Computerized Control in FMS

Introduction

Computerized control in Flexible Manufacturing Systems (FMS) refers to the use of computers and automation to control and coordinate the various components and processes within an FMS. It involves the hierarchical control of machines, work centers, and assembly lines to optimize production efficiency and flexibility. This topic explores the hierarchy of computer control in FMS, the role of computers in work center and assembly line control, FMS supervisory computer control, typical problems and solutions, real-world applications, and the advantages and disadvantages of computerized control in FMS.

Hierarchy of Computer Control

The hierarchy of computer control in FMS consists of multiple levels, each with its own role and responsibilities. These levels include:

1. Level 0: Machine Control

At this level, computers are responsible for the control and monitoring of individual machines within the FMS. They ensure that the machines operate correctly and efficiently.

1. Level 1: Cell Control

Cell control involves the coordination and control of multiple machines within a cell. Computers at this level manage the workflow and communication between machines to optimize production.

1. Level 2: Work Centre Control

Work center control focuses on the control and coordination of multiple cells within a work center. Computers at this level ensure that the cells within the work center operate in sync and meet production targets.

1. Level 3: Shop Floor Control

Shop floor control involves the control and coordination of multiple work centers within the FMS. Computers at this level manage the scheduling, routing, and dispatching of jobs to different work centers.

1. Level 4: FMS Control

FMS control is the highest level of control in the hierarchy. Computers at this level oversee the entire FMS, coordinating the activities of multiple shop floor control systems and ensuring the overall efficiency and performance of the system.

Computer Control of Work Centre and Assembly Lines

Computers play a crucial role in the control of work centers and assembly lines within an FMS. They enable various functions and tasks, including:

1. Machine Monitoring and Control

Computers monitor the status and performance of individual machines within a work center. They collect data on machine utilization, downtime, and maintenance requirements, allowing for proactive maintenance and optimization of machine performance.

1. Tool Management

Computers manage the availability and usage of tools within a work center. They track tool inventory, schedule tool changes, and ensure that the correct tools are available for each operation, minimizing downtime and improving productivity.

1. Quality Control

Computers facilitate quality control processes within a work center. They collect data on product quality, perform statistical analysis, and provide real-time feedback to operators. This helps in identifying and resolving quality issues, ensuring that products meet the required standards.

Computers also play a crucial role in the control of assembly lines within an FMS. They enable functions such as:

1. Sequence Control

Computers control the sequence of operations in an assembly line. They ensure that the correct parts are assembled in the correct order, minimizing errors and improving efficiency.

1. Part Tracking and Identification

Computers track the movement and location of parts within an assembly line. They use various identification technologies, such as barcodes or RFID tags, to ensure that the right parts are used at each stage of the assembly process.

1. Error Detection and Recovery

Computers detect errors or faults in the assembly process and take corrective actions. They can automatically stop the line, alert operators, or initiate error recovery procedures to minimize the impact on production.

FMS Supervisory Computer Control

FMS supervisory computer control involves the integration and coordination of multiple work centers and assembly lines within an FMS. The supervisory computer performs functions such as:

1. Role and Functions of the Supervisory Computer

The supervisory computer acts as the central control unit of the FMS. It oversees the operation of all work centers and assembly lines, ensuring that they work together seamlessly.

1. Integration of Work Centres and Assembly Lines

The supervisory computer integrates the activities of different work centers and assembly lines. It ensures that the flow of materials, parts, and information between these components is smooth and efficient.

1. Scheduling and Dispatching of Jobs

The supervisory computer schedules and dispatches jobs to different work centers based on their availability and capabilities. It optimizes the allocation of resources and ensures that production targets are met.

1. Monitoring and Reporting of System Performance

The supervisory computer monitors the performance of the entire FMS. It collects data on key performance indicators, such as production output, cycle time, and machine utilization, and generates reports for management and decision-making.

Typical Problems and Solutions

In the operation of an FMS, various problems can arise. However, computerized control offers solutions to these problems, including:

1. Machine Breakdowns and Faults

Automated error detection and recovery systems can quickly identify machine breakdowns and faults. Computers can initiate maintenance and repair procedures, minimizing downtime and ensuring continuous production.

1. Job Scheduling and Optimization

Algorithms for job sequencing can optimize the scheduling of jobs within an FMS. Real-time monitoring and adjustments allow for efficient resource allocation and adaptation to changing production demands.

1. Communication and Integration Issues

Standardized protocols and interfaces enable seamless communication and integration between different components of an FMS. Data exchange and sharing solutions ensure that information flows smoothly between work centers and assembly lines.

Real-world Applications and Examples

Computerized control in FMS has found applications in various industries, including:

1. Automotive Manufacturing

In car assembly lines, computerized control ensures efficient and accurate production. FMS supervisory control is used in automotive plants to coordinate the activities of multiple work centers and assembly lines.

1. Electronics Manufacturing

In PCB assembly, computerized control enables precise and reliable production. FMS integration is used in electronics production to optimize the flow of materials and components.

Advantages and Disadvantages of Computerized Control in FMS

Computerized control offers several advantages in FMS, including:

1. Increased Efficiency and Productivity

By automating and optimizing production processes, computerized control improves efficiency and productivity. It reduces manual errors, minimizes downtime, and maximizes machine utilization.

1. Improved Quality and Accuracy

Computerized control enables real-time quality control and monitoring. It ensures that products meet the required standards and minimizes defects and rework.

1. Enhanced Flexibility and Adaptability

Computerized control allows for quick reconfiguration and adaptation to changing production requirements. It enables rapid changeovers, flexible scheduling, and efficient resource allocation.

However, there are also some disadvantages to computerized control in FMS, including:

1. Initial Investment and Implementation Costs

Implementing computerized control systems in FMS requires significant upfront investment. It involves the purchase of hardware, software, and training of personnel.

1. Technical Complexity and Maintenance Requirements

Computerized control systems can be complex and require specialized technical knowledge for operation and maintenance. Regular maintenance and updates are necessary to ensure optimal performance.

1. Potential Job Displacement and Workforce Concerns

The automation and optimization of production processes through computerized control may lead to job displacement. This can raise concerns among the workforce regarding job security and the need for retraining.

Conclusion

Computerized control plays a vital role in the efficient and flexible operation of FMS. It enables hierarchical control, facilitates the control of work centers and assembly lines, and provides supervisory control for the entire system. Despite some challenges, the advantages of computerized control in FMS, such as increased efficiency, improved quality, and enhanced flexibility, make it an essential component of modern manufacturing.

Summary

Computerized control in Flexible Manufacturing Systems (FMS) refers to the use of computers and automation to control and coordinate the various components and processes within an FMS. It involves the hierarchical control of machines, work centers, and assembly lines to optimize production efficiency and flexibility. This topic explores the hierarchy of computer control in FMS, the role of computers in work center and assembly line control, FMS supervisory computer control, typical problems and solutions, real-world applications, and the advantages and disadvantages of computerized control in FMS.

Analogy

Imagine a symphony orchestra where each musician plays a different instrument. The conductor acts as the supervisory computer, coordinating the musicians and ensuring that they play in harmony. The musicians represent the different levels of computer control in an FMS, with each level responsible for a specific set of instruments. The conductor communicates with the musicians, ensuring that they follow the correct sequence and timing, just like computers in an FMS control the flow of materials and operations.