Flexible ManufacturingAs an introduction to the subsequent discussions of production systems and advanced manufacturing technologies it is useful to present a definition of the term manufacturing system. A manufacturing system can be defined as a series of value-adding manufacturing processes converting the raw materials into more useful forms and eventually finished products.In the modern manufacturing setting, flexibility is an important characteristic. It means that a manufacturing system is versatile and adaptable, while also capable of handling relatively high production runs. A flexible manufacturing system is versatile in that it can produce a variety of parts. It is adaptable because it can be quickly modified to produce a completely different line of parts.A flexible manufacturing system is an individual machine or group of machines served by an automated materials handling system that is computer controlled and has a tool handling capability. Because of its tool handling capability and computer control, such a system can be continually reconfigured to manufacture a wide variety of parts. This is why it is called a flexible manufacturing system.A FMS typically encompasses:* Process equipment e.g. , machine tools, assembly stations, and robots* Material handling equipment e.g. , robots, conveyors, and AGVs (automated guided vehicles) * A communication system* A computer control system Flexible manufacturing represents a major step toward the goal of fully integrated manufacturing. It involves integration of automated production processes. In flexible manufacturin , the automated manufacturing machine and the automated materials handling system share instantaneous communication via a computer network. This is integration on a small scale. Flexible manufacturing takes a major step toward the goal of fully integrated manufacturing by integrating several automated manufacturing concepts: * Computer numerical control (CNC) of individual machine tools* Distributed numerical control (DNC) of manufacturing systems* Automated materials handling systems* Group technology (families of parts)When these automated processes, machines, and concepts are brought together in one integrated system, an FMS is the result. Humans and computers play major roles in an FMS. The amount of human labor is much less than with a manually operated manufacturing system, of course. However, humans still play a vital role in the operation of an FMS. Human tasks include the following: * Equipment troubleshooting, maintenance, and repair* Tool changing and setup * Loading and unloading the system* Data input* Changing of parts programs* Development of programsFlexible manufacturing system equipment, like all manufacturing equipment, must be monitored for bugs, malfunctions, and breakdowns. When a problem is discovered, a human troubleshooter must identify its source and prescribe corrective measures. Humans also undertake the prescribed measures to repair the malfunctioning equipment. Even when all systems are properly functioning, periodic maintenance is necessary.Human operators also set up machines, change tools, and reconfigure systems as necessary. The tool handling capability of an FMS decreases, but does not eliminate involvement in tool changing and setup. The same is true of loading and unloading the FMS. Once raw material has been loaded onto the automated materials handling system, it is moved through the system in the prescribed manner. However, the original loading onto the materials handling system is still usually done by human operators, as is the unloading of finished products.Humans are also needed for interaction with the computer. Humans develop part programs that control the FMS via computers. They also change the programs as necessary when reconfiguring the FMS to produce another type of part or parts. Humans play less labor-intensive roles in an FMS, but the roles are still critical.Control at all levels in an FMS is provided by computers. Individual machine tools within an FMS are controlled by CNC. The overall system is controlled by DNC. The automated materials handling system is computer controlled, as are other functions including data collection, system monitoring, tool control, and traffic control. Human/computer interaction is the key to the flexibility of an FMS.1 Historical Development of Flexible ManufacturingFlexible manufacturing was born in the mid-1960s when the British firm Molins, Ltd. Developed its System24. System 24 was a real FMS. However, it was doomed from the outset because automation, integration, and computer control technology had not yet been developed to the point where they could properly support the system. The first FMS was a development that was ahead of its time. As such, it was eventually discarded as unworkable.Flexible manufacturing remained an academic concept through the remainder of the 1960s an