Flexible Manufacturing System Case Study Pdf

www.theinternationaljournal.org > RJSITM: Volume: 02, Number: 06, April-2013 Page 8

research, seems to be an alternative to other competitors and fragmented. Competition in the

manufacturing sector in the next ten years would be focused on flexibility and quick response to

market changes. Manufacturing giants have discovered that the production in large quantities forthe

mass market is no longer the way to stay in business (Fulkerson, Bill 1997). The flexible

manufacturing system covers a wide range of automated production system, it basically consists of

CNC machines, material handling system, and a control mechanism (Sidhartha, Cem 2004).

Manufacturing flexibility is the ability to produce system adapt to uncertain environments and it can a

competition concerns (Correa 1994, Fine CH 1985), but gains flexibility has cost associated with it

(Sethi AK, Sethi SP 1990) and must be estimated ( Pellegrino R, 2010). Different types of flexibility

such as product mix flexibility process flexibility and volume flexibility respectively as capability,

multiple products can be defined without much setup costs manufacture, which develops different

processes and routing and the possibility of having different output levels (Browne Jet al produce

1984, Fontes D 2008).

Two main factors which are drivers of the necessity of manufacturing flexibility are identified as

Environmental uncertainty and

Variability of products and processes (Correa 1994).

In the first case, flexibility confronts unexpected situations both from inside the system and outside the

system whereas in second case, flexibility is supposed to offer variety of products in order to keep up

manufacturing processes. Changes within the manufacturing system are considered inconveniencies

like machine failure, variability in work time and unavailability of raw material (Buzacott 1989)

Machine flexibility and routine flexibility are more specific categories of flexible manufacturing (Peter

Kostal, Karol Velisek 2011). Machine flexibility deals in manufacturing of different products with a

given machine and routine flexibility addresses the execution of the same operation bya range of

machines. This study will stick with these categories of manufacturing flexibility. The need of

flexibility is emerged from factors such as uncertainty of demand, shorter product and technology life

cycles, shorter delivery times, increased product variety and increased customization (Toni, Tonchia

1998). The flexibility offered by FMS has limits such as its development is based on fixed amount of

information and absence of learning process (Schonberger 1986). Thus, to address highly uncertain

demand and manufacturing of very wide variety of products, more responsive system is required so

from here shift from flexible to agile manufacturing takes place.

3.The Case SME

The understudy enterprise is situated in the capital territory of Pakistan. It is leading manufacturer of

CNG equipment electrical control devices from last fifteen years. Domestic and industrial appliances

are included in the broad list of Tesla Technologies. Electric element, Electric thermostat, heater safety

devices, hoses, gas geysers, Hydraulic compressed natural gas compressor and LPG dispensers are

among the products of the understudy enterprise. The products of the enterprise are spread overthe

markets of thirty cities of Pakistan and from last eight years the enterprise has entered into the global

market and expanding its exports at fast pace.

The exported products of the enterprise are certified by the British Electro-Technical Approvals Board

and British Gas. Various ISO certifications are also part of the credentials of the Case enterprise (Tesla

Technologies). The Electric Element shortly known as “EE”is one of the products of the enterprise

whose manufacturing and assembly process is focused in this study.

The process of making electric element starts from tube cutting. The tubes are cut in various lengths as

per demand by the customers. A semi automatic machine is employed to cut the hollow tubes. The lot

of cut tubes is transferred to the head closing lathe where one side of the hollow tube is closed. The

  • Berrada, M. and Stecke, K.E., “A Branch and Bound Approach for Machine Load Balancing in FMSs,”Management Science, Vol. 32, No. 10, pp. 1316–1335 (1986).Google Scholar

  • Cheng, Q. and Wang, X., “Performance Evaluation for Priority Rules in Job Shop Scheduling Problems,”Academic Collections of Discrete Event Dynamic Systems and Dispatch Theory, Department of Computer and System Sciences, NanKai University, People's Republic of China, pp. 284–293 (1990).Google Scholar

  • Ding, Q. and Tu, F., “Simulation of Scheduling with Finite Buffers and Performance Evaluation of Heuristic Methods,”Academic Collections of Discrete Event Dynamic Systems and Dispatch Theory, Department of Computer and System Sciences, NanKai University, People's Republic of China, pp. 333–347 (1990).Google Scholar

  • Dubois, D. and Stecke, K.E., “Using Petri Nets to Represent Production Processes,”Proceedings of the 22nd IEEE Conference on Decision and Control, San Antonio, TX, pp. 1062–1067 (December 1983).Google Scholar

  • Ho, Y. and Cassandras, C., “A New Approach to the Analysis of Discrete Event Dynamic Systems,”Automatica, Vol. 19, No. 2, pp. 149–167 (1983).Google Scholar

  • Panwalker, S.S. and Iskander, W., “A Survey of Scheduling Rules,”Operations Research, Vol. 25, No. 1, pp. 45–61 (1977).Google Scholar

  • Peterson, James L.,Petri Net Theory and the Modeling of Systems, Prentice-Hall, Inc., Englewood Cliffs, NJ (1981).Google Scholar

  • Rajagopalan, S., “Flexible Versus Dedicated Technology: A Capacity Expansion Model,”International Journal of Flexible Manufacturing Systems, Vol. 5, No. 2, pp. 129–142 (June 1993).Google Scholar

  • Schriber, T.J. and Stecke, K.E., “Machine Utilization Achieved Using Balanced FMS Production Ratios in a Simulated Setting,”Annals of Operations Research, Vol. 15, pp. 229–267 (1988).Google Scholar

  • Smith, T.M. and Stecke, K.E., “On the Robustness of Using Optimal Part Mix Ratios to Determine Cyclic Part Input Sequences into Flexible Flow Systems,” Working Paper No. 658-b, Division of Research, School of Business Administration, The University of Michigan, pp. 1–28 (May 1994).Google Scholar

  • Stecke, K.E., “Formulation and Solution of Nonlinear Integer Production Planning Problems for Flexible Manufacturing Systems,”Management Science, Vol. 29, No. 3, pp. 273–288 (March 1983).Google Scholar

  • Stecke, K.E. and Solberg, J.J., “The Optimality of Unbalancing Both Workloads and Machine Group Sizes in Closed Queueing Networks of Multiserver Queues,”Operations Research, Vol. 33, No. 4, pp. 882–910 (1985).Google Scholar

  • Stecke, K.E., “Procedures to Determine Both Appropriate Production Ratios and Minimum Inventory Requirements to Maintain These Ratios in Flexible Manufacturing Systems,”IEEE Transactions on Engineering Management, Vol. 39, No. 4, pp. 359–369 (November 1992).Google Scholar

  • Stecke, K.E. and Kim, I., “A Study of FMS Part Type Selection Approaches for Short-Term Production Planning,”International Journal of Flexible Manufacturing Systems, Vol. 1, No. 1, pp. 7–29 (April 1988).Google Scholar

  • Stecke, K.E. and Kim, I., “Performances Evaluation for Systems of Pooled Machines of Unequal Sizes: Unbalancing Versus Balancing,”European Journal of Operational Research, Vol. 42, pp. 22–38 (September 1989).Google Scholar

  • Wu, P. and Shi, W., “A New Job Planning and Dispatching Method for FMSs with Limited Tool Magazine Capacity,”Scientific Periodical of Southeast University, People's Republic of China (1993).Google Scholar

  • Wu, P., “A Study of FMS Production Planning and Dispatching,” Master's thesis, Southeast University, People's Republic of China (March 1993).Google Scholar

  • One thought on “Flexible Manufacturing System Case Study Pdf

    Leave a Reply

    Your email address will not be published. Required fields are marked *