OCTOBER 19-20, 2012 - YMCA University of Science & Technology

Proceedings of the National Conference on
Trends and Advances in Mechanical Engineering,
YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012
2. The Motivation for FMS
There is a general perception that manufacturing industry has to alter more rapidly now than in past. This
exemplified by the following:
“Automobile production in the U.S was down a million cars in 1927- not because it was a bad year
economically , but because Henry ford’s plant took five months from may 26 to November 1.to switch
production from model T to model A. In 1927, many of Henry’s customers and dealers were content to wait. But
in today’s market place such a long changeover could spell corporate suicide.” [9]
FMS have been viewed as helping the process of rapid changeover. According to Palframan [10], “The figures
are impressive .FMS promise 50% reduction in lead and machining times using only a handful of machining
times using only a handful of machines and a few operators.” Green [1] is more specific in his list of potential
benefits:
‣ Increased machine utilization;
‣ Reduced -work in –process inventory;
‣ Increased productivity of working capital;
‣ Reduced number of machine tools;
‣ Reduced labor costs;
‣ Reduced led times;
‣ Less floor space;
‣ Reduced setup costs;
Molins Ltd. Is credited with introducing the ideas behind the ideas behind FMS in the mid-1960’s and their
design embodied many of today’s essential FMS characteristics- in particular, the importance of streamlining the
manufacturing process.
However growth in the use of FMS technology has been slow. In 1981 the world FMS population was only [2]
115.By 1986 the population had grown to 200, an average increase of only 17 systems per year. These figures
are based on the definition of FMS given by Young and Greene [2]. Slightly different and more detailed
estimates are given by Owen [11]. Approximately half of the installations are in Europe; the remainder split
between Japan and the U.S. In the U.S. and Europe, FMS are mostly found in the automotive industry. Japan is
thought to use FMS primarily in Machine tool industry [2].
3. Examples of FMS installations
The present development status of FMS can be illustrated by the examples of the FMS at Cummins Engine Co.,
Applied Power Inc., International-Hough., Iveco and by the success stories reported by the success stories
reported by Dornan [12]. Other reviews of implemented FMS’s are contained in draper labs [3], Dupont-
Gatelmand [13], Bilalis [14], American Machinist [15] and Techno craft [16].
The FMS at Cummins Engine Co., Walesboro, Indiana was supplied by LeBlond Makino Cincinnati, Ohio at a
cost of $2.5 million [17]. It is mainly being used to machine a family of parts for lubricator, Water pumps, and
other components used on diesel engines. All parts are being machined from cast iron. The FMS contains three
MC65-A123 horizontal machining centers, one Baron 50 two-axis turning center, a rail-guided vehicle for parts
transport, a Devlieg tool presetter, two pallet queue areas, and a computer control system. It is reportedly planned
to expand the FMS to include a total of six MC65-A123 machining centers. It helps in decreased lead times,
reduced inventory, higher quality and the ability to make parts to order in small quantities and on short notice are
reportedly listed as reasons for turning to FMS.
The FMS at Applied power Inc., Milwauke, Wisconsin was supplied by Toyada Machinery USA Inc.,
Schumburg, Illinois. It is used for the manufacture of hydraulic tools, including clamping systems, modular
fixtures and systems, and related power supplies [18]. The international-Hough division of Dresser industries,
Inc., Libertyville, Illinois have an FMS supplied by Giddings & Lewis unit of AMCA international, Fond du
Lac, Wisconsin at a cost $7 million. The FMS was originally designed for a series of six crawler tractor rear
mainframes, including a 3100-lb model TD12 rear mainframe housing, one of the more complex parts machined
on the FMS. The FMS consists of four DNC horizontal machining centers, each equipped with two pallet
stations, a material transporter system and two load and unload stations [19]. All four machines perform milling,
boring, drilling and tapping operations. Each machine is equipped with a 100-tool capacity automatic tool
changer.
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