Programmable cells for mixed production
A Flexible Manufacturing System (FMS) is a set of programmable machine tools linked by an automated material-handling system that can process multiple part types with minimal human intervention. A traditional dedicated production line produces one part design at high volume. An FMS can switch between part types by reprogramming the machines and routing material to different work cells. An FMS producing aircraft wings can manufacture wing styles for different aircraft; when an order for a different wing arrives, the system retools and processes the new design without dismantling the line.
This flexibility comes from modularity. Each work cell contains a machine capable of multiple operations. Automated guided vehicles or conveyor systems route parts between cells. A central computer maintains a queue of jobs and routes each part to the appropriate cell sequence.
Balancing responsiveness and efficiency
FMS excel when production runs are medium-volume, product variety is moderate, and orders arrive unpredictably. The setup costs are high due to the control systems, material handling, and machine programming. Small batch sizes amortize these costs by spreading them across many part types. A company receiving orders for ten variants of a part, each in quantities of 100 units, benefits from FMS. A company producing a single part in quantities of 100,000 runs a simpler dedicated line. The trade-off between the flexibility of FMS and the efficiency of dedicated lines shapes manufacturing strategy.