain enablers, which help in the implementation of FMS or in the transition process from traditional manufacturing systems to FMS. The utmost need is to analyse the behaviour of these enablers for their effective utilization in the implementation of FMS. The main objective of this paper is to understand the mutual interaction of these enablers and identify the ‘driving enablers’ (i.e. which influence the other enablers) and the ‘dependent enablers’ (i.e. which are influenced by others). In the present work, these enablers have been identified through the literature, their ranking is done by a questionnaire-based survey and interpretive structural modelling (ISM) approach has been utilized in analysing their mutual interaction. An ISM model has been prepared to identify some key enablers and their managerial implications in the implementation of FMS.

A review of some issues and identification of some barriers in the implementation of FMS

Global competition, advancements in technology and ever changing customers’ demand have made the manufacturing companies to realize the importance of flexible manufacturing systems (FMS). These organizations are looking at FMS as a viable alternative to enhance their competitive edge. But, implementation of this universally accepted and challenging technology is not an easy task. A large number of articles have been reviewed and it is found that the existing literature lacks in providing a clear picture about the implementation of FMS. In this paper, work of various researchers has been studied and it is found that it is really a very difficult task for any organization to transform into FMS on the basis of existing research results. A wide gap exists between the proposed approaches/algorithms for the design of different components of FMS and the real-life complexities. Besides describing the gap in various issues related to FMS, some barriers, which inhibit the adaptation and implementation of FMS, have also been identified in this paper.

A mathematical model for optimal and phased implementation of flexible manufacturing systems

The mathematical programming is one of the analytical techniques previously used for the justification and the selection of advanced manufacturing systems. In this paper an integrated dynamic programming model has been introduced in order to analyze the optimal and phased implementation of flexible technology in a manufacturing system. The objectives of the model are minimizing the cost network flow and represented capital investment decisions, aggregate production decisions, and the functional of the production costs.

AGV controlled FMS

One of the key factors that prevent the implementation of Flexible Manufacturing Systems (FMS) is the elaborate cost associated with the control software. In a FMS there is often a wide range of equipment, such as personal computers, Programmable Logical Controllers (PLCs), CNC Machines or robots, each of these having their own 'intelligence' and library of data. Providing a means of communication between these individual controllers has traditionally been achieved using a Local Area Network (LAN). This proves more expensive when traditional manual operated machines have to be integrated into the system. The model described in this paper provides an alternative to the conventional use of a LAN in a FMS environment. In the design solution, an Automatically Guided Vehicle (AGV) is used as both the materials handling unit and the communications line linking each station to the host controller. Communications between the AGV and peripheral equipment is achieved using a standard infrared data link, eliminating hard-wiring and network protocols. A simulation model has been developed to demonstrate the feasibility of such a system, using industrial data. The software package Witness is used to develop the simulation model. The objective from developing this simulation model is to test whether an AGV is capable of meeting the demands of such a scenario. The research undertaken aims to test this by modelling an existing factory layout. Using this layout and captured machining times and part routes, from the factory database, the feasibility of such AGV controlled production system is established. The model shows that such a system is plausible in a scenario where machine times are high and the distance between machines is large.

A generic event control framework for modular flexible manufacturing systems

A generic event control framework is presented for a class of modular flexible manufacturing systems (FMSs). A modular FMS is characterized as a set of flexible workstations inter-connected by a material handling system consisting of a transporter and a stocker. Many of the existing FMS implementations in industry fall into this class. Furthermore, the modularity also allows the capability to effectively model a complex FMS by decomposing it into several modular FMSs. In order to achieve reconfigurability of control system for various FMS implementations and control policies, the proposed control framework is defined as a set of distributed resource controllers and a central system supervisor coordinating them. The resource controllers are further classified into workstation, transporter, and stocker controllers. As the controllers exchange a series of events according to pre-defined protocols, they are modelled as event handlers in which control actions are made based on the event occurrences. Specifically, for each controller, an event-based control structure specified in terms of generic logical and performance control functions, is presented. Since the proposed framework is defined by the use of the interacting distributed processes with the well-defined protocols and computationally efficient algorithms, it is expected that the framework is easily implementable for most industrial FMSs. Finally, the performance and reconfigurability is demonstrated by the distributed simulation from which we can also verify the correctness of the proposed algorithms.

A strategic investment model for phased implementation of flexible manufacturing systems

AbstractThis paper describes a set of strategic, tactical, and operational models that can be used to analyze the phased implementation of flexible technology in a manufacturing system. The strategic model represents capital investment decisions, the tactical model represents aggregate production decisions, and the operational model represents the functional form of the production costs. Learning effects and other nonlinearities (such as setup costs, economies of scale, and congestion effects) can be quantified in the models. An efficient solution procedure (using dynamic programming and minimum cost network flow optimization) is described. The efficiency of the solution method permits a host of ‘what‐if’ scenarios to be examined by the decision maker.

A strategic investment model for phased implementation of flexible manufacturing systems

This paper describes a set of strategic, tactical, and operational models that can be used to analyze the phased implementation of flexible technology in a manufacturing system. The strategic model represents capital investment decisions, the tactical model represents aggregate production decisions, and the operational model represents the functional form of the production costs. Learning effects and other nonlinearities (such as setup costs, economies of scale, and congestion effects) can be quantified in the models. An efficient solution procedure (using dynamic programming and minimum cost network flow optimization) is described. The efficiency of the solution method permits a host of ‘what-if’ scenarios to be examined by the decision maker.

Off-line programming of flexible welding manufacturing cells

Abstract The use of robotized welding to achieve better quality has demanded research of new technologies to integrate and test the systems. The complete control of a flexible manufacturing cell involves perfect task synchronisation among all of its robots and equipment. Off-line programming provides an essential link between CAD and CAM. The development of off-line programming systems should result in greater use of robots and accelerate the implementation of flexible manufacturing systems (FMS). It also offers an alternative for complex automated production lines and should allow rapid response to changing product/process issues. This article describes some features of graphic simulation and off-line programming focusing on its applications to robotized welding.

Capacity planning for phased implementation of flexible manufacturing systems under budget restrictions

We consider a problem of gradually replacing conventional dedicated machines with flexible manufacturing modules (FMMs) under budget restrictions over a finite planning horizon assuming that dedicated machines cannot be purchased during the planning horizon and acquired FMMs are kept until the end of the horizon. In the problem, a replacement schedule is to be determined and operations are to be assigned to the FMMs or the dedicated machines with the objective of minimizing the sum of discounted costs of acquisition and operation of FMMs and operation costs of conventional dedicated machines. In this research, the problem is formulated as a mixed integer linear program and solved by a Lagrangean relaxation approach. A subgradient optimization method is employed to obtain lower bounds of solutions and a multiplier adjustment method is devised to improve the lower bounds. We develop a linear programming-based Lagrangean heuristic algorithm to find a good feasible solution of the original problem in a reasonable amount of computation time. The algorithm is tested on randomly generated test problems and the results are reported.