What Is a Flexible Manufacturing System (FMS)?

What Is a Flexible Manufacturing System (FMS)?

Let me explain what a flexible manufacturing system, or FMS, really is. It's a production setup designed from the start to handle shifts in the type and volume of products you're making. You can reconfigure the machines and computerized systems to produce different parts and adjust to varying production levels without much hassle.

Key Takeaways

Here's what you need to know upfront: An FMS is built to adapt quickly to changes in goods production, both in type and quantity. The process is mostly automated, which cuts down on labor costs overall. That said, designing and implementing an FMS is more expensive than a traditional fixed system, and it demands skilled technicians to keep it running.

Understanding a Flexible Manufacturing System (FMS)

If you're looking to boost efficiency and cut costs in your manufacturing operations, an FMS could be worth considering. It plays a big role in business development by allowing for make-to-order strategies where you customize products and keep inventory low. Flexibility like this doesn't come cheap, though—buying and setting up the specialized equipment for customization is pricier than standard systems.

The idea behind FMS comes from Jerome H. Lemelson, an American industrial engineer and inventor who lived from 1923 to 1997. He filed patents for it in the early 1950s, envisioning a robot-based system that could weld, rivet, convey, and inspect goods.

Lemelson never actually built his system because the technology wasn't there yet. But by the late 1960s, it became feasible, and FMS started appearing on factory floors in the US and Europe, really taking off in the 1970s.

In practice, an FMS might consist of interconnected workstations with computer terminals handling the entire product creation process. This includes loading and unloading, machining and assembly, storage, quality testing, and data processing. You program it to produce one batch of products in a specific quantity, then it automatically switches to another batch with different specs.

Advantages and Disadvantages of a Flexible Manufacturing System (FMS)

The primary advantage of an FMS is how it boosts production efficiency. You minimize downtime since you don't have to stop the line to retool for a new product.

On the downside, expect higher initial costs and more time to design the system for future requirements. You'll also need specialized technicians to operate, monitor, and maintain it, which adds to expenses. Still, proponents argue that the automation leads to an overall drop in labor costs.

How Is a Flexible Manufacturing System (FMS) Set Up?

You can set up an FMS in various ways, given its core strength is adaptability. One common setup involves interconnected computer workstations that manage the full product lifecycle, from loading and unloading to machining, assembly, storage, quality testing, and data processing. The programming lets it switch automatically from one product batch in a set quantity to another with different parameters.

What Are the Benefits and Drawbacks of an FMS?

As I mentioned, the key benefit is enhanced production efficiency, with reduced delays because you avoid shutting down for product changes. Drawbacks include the steep upfront costs and the time to specify designs for future needs, plus the expense of specialized technicians. That said, the automation usually results in lower overall labor costs.

Who Invented the FMS?

Credit goes to Jerome H. Lemelson, the American engineer and inventor from 1923 to 1997, for conceptualizing flexible manufacturing. His design was a robot system for welding, riveting, conveying, and inspecting goods. Systems inspired by this appeared in the late 1960s in the US and Europe, gaining popularity in the 1970s.

The Bottom Line

In summary, a flexible manufacturing system is what you use in manufacturing to adapt production lines swiftly to product changes. It relies on computer-controlled robots and sensors to adjust processes based on customer demands.