TECHNICAL REPORT

1 II1I33 Iand B5~ 0K ' RE A! U 0,: '',TikTECHNICAL REPORTNO. 12703 II I III Il lllI FLEXIBLE MANUFACTURING SYSTEM HANDBOOKVOLUME II: DESCRIPTION OF THE TECHNOLOGYCONTRACT NUMBER: DAAE07-82-C-4040 FEBRUARY Stark Draper Lab., Cambridge, Massachusetts 02139 Approved for Public ReleaseDistribution Unlimited ARMY TANK-AUTOMOTIVE COMMANDRESEARCH AND DEVELOPMENT CENTERW arren, Michigan 480909~oo) gi&6@O02 SECURITY CLASSIFICATION OF THIS PAGE (When Data Entered) REPORT DOCUMENTATION PAGE READ INSTRUCTIONSBEFORE COMPLETING FORMI. REPORT NUMBER 2.

2 GOVT ACCESSION NO. 3. RECIPIENT'S CATALOG NUMBER127034. TITLE (and Subtitle) S. TYPE OF REPORT & PERIOD COVEREDF lexible Manufacturing System HandbookVolume II:. Description of the Technology Final TECHNICAL Report6. PERFORMING ORG. REPORT NUMBER___CSDR-R- 15997. AUTHOR(a) S. CONTRACT OR GRANT NUMBER(a)DAAE07-82-C-40409. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT, PROJECT, TASKAREA & WORK UNIT NUMBERSC harles Stark Draper Lab., , Massachusetts11. CONTROLLING OFFICE NAME AND ADDRESS 12. REPORT DATEUS Army Tank-Automotive Command February 1983 Warren, MI 48090 I1.

3 NUMBER OF PAGESATTN: DRSTA-RCKM 5114. MONITORING AGENCY NAME & ADDRESS(if different from Controlling Office) 15. SECURITY CLASS. (of this REPORT )Unclassified"ISa. DECLASSI FICATION/DOWNGRADINGSCHEDULE16. DISTRIBUTION STATEMENT (of this REPORT )Approved for public release; distribution unlimited.'1. DISTRIBUTION STATEMENT (of the abstract entered In Block 20, if different from REPORT )1S. SUPPLEMENTARY NOTESThe five volume handbook has four volumes of general information and areavailable for public release. The fifth contains specific computer programsand has a limited KEY WORDS (Continue on reverse side if necessary and Identify by block number)"2Q.

4 ABSTRACT' (Cus h kf Itwcwy ad deotify by block number)Flexible Manufacturing Technology is a means to increase productivity for environments in the middle ranges of production volume. It is ef- __fective for "one of a kind" and true "mass production" quantities. Volumes Ithrough IV of this handbook help determine if a flexible machining system (FMSwill be cost effective for a given application. These volumes explain theconfiguration and procurement of a FMS, and its impact on the existing organ-ization. The fifth volume of the handbook details the computer programs forthe FORM 1473 EDITo OF, NOV 65IS OBSOLETESECURTY OF T"hS PAGE (When Dat* Entered)FMS18762-380(II)CSDL-R-1599 FLEXIBLE MANUFACTURING SYSTEM HANDBOOKVOLUME II: DESCRIPTION OF THE TECHN*OLOGYF ebruary, 1983 Prepared Army Tank Automotive CommandWarren, Michigan 48090 Under Contract No.)

5 DAAEO7-82-C-4040 The Charles Stark Draper Laboratory, , Massachusetts 02139ii FMS Handbook, Volume IIPREFACEThis is the second volume in a five-volume series designed to answer thefollowing questions concerning Flexible Manufacturing Systems (FMS):* Why an FMS?* Will an FMS best serve your application?0 What problems might be encountered?* How do you design an appropriate system?W What is required to operate a system?In the series, Volume I is intended to help answer broad policy questionsat corporate levels. This volume contains detailed descriptions of thesubsystems that make up a typical FMS as well as descriptions of severaloperational FMSs.

6 Volume III is designed to serve as a detailed guide toplanners at corporate and plant levels. Volume IV contains a samplerequest-for-proposal, a proposal, a glossary of FMS terms, abibliography, and other TECHNICAL material. Volume V contains user's man-uals for various software FromBest Available CopyCopies Furnished to DTICR eproduced FromBound OriginalsPreface iiiiv FMS Handbook, Volume DESCRIPTION OF FLEXIBLE MANUFACTURING SYSTEM ELEMENTS .. Description of a Flexible Manufacturing System .. Work Stations .. Machining Stations.

7 Load/Unload Stations .. Control Station .. Cleaning Stations .. Material Handling System .. Part Transport .. Buffer Storage .. Control System Software .. Control System Architecture .. Software Description .. FMS Level-1 Operations .. FMS Level-2 Operations .. FMS Level-3 Operations .. Other Significant Elements .. Fixtures and Pallets .. Tooling .. Coolant and Chip Handling Systems .. People .. Inspection Systems .. FMS Off-Line Components .. THREE EXAMPLE FLEXIBLE MANUFACTURING SYSTEMS .. Kearney and Trecker FMS at AVCO-Lycoming, Stratford,Connecticut.

8 Overview .. System Elements .. Detroit Diesel Allison, Indianapolis, Indiana .. Overview .. System Elements .. Giddings and Lewis FMS at Caterpillar Tractor Company,Aurora, Illinois .. Overview .. System Elements .. PROJECTED TRENDS ZN FMS TECHNOLOGY .. MACHINE CHARACTERISTICS DATA BASE .. 37 Contents vvi FMS Handbook, Volume IILIST OF ILLUSTRATIONSF igure 1. Conceptual Drawing of an FMS .. 2 Figure 2. Manual Production Environment .. 12 Figure 3. FMS Control System Architecture .. 14 Figure 4. FMS Installations.

9 24 Figure 5. Kearney and Trecker FMS .. 25 Figure 6. White-Sundstrand FMS .. 27 Figure 7. Giddings and Lewis FMS .. 30 List of Illustrations viiviii FMS Handbook, Volume DESCRIPTION OF FLEXIBLE MANUFACTURING SYSTEM ELEMENTSThis section describes the major elements of an FMS. It begins with adiscussion of the principal physical characteristics of a system, includ-ing the central elements, the machining stations, the load/unload sta-tions, control station, and cleaning stations. The material handlingsystems are next considered, followed by a detailed description of thecontrol system.

10 The multitude of software functions are then explored indepth. Finally, the remaining significant elements of an FMS areaddressed. These include fixtures and pallets, tooling, chip handling,deburring, inspection, and requirements for line personnel. To establisha frame of reference, a description of the operation of an entire systemis presented in the following DESCRIPTION OF A FLEXIBLE MANUFACTURING SYSTEMA Flexible Manufacturing System (FMS) can be defined as a"computer-controlled configuration of semi-independent work stations anda material handling system designed to efficiently manufacture more thanone kind of part at low to medium volumes".