Flexible manufacturing systems (FMS) allow equipment to be used for multiple purposes, controlled by computers. FMS offers speed and quality, reduces expenses, and is commonly used in automobile manufacturing. FMS saved Ford Motor Company $2.5 billion and can improve customer satisfaction by lowering prices.
A flexible manufacturing system (FMS) is a type of industrial process that allows equipment to be used for more than one purpose, although they may be somewhat related. The tooling is often used to make custom parts or make different parts for different product models. This type of system can be changed manually, but is more likely to be controlled by a computer and changed through a fully automated process.
The main objective of a flexible manufacturing system is to offer the speed needed to change rapidly with market conditions, without sacrificing any quality. The equipment that does this most effectively is probably designed for two or more purposes. While it is possible to modify or upgrade some types of industrial equipment to do a job adequately, most FMSs are designed for more than one purpose from the outset.
While equipment for a flexible manufacturing system may initially be more expensive than traditional equipment, the overall goal is to reduce expenses. Manufacturers can save money by using the same equipment to perform essentially two or more functions. With traditional equipment, producing two different products may require not only different equipment, but also two different lines and possibly two different facilities. Thus, this type of system can reduce overhead, despite the higher initial start-up costs.
One of the most common examples of a flexible manufacturing system can be seen in automobile manufacturing. Some equipment is used to attach doors to a sedan. With a few simple adjustments, that same line and rig can be used to connect the doors to an SUV or some other type of vehicle. Often, the switch can occur with minimal line disruption and can even occur during shifts.
In fact, the automotive industry has the potential to save a significant amount of money by using a flexible manufacturing system. A 2004 report indicated that Ford Motor Company saved approximately US$2.5 billion by installing flex systems at five manufacturing plants. The company estimated that it could save at least half the cost of manufacturing upgraded models by using the systems.
In some cases, the machines can be used not only to produce or assemble different parts for different models, but to make customizations. These customizations, without a flexible system in place, would take much longer and be much more expensive for the customer. Using machines with the ability to be flexible can not only speed up the process but can improve customer satisfaction by lowering the price.
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