Design and analyse the dual flow at part and tools in a flexible manufacturing system

Key Words: Flexible Manufacturing System (FMS), Simulation, Artificial Neural Networks, Tool Management This study was carried out to design and analyse the dual flow of parts and cutting tools in a flexible manufacturing system, and comprised three main phases: planning, design and analysis. In the planning phase, parts types to be produced and machines to be used, batch sizes and production rates, operations plans, required tools and their specifications were determined using data obtained from previous industrial implementations. In the design phase; simulation was used as a tool for analysing the number of machines and maximum level of work in process in each cell of the multi-cell flexible manufacturing system and the number of AVG's required for efficient materials handling. Here, neural networks were used along with simulation to obtain the optimal system configration that prevents disadvantages of pure simulation techniques such as not reaching a global optima or time-consuming experimentation. In the analysis phase; a sub-program for tool management was integrated to the main program and the results of the dual flow of parts and tools were obtained. These two dynamic elements of the system were explored together, and their performance criteria was determined by using various scheduling and tool management strategies for alternative design configurations. For each alternative design, these criteria were analysed by using tables and graphics. Based upon the results of this study, a dominant system behaviour for a particular multicell-FMS was determined and conclusions were drawn.