NBS

PUBLICATIONS A 11 ID 2 bbDlfll

NATL INST OF STANDARDS & TECH R.I.C.

All 1026601 81

Darrow, William Pete/A survey of flexlbl QC100 .U56 NO.86-341 3 1986 V19 C.1 NBS-P

REFERENCE

5-3413

A Survey of Flexible Manufacturing

Systems Implementations

Dr. William P. Darrow*

U.S. DEPARTMENT OF COMMERCE

National Bureau of Standards

National Engineering Laboratory

Center for Manufacturing Engineering

Factory Automation Systems Division

Gaithersburg, MD 20899

*Guest Worker from Towson State University

July 1986

U.S. DEPARTMENT OF COMMERCE

. qq

NAL BUREAU OF STANDARDS

100

• U56

86-3413

1986

NBSIR 86-3413

A SURVEY OF FLEXIBLE MANUFACTURING

SYSTEMS IMPLEMENTATIONS

E.esearcli Information Center

National Bureau of Standards

Gaithersburg, Maryland 20899

/V)3s2-

ClUoo

, USZ,

)9%c

Dr. William P. Darrow*

U.S. DEPARTMENT OF COMMERCE

National Bureau of Standards

National Engineering Laboratory

Center for Manufacturing Engineering

Factory Automation Systems Divison

Gaithersburg, MD 20899

*Guest Worker from Towson State University

July 1986

U.S. DEPARTMENT OF COMMERCE, Malcolm Baldrige, Secretary

NATIONAL BUREAU OF STANDARDS. Ernest Ambler, Director

ABSTRACT

This report presents descriptive data on three hundred manufacturing

facilities that are using computer integrated manufacturing (CIM) techniques

to machine component parts for commercial, industrial, and military products.

Of these , 258 were categorized as Flexible Manufacturing Systems (FMS). Key

descriptive statistics were gathered for each system. The data is organized

into records by the user's country, company, and geographic location. Each

record is made up of 24 fields that describe the facility, the product, and

the operating parameters, as well as providing a reference to the source(s) of

information. In many instances the information has proven to be sparse.

Nevertheless, taken in aggregate, a picture of the state of the art for FMS

nas emerged from the study. Tnis picture is reflected in the graphical

summaries of the data, which are presented by region for Eastern Europe,

western Europe, Japan, and the United States. An analysis of trends in FMS

implementation, product and material characteristics, and materials handling

tecnnology is made for each the above regions.
?>; *
TABLE OF CONTENTS PAGE

Abstract ii

Acknowledgments iv

List of Figures vi

Introduction 1

Background 1

Objective 2

Benefits ..... 2

Methodology 2

Scope and Limitations 3

A Working Definition of FMS 5

Comparisons and Contrasts Between the NBS and the ITA Report 6

Analysis of Survey Results 7

FMS Implementations By Region 8

Product Characteristics for FMS 11

Materials Handling Trends for FMS 13

Graphical Analysis of FMS Trends and Attributes 15

Summary and Conclusions 29

Appendices

A. Data Base Schema and Data Dictionary 33

B. List of Abbreviations 35

C. FMS Implementation Data Base 38

D. Bibliography 189

ACKNOWLEDGEMENTS

It is most appropriate to acknowledge tine National Bureau of Standards

(NBS), whose policies foster joint research projects with U.S. colleges and

universities. In particular I would like to acknowledge Dennis Swyt, who was

most helpful in securing an NBS appointment for the writer as a Guest Worker.

Of equal importance was the contribution of the personnel in tne Factory

Automation Systems Division, especially Howard Bloom, Albert Jones, and

Charles McLean, who were instrumental in establishing tne project goals, and

who have continued to offer encouragement throughout the life of the project.

Early on in the project contact was made with Thomas Gallogly and John

nearman of the Department of Commerce (DOC), Office of Capital Goods and

International Construction Sector Group, in the International Trade

Administration (ITA). The International Trade Administration had just

completed the rirst draft of "A Competitive Assessment of the U.S. Flexible

Manufacturing Systems Industry," (the ITA report) which has since been

puDlisned. The ITA report had many of the same objectives as the present

study. The Office of Capital Goods personnel cooperated fully with the author

in preparing this report, including sharing a number of their source

documents. There is no question that their support greatly strengthened the

study at hand, and that the ITA report provided the most comprehensive study

of FMS implementations published to date.

George Hutchinson at the University of Wisconsin-Mi 1 waukee , who has

done extensive researcn on Eastern European manufacturing technology, was kind

enough to provide a number of his publications. His work has proven to be the

single most valuable source of information available on manufacturing

technology in the Eastern Block countries.
ACKNOWLEDGEMENTS (CONT'D)

Towson State University's Department of Business Administration provided

moral support, and absorbed the mileage costs incurred in traveling between

the university and both NBS and the DOC. These costs were substantial, and

their contribution greatly appreciated. Charles Mott, the Department Chair, is

recognized in particular for promoting research among the business faculty.

The Faculty Research Committee, at Towson State, provided funding for the

purchase of reference materials, which is gratefully acknowledged.
LIST OF FIGURES PAGE

1. Distribution of FMS Technology Based Upon Number of Systems 15

2. Distribution of FMS Technology Based Upon Number Machine Tools 15

3. Eastern Europe Number of FMS Machine tools 16

4. Western Europe Number of FMS Machine tools 16

5. Japan Number of FMS Machine tools 17

6. USA Number of FMS Machine tools 17

7. Eastern Europe Lot Size Distribution 18

8. Western Europe Lot Size Distribution 18

9. Japan Lot Size Distribution 19

10. USA Lot Size Distribution 19

11. Eastern Europe FMS Product Mix 20

12. Western Europe FMS Product Mix 20

13. Japan FMS Product Mix 21

14. USA FMS Product Mix 21

15. Eastern Europe FMS Materials Usage 22

16. Western Europe FMS Materials Usage 22

17. Japan FMS Materials Usage 23

18. USA FMS Materials Usage 23

19. Eastern Europe Part Cube Distribution 24

20. Western Europe Part Cube Distribution 24

21. Japan Part Cube Distribution 25

22. USA Part Cube Distribution 25

23. Eastern Europe Materials Handling Distribution 26

24. Western Europe Materials Handling Distribution 26

25. Japan Materials Handling Distribution 27

26. USA Materials Handling Distribution 27

INTRODUCTION

Tha introduction briefly summarizes the background, objectives, and

benefits of this project. This is followed by a discussion of the methodology

used to carry out the project. The scope, and limitations of this project are

given, along with a working definition of FMS. This section also includes a

comparison and contrast between tnis report and a related report produced by

DOC/ITA.

background

This research was done while the author was affiliated with the NBS as a

uuest Norker. The work was first suggested by Howard Bloom, Cnarles HcClean,

and Albert Jones of the Factory Automation Systems Division of the National

Bureau of Standards (NBS). The Factory Automation Systems Division is

responsible for the continuing development of elements of a hierarchical

control system for the bureau's Automated Manufacturing Research Facility

(AMRF). The personnel working on the AMRF project have consistently maintained

close communication with both industry and the academic community, and thus

were very much aware of what was going on in FMS technology. However, they

nad never formally undertaken an international survey. These interests were

consistent with the author's own interests in manufacturing research, and

inspired the project at hand.

1
Objective

The objective of this research was to survey the existing literature on FMS implementations and develop a data base to assess the state of the art in

flexible manufacturing systems. Included in this objective was the development

of data for each system implementation that described the facility, the

products, and the operating parameters.

Benefits

There are four main benefits expected to result from this work:

1. Providing a data base for further study of FMS implementations

2. Identifying broad FMS technological trends in terras of:

a) Design and implementation

b) Product characteristics

c) Materials handling systems

3. Providing additional data to assess the state of the art for FMS

from an international perspective

4. Providing a bibliography on FMS implementations

Methodology

Appendix D of this report lists a data base of 300 records that was put

together based upon the results of a literature survey. The data provides

descriptive information on FMS system design in terms of the machine tools

used, tool management, and the materials handling technology. Both the

computer and control systems used are identified. In addition systems

2
capabilities such as real time scheduling, the use of alternate operations,

automated inspection, and the use of adaptive control are noted. Product data

is collected in terms of the part geometry, part cube, the material used to

fabricate the part, production rates, and the part’s product application.

Management practices in terms of lot sizing, labor and machine scheduling, and

financial justification are also included. All data is tied to the year of

system implementation, thus providing the raw data for trend analysis.

A subset of the data base, consisting of 253 records which were

classified as FMS, was used to develop a set of 26 graphs. The graphs were

used to analyze broad FMS technological trends in terms of design and

implementation, product characteristics, and materials handling systems.

An international perspective was provided for by partitioning the FMS

data into four parts representing Eastern Europe, Western Europe, Japan, and

the United States. While the main objective of the study was not to evaluate

international competitiveness, this turned out to be a convenient framework

for analysis.

The report includes a bibliography of 86 articles which were referenced

by the data base. Each record includes a field with specific references to the

appropriate source document(s). This provides a convenient way of locating

additional information about a particular implementation, or about any subset

of the data base. Further analysis is facilitated by the fact that this

information is available on a floppy disk as a DBase III file.

Scope and Limitations

The scope of the report is limited to FMS that are used in machining, or

metal cutting, applications. A number of FMS systems have been encountered in

3
both electronic and mechanical assembly operations. There have also been

recent reports of FMS systems used for sheet metal and grinding operations.

However, the vast majority of FMS continue to be in metal cutting operations,

and that area serves as the focus of this report. The scope of the report is

further refined below, where a working definition of FMS is developed.

The principal limitation was restricting this investigation to a literature survey. Other techniques would have included the use of survey

forms, telephone interviews, and plant visitations. These other techniques

were ruled out, as a practical matter, due to lack of funding for the project.

This limitation did not turn out to be as severe as it was first thought to

be. The region most affected by lack of funding was the United States, where

other means of data collection would be most applicable. However, data for US

implementations was readily available in technical publications.

A second limitation is the lack of complete information. This is

especially true of the Eastern European countries. There is no question that

this region's numbers are understated due to the lack of published information

on advanced manufacturing capabilities in Eastern Europe. This problem is

quite serious. However, if the reader thinks of the information presented for

the Eastern Bloc as a lower bound on their true capabilities, the report makes

a contribution to an assessment of the state of the art for FMS implementation

in Eastern Europe.

A third limitation is the rapid growth and diffusion of this technology,

which appears to be exponential at the present time. This study represents a

"snapshot" of the technology taken in the Fal 1 of 1985, which can be used t o

understand the evolutionary trends in this industry.

4
A Working Definition of FMS

There is at present no consensus on a definition for FMS. The working

definition in this report is a system defined by the following attributes:

1. A set of two or more general purpose metalworking machine tools

2.

A host computer linking the machine tools to supervise computer

numerical control (CNC) operations

3. An automated materials handling system, linking the machine tools and

the other work centers in the system together

This definition is virtually identical to that given in the FI exib 1 e

Manufacturing Systems Handbook (22).

There are other attributes that are desirable, and in the future may be

incorporated into a definition of FMS. For example:

1. Flexible scheduling

a. Alternate routings

b. Alternate operations

c. Real time schedule revisions

2. The ability to process a variety of parts

a. A number of parts in a given part family

b. A number of different part families

c. The ability to economically produce a lot size of one part

3. The ability to have random (non-unidirectional ) flow of material

4. Automatic tool changing (ATC)

5. Adaptive control

6. Automated part inspection

Many of the systems reported in this study have one or more of these advanced

features, and a few systems have all of the above capabilities.

5
Comparisons and Contrasts Between the NBS and the ITA Report

The ITA report, " A Competitive Assessment of the U.S. Flexible

Manufacturing Systems Industry," (14) and this report (the NBS report) share

tne objective of trying to develop descriptive iniormation about FMS

implementations. The main difference is in focus. The ITA report attempts to

assess FilS technology in terms of international trade and competition, while

the NBS report focuses upon FMS technology in terms of system design and

operating practices. As a result, tne ITA report is organized from the

perspective of suppliers of FMS technology, while the NBS report is organized

from the user's perspective. Differing objectives also lead to tne inclusion

of operating parameters in the NBS report.

There was also a highly significant difference in methodology. The ITA

report is Dased largely on first hand information made by contacting FMS

suppliers and users in the USA. Information on overseas implementations was

obtained rrom reports submitted by botn JS roreign service orricers stationed

overseas, and from foreign embassy officials stationed in Washington D.C.

Another dirlerence in metnoaology is tne availability of computer Mata base

containing the results of this project on a floppy disk (DBase III format for

IBM -PC compatible computers).

As previously acknowledged, the ITA report provided an excellent

foundation, upon which this report was able to build.

6
ANALYSIS OF SURVEY RESULTS

Tnere are OOO records in tne data base. The analysis section is based

upon a subset of the data base made up of 253 records. This subset is made up

of all or the systems, for the regions of interest, that were classified as

either a FMS or as a Flexible Transfer Line (FTL). Most of the other records

included in tne uata base were for Machine Cells (MC). Tne main reason for

including Machine Cells in the study was to disseminate information on Eastern

European uanuracturing technology. This region has a significant level of

activity in Computer Aided Manufacturing (CAM). However, as in other regions,

many or tne CAM racilities can not be properly classified as FMS.

Flexible transfer lines, as classified herein, are technologically the

same as FMS. Tne only difference is that tne FTL is dedicated to the

production of one or two specific parts, while the FMS has demonstrated

greater flexibility by producing a greater variety of parts. Tne main

difference between FTL and a traditional transfer line is the use of general

purpose machine tools in the former, and custom designed macninery in the

latter. It is the flexibility of the FTL that makes it an economically viable

alternative to tne traditional transfer line.

The 258 records in the data base representing flexible systems were then

sorted by region. The four regions used were Eastern Europe, Western Europe,

Japan, and the United States (USA). A series of graphs, which are presented in

tne next section of this report, were developed to support the analysis tnat

follows. There were five FMS implementations omitted from the analysis, four

in Taiwan and, one in Worea. This was done to clearly focus attention on tne

Japanese systems, rather than to try and include the Japanese in an broader

definition of an Asian region.

7
In order to have a common basis for comparison between regions, the

number of machine tools in the FMS (or FTL) systems was used. For example, in

evaluating product mix for a given region, each category of product was

weighted by the number of FMS machine tools (not the number of FMS

implementations) associated with the production of that class of product. If

the number of machine tools for a given implementation was not found in the

literature, a conservative estimate of two machines was used. This assumption

was necessary, as omitting the records without machine tool counts would

distort the analysis much more than any bias introduced through estimation.

The year of implementation is often difficult to assess through the

literature. This comes about because there are several milestones in an FMS

project that are newsworthy. When given, the date used was the date that

routine production began. Otherwise the best date available was used.

Unfortunately, in a number of cases it was necessary to take the date of the

publication which first referenced the FMS as the year of implementation.

Fortunately, the uncertainty about the exact implementation date does not

obscure the underlying trends.

FMS Implementations 3y Region

When looking at the number of FMS implementations, shown in Figure 1, the

West Europeans lead with 107 systems, an impressive 42.3 % of the total. The

USA and Japan follow with 64 and 59 systems, representing shares of 2 5.3 in I

23.3 % respectively. Eastern Europe trails with 23 systems, wnich accounts for

the remaining 9.1% of the reported FMS implementations.

Pernaps of greater significance is tne fact that Western Europe leads all

other regions in terms of the number of firms with FMS experience, vita it

8
least 82 different firms having reported FMS installations. Both the USA and

japan nave at least j 9 firms with FMS experience, while only 13 unique firms

were identified for the Eastern Block. Although economic conditions and

government policy can greatly iniluence tne growth and diifusion of FMS

technology, the number of firms with experience is a key factor in determining

tne potential of any region.

When the comparison is based upon the number of FMS machine tools, as in

Figure z, Western Europe loses snare to both Japan and Eastern Europe, while

the USA share remained essentially unchanged. This shift reflects the fact

that many Western European FMS installations have only two machine tools. It

also reflects the fact that the machine tool count for a large number of West

European facilities was not availatle. In tne latter case, a Dias may have

been introduced, as an estimate of two machine tools was used. The increase in

Japanese snare is not due entirely to a bias in estimation. Several Japanese

installations have large numbers of machine tools under computer control.

Using tnis method or comparison, Western Europe and japan are rougnly equal at

shares of 31.5 % and 30.9 % . The USA is close with a share of 25.2 % , while

Eastern Europe trails with a 12.4 % share.

The growth of FMS technology is shown for each region in Figure 3 thru

Figure u. Each figure plots tne cumulative number of machine tools, for the

given region, by year. Each graph is a stacked bar chart, including prismatic,

rotational, and other systems. The other systems either handle both prismatic

and rotational parts, or they are unclassified. The figures show a rapid

exponential-like growth in both Western Europe and japan. The USA also

exhibits an exponentially shaped growth curve. However, the curve for the USA

reflects a significantly slower rate of growtn. The growth curve for Eastern

9
European countries shows a slow, nearly linear, rate of growth.

Eastern European systems are under represented in this report. This

follows directly from the limited amount of published information available on

Eastern European manufacturing technology in general, and in particular to

policies relating to publication of technology related to their defense

industry

In comparing rotational versus prismatic systems, the former are found to

represent a small but nearly constant proportion of the installations for all

regions except Eastern Europe. In Eastern Europe, rotational systems

predominated in the seventies, and continue to account for approximately half

of the FMS facilities.

Lot sizing data is shown by category in Figures 7 thru 10. The definition

for each category is given below:

Category Lot Size

1 1-10

2 11-50

3 51 - 100

4 101 - 500

5 Over 500

The data for Eastern Europe is inconclusive, as it is based upon two

observations. It is included because it shows that at least one system has a

high enough degree of automation to produce minimal lot sizes. The

distributions for both the USA and Japan are skewed to the left, which is an

indication of a high degree of flexibility. The distribution for Western

Europe is significantly different, indicating the likelihood that a typical

lot size is in excess of 50 parts.

10
Product Characteristics for FMS

The product mix for each region is represented as a series of pie charts

in Figure 11 thru Figure 14. Unknown product applications, which are shown on

the graphs, are omitted in the estimates of product mix given below. This

results in the numerical values for product mix figures used in the report

being different than the corresponding figure as shown on the graph. Product

and materials categories were developed to analyze product characteristics, as

indicated below:

Product Categories Material Categories

1 . Machine Tools 1. Steel or Cast Iron

2. Heavy Equipment (Commercial) 2. Aluminum

3. Heavy Equipment (Military) 3. Stainless Steel

4. Aerospace (Commercial) 4. Nonferrous Alloys

5. Aerospace (Military) 5. Unclassified

6. Automotive

7. Consumer Products

8. Industrial Products

9. Unclassified

Little is known about the product mix in Eastern Europe. The sketchy

information presented in Figure 11 reflects traditional product applications

of FMS technology in the machine tool and heavy equipment industries. Notably

absent is any information on military products. The Eastern block countries

are world leaders in arms production, and yet there are no military product

applications reported for Eastern Europe. A much more representative range of

products is seen in graphs for the other regions.

Japan, as might be expected, has no significant application of FMS

11
technology to military products. Japan’s primary focus is in manufacturing

machine tools , which represents 61.4 % of the mix, and other industrial

products, which accounts for an additional 25.2 % of the product mix.

Western Europe has a balanced product mix. Traditional applications such

as heavy equipment, industrial products, and automotive products account for

7o. 9 7» of tiie mix. Machine tool applications are a surprisingly small l-t.3 /<>

of the mix, and military applications only accounted for 5.1 % of the mix.

The USA nas a mix reaturing ^.y.9 /o heavy equipment (civilian), 25 %

various industrial products, and 27.2 % military products. Only 7.1 % of the

mix represents tne macnine tool industry. The USA diners irom its

international competitors in having a much larger military component, and a

mucn smaller macnine tool component in its product mix.

Materials applications are shown in Figures 15 - 18 As expected, they

correspond to tne product mix. The predominant materials being used in every

instance are iron and steel. The use of aluminum and stainless steel is

evidenced in both Western Europe and the USA, where aerospace products maice up

a significant part of the mix. The use of other nonferrous materials is rare.

Early product applications in FMS were typically for large prismatic

parts used in heavy equipment applications such as housings for transmission

and difierential gears on trucKS, tractors, and construction equipment, in

looking at trends in FMS product applications it is useful to look at the part

cube. The part cube distributions are shown in Figures ly - tt. Eastern

European systems have a wide range of part volume capabilities, as do those of

Japan. Fart volumes in Western Europe are skewed toward smaller part v>l i . .

and yet none of the reported part volumes is less than a cubic foot. The part

cube distribution tor FMS machine tools in the United States ran ,o ; r mi a

minimum of a 1 foot cube up to a 4 ft x 4 ft x 5 ft part volume. The number >1

12
part cubes less than or equal to one cubic foot in volume suggests that there

is a greater diversity at present, by comparison with earlier FMS product

applications. The categories used to evaluate part cube distribution are

listed oelow:

Category

1

2

3

4

5

Cube Size (Edge Length)

Up to I foot

Between 1 and 2 feet

Between 2 and 3.28 feet

Between 3.28 and 6.42 feet

Over 6.42 feet

Materials Handling Trends for FMS

Summaries were made for seven different types of materials handling

equipment. The frequency of use for each type of equipment is shown by

category for each region in Figures 23 thru 26. Any installations that did not

have inrormation of materials handling technology was excluded from this

summary. The resulting sample sizes were 13, 71, 42, and 46 for Eastern

Europe, Western Europe, Japan and tne USA. The categories are defined below:

Category Materials Handling Equipment

1 Roller Conveyor (RC)

2 Cart with Towline (CT)

3 Rail Guided Cart (RG)

4 Automatic Guided Vehicle (AGV)

5 Robotic Application(s) (RA)

6 Stacker Crane (STK)

7 Automatic Storage and Retrieval System (A3RS)

13
As the categories are not mutually exclusive, the percentages may add to more

than 100 % for any region.

One of the surprising observations is the large number (53.8 %) of

facilities in Eastern Europe that have robotic applications. Though based upon

a small sample size of 13, this suggests a high degree of automation. The data

for Western Europe and in the USA includes a representative mix of each of the

available technologies. The only marked difference between these two regions

appears to be in the use of ASRS, where the USA has an estimated 17.4 % usage

versus a 5.6 % usage in Western Europe. Japanese FMS installations make a

greater use of ASRS (40.5 %) and AGV’s (47.6 %) than other regions, while

making smaller but substantial use of robotic technology (26.2 %). Overall,

the use of AGV's is becoming more common in the more recent systems.

14
GRAPHICAL ANALYSIS OF FMS TRENDS AND ATTRIBUTES

15
FIGURE 1 Distribution of FMS Technology

Based Upon Number of Systems

W. EUR. (42.3X)

FIGURE 2 Distribution of FMS Technology

Based Upon Number of Machine Tools

W. EUR. (31 .6K)

16
500

FIGURE 3. Eastern Europe

Number of FMS Machine Tools

\7~7\ PRISMATIC ROTATIONAL U77A UNSPECIFIED

FIGURE 4. Western Europe

Number of FMS Machine Tools

YEAR V~7\ PRISMATIC r\X] ROTATIONAL V77/1 UNSPECIFIED

17
FIGURE 5. Japan

Nunber of FMS Machine Tools

500

400 -

300 -

200 -

100 -

FIGURE 6. USA

Nurtber of FMS Machine Tools

X7~7\ PRISMATIC fV"\] ROTATIONAL T777X UNSPECFED

18
PERCENTAGE

PERCENTAGE

FIGURE 7. Eastern Europe

Lot Size Distribution

FIGURE 8. Western Europe

19
PERCENTAGE

PERCENTAGE

FIGURE 9. Japan

Lot Size Distribution

FIGURE 10. USA

Lot Size Distribution

20
FIGURE 11. Eastern Europe

FMS Product Mix

FIGURE 12. Western Europe

FMS Product Mix

21
FIGURE 13. Japan

FMS Product Mix

AUTO. (1.9X) HVY.EQ.(CIV.) (6. OX)

FIGURE 14. USA

FMS Product Mix

22
FIGURE 15. Eastern Europe

FMS Materials Usage

FIGURE 16. Western Europe

FMS Materials Usage

23
FIGURE 17. Japan

FMS Materials 11*090

STAINLESS (

1 . 6%)

FIGURE 18. USA

FMS Material Liny.

24
PERCENTAGE

PERCENTAGE

FIGURE 19. Eastern Europe

Port Cube Distribution

FIGURE 20. Western Europe

Part Cube Distribution

25
PERCENTAGE

PERCENTAGE

60

FIGURE 21. Japan

Pori Cube Distribution

FIGURE 22. USA

Port Cube Distribution

26
PERCENTAGE

PERCENTAGE

FIGURE 23. Eastern Europe

Materials Handling Distribution

FIGURE 24. Western Europe

Materials Handling Distribution

27
PERCENTAGE

PERCENTAGE

FIGURE 25. Japan

Material* Handling Distribution

FIGURE 26. USA

Materials Handling Distribution

MATERIALS HANOJNO MODE

28
SUMMARY AND CONCLUSIONS

In order to assess the state of tne art and to provide a basis for

comparison, the main points from the analysis section will be summarized for

each region. Overall conclusions for the report will also be given.

Eastern Europe

In Eastern Europe the numbers of systems reported are fewer than for any

of tne otner regions studied. In addition, the growth of FMS tecnnology

appears to be linear, occurring at a slow and constant rate. This is in marked

contrast to all other regions, which appear to have an exponential growth

rate. However, Eastern European FMS implementations may be greatly underestimated in this report, reflecting the lack of published information on

eastern block technology. One factor that suggests that the eastern block

systems are being underreported is the complete lack of information on any

military product applications.

The FMS systems in Eastern Europe are approximately half rotational

systems, and half prismatic systems. Some evidence of the state of the art in

these systems comes from the report that at least one system can economically

produce a lot size of one. One available indication of tne level of automation

in these systems comes from the fact that slightly more than half of the

implementations, which reported on tneir materials handling technology, use

robotics. Although based upon a small sample size of 13, the use of robotics

suggests a relatively nign degree of automation.

29
Western Europe

Western Europe leads the other regions in terms of the number of FMS

implementations and the growth rate for FMS implementations. This region has

more individual firms with experience in FMS technology than any other.

Although both governmental policy and economic conditions have a strong

influence on the growth and diffusion of technology, Western Europe clearly

has a great potential for technological growth in this area.

In terms of product mix, Western Europe has a balanced mix of traditional

products with heavy equipment, industrial, and automotive products accounting

for nearly 80 % of the product mix. The minimum lot size reported was 50,

which may be an indication that the Western European systems have less

flexibility than those found in other regions. A wide variety of materials

handling technologies are used. There is some evidence that the Western

European systems make less use of automation in their materials handling

systems. The use of robotics is about the same as in Japan and the USA.

However, the use of AGV's and ASRS is less prevalent in Western European

Systems than for those surveyed in Japan or in the USA.

Japan

Japan trails the USA and Western Europe in terms of the number of

implementations reported. The Japanese share of FMS technology increases when

the comparison is based upon the number of machine tools, reflecting the fact

that several of their FMS implementations are very large. The product mix t r

the Japanese systems differs markedly from the other regions in that the

principal product is machine tools, which represent 64 « of all produc ts

30
manufactured on FMS. This fact suggests that Japan has the potential to

rapidly increase the use of F M S tecnnology, even though they trail both

Western Europe and the USA in terms of the number of firms employing FMS.

USA

The USA has a strong position in FMS technology. However, there are at

least two areas of concern. First, the growtn rate of FMS tecnnology seems to

be somewhat lower than that for Western Europe or Japan. Second, the product

mix differs in tnat macnine tool production on FMS is lower than that for any

other region. Partly offsetting this is the drive for further automation

provided by defense related products.

Conclusions

The data base, graphical comparisons, analysis, and summary above

presents a state of the art picture of FMS technology in terms of the major

operating characteristics. The report also provides an international

comparison, in terras of growth and difrusion, for the four regions studied.

However, this was not the only objective of this project. Perhaps of greater

importance is the potential to use this research to provide a framework for

further studies. The first contribution to future research is identifying the

users of FMS technology. A second contribution is providing tne information in

a computerized data base to facilitate further work. The data base is highly

flexible, and can be expanded to include both additional implementations

(records) and additional data (fields). It is hoped that this report serves to

encourage further investigations into FMS implementation.

31
APPENDICES

32
APPENDIX A. DATA BASE SCHEMA AND DATA DICTIONARY

COUNTRY: User country

COMPANY: User company

LOCATION: Location of FMS installation

DIVISION: Division of user company

SUPPLIER: Principal supplier of FITS

CLASS: System classification: FMS, FTL, or MC (see FITS abbreviations)

YEAR: The reported, or estimated, year when the FMS began routine

production

FIN_JUST: Financial justification information

COMPUTER: The host computer

CONTROLSThe process controls. In the Eastern European installations the

FMS system nomenclature is given in this field.

PRODUCTS: The principal products produced by the FMS

MATERIALS: The materials used to produce the product. Where not specified, this

was inferred from the product when obvious. For example, aluminum

was given as the material for aircraft parts, cast iron and steel

were given as materials for machine tool parts.

NO_PARTS: The number of different unique parts produced by the FMS

NO_FAMILYS :The number of product (or part) families produced by the FMS

PARTS_ANN : The number of parts produced annually, or the production rate

PART_CUBE: The dimensions of the part envelope

PART_SHAPE:The basic part geometry/production mode: prismatic (P),

rotational (R), and unrestricted (U)

SCHEDULING: Descriptive information about the operation's scheduling

SCHEDULE2: A continuation of the SCHEDULING field

33
APPENDIX A. DATA BASE SCHEMA AND DATA DICTIONARY (CONT'D)

LOT_SIZE:

CREWJ3IZE:

MACH_SET

MATL_HANDL

TOOLING:

FEATURES

REFERENCES

Lot size information

Crew size information. This is given by shift when possible.

A list of the number and types of machines in the FMS (see FMS

abbreviations)

A brief description of the material handling equipment (see FMS

abbreviations)

A brief description of the tool system used in the FMS (see FMS

abbreviations)

A brief description of the FMS system features (see FMS

abbreviations)

A listing of the bibliographic reference numbers of the articles

used in defining the record

34
APPENDIX B. LIST OF ABBREVIATIONS

Class

FMS: Flexible Manufacturing System

FTL: Flexible Transfer Line

MC: Machine Cell

Machine Tools

MC: Machining centers

NHM: NC Horizontal Mill

NVM: NC Vertical Mill

NM: NC Mill

NV: NC Vertical Lathe

NT: NC Lathe

ND: NC Drill

NB: NC Boring

NG: NC Gear Cutting

NGR: NC Grinding

WS: Wash Station

CMM: Coordinate Measuring Machine

MT: Unspecified Machine Tool

SP: Special Purpose Machine Tool

Organizational Abbreviations.

DOC: Department of Commerce

NBS

National Bureau of Standards

ITA: International Trade Administration

35
APPENDIX B. LIST OF ABBREVIATIONS (CONT’D)

Materials Handling:

CT: Cart with towline

AGV's: Automatic Guided Vehicle(s) (Wire Guided)

RA: Robotic Application

RG: Rail Guided Shuttle

RC: Roller Conveyor

CAR: Carrousel

ASRS: Automatic Storage & Retrieval

STK: Stacker Crane

X: Other

Features:

AC: Adaptive Control

AE: Acoustic Emission

CC: Central Coolant

SC: Self-contained Coolant

P: Probing

I: Inspection

X: Other

WS: Wash Station

Miscellaneous Abbreviations

CAM: Computer Aided Manufacturing

CIM: Computer Integrated Manufacturing

CNC: Computer Numerically Controlled (Machining)

DNC: Direct (Computer) Numerically Controlled (Machining)

36
APPENDIX B. LIST OF ABBREVIATIONS (CONT'D)

Justification:

WIP: Work in process reductions

FLR: Floor space

LT: Lead time

MT: Reduction in the number of machine tools required

LAB: Reduced labor cost

PMX: Changing product mix

ROI: Return on investment

PB: Pay back period

UT: Machine utilization

PRD: Increased production

CST: Reduced manufacturing cost

Tooling:

CAR: Carrousel

HI: Head Indexer

HC: Head Changer

ATC: Automatic Tool Changing

Part Geometry:

R: Rotational

P: Prismatic

U: Unrestricted

37
4

APPENDIX C. FMS IMPLEMENTATION DATA BASE

38
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Austria

Steyr Puch

Mandelli

FMS

84

Prismatic

2 MC

14

Belgium

Caterpillar

Gosselies

Hueller Hille

FMS

80

Siemens

Wheel loader lift arras Steel

Prismatic

2 NM, 2 MC

14
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Belgium

Caterpillar

Gosselies

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

Scharmann

FMS

80

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Dual DEC PDP 11/34's

Siemens

Wheel loader engine frames

Steel

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

2.5 hrs./part

3 x 1 .5 x .8 m Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

4 MC, 1 NM, 1 NB (vertical), 5 NB (duplex), 6 meas. sta

Rail guided cart

ATC: 70 tool capacity

Inspection, probing, and adaptive control

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Belgium

Caterpillar

Gosselies

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

Pegard

FMS

80

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Siemens

Wheel loader frames

Steel

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

1 NM, 3 MC

Pallet shuttle

23. FEATURES:

24. REFERENCES:

Probing, adaptive control

14

40
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Belgium

2. COMPANY: DAF Trucks

3. LOCATION:

4. DIVISION:

5. SUPPLIER: Comau

6. CLASS: FMS

7. YEAR: 85

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Rear axle parts

12. MATERIALS: Cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 2 ND, 1 NB, 1 MC

21. MATL. HANDLING: Cart with towline, robots

22. TOOLING:

23. FEATURES: Automated inspection

24. REFERENCES: 14

c

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Bulgaria

ITCR

MC

80

4-6 fold increase in productivity, reduced WIP inventory

20,000 + parts per year

Rotational

Work centers are operated independently, two shift

operation

5 NT, 1 ND, 1 WS

AGV, ASRS, manually loaded machines

83

41
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Bulgaria

2. COMPANY: ITCR

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS: MC

7. YEAR: 80

8. FINANCIAL DATA: 3-7 fold increase in productivity,

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Gear boxes for machine tools

12. MATERIALS: Cast iron

13. NUMBER OF PARTS: 12

14. PART FAMILIES:

15. PRODUCTION RATE: 1,600 per year

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION Two shift operation

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 3 NHM, 2 NVM, 1 CMM

21. MATL. HANDLING: Rail guided vehicle

22. TOOLING: ATC: capacities of 32,48,60, and 90

23. FEATURES:

24. REFERENCES: 83

1. COUNTRY: Bulgaria

2. COMPANY:

3. LOCATION

4. DIVISION

5. SUPPLIER: Hitachi Seiki, Fanuc

6. CLASS: FMS

7. YEAR: 82

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

Prismatic

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 30 MC

21. MATL. HANDLING:

22. TOOLING:

Robots

23. FEATURES:

24. REFERENCES: 14

less than 1% scrap

42
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Bulgaria

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

MC

79

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

SSHO System

Electric motor shafts

Steel

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Rotational

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

4 NGR

Overhead robot

24. REFERENCES: 86

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Bulgaria

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

MC

77

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

ZMM System, Fanuc licensed NC controls

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

4 MC

24. REFERENCES: 86

43
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Bulgaria

MC

76

ZMM System (DNC)

Rotational

4 NT

2 Robots

86

1. COUNTRY:

2. COMPANY:

3. LOCATION

Czechoslovakia

Kovosvit Sezimovo

4. DIVISION: ISTU, N.E.

5. SUPPLIER: Tos Kurim

6. CLASS: MC

7. YEAR: 77

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: IVU 320 System

11. PRODUCTS: Flanges and shafts

12. MATERIALS: Steel

13. NUMBER OF PARTS: 5,000

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE: 120 mm round x 500 ram long

17. PART SHAPE: Rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE: Average of 39

20. MACHINE SET: 22 NT, 1 NHM, 1 ND, 1 NHM

21. MATL. HANDLING: Stacker crane

22. TOOLING:

23. FEATURES:

24. REFERENCES: 41

44
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Czechoslovakia

Pvazke-Strojirney Works

Tos Kurim

MC

77

IVU 200 System

200 mm Prismatic

1 NHM, 1 NVM, 1 CMM, 1 WS

Stacker crane, ASRS

41, 69

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Czechoslovakia

Sezimovo Usti

Kosovit Plant

Tos Kurim

MC

77

IVU 320 System

Flanges and shafts

Carbon steel

5,500

Shafts: 120 mm round x 500 mm long, flanges 50-320 mm rd.

Rotational

Crew of 13

Average of 39, minimum of 10

22 NT, 2 NVM, 1 ND

Stacker crane

41

45
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Czechoslovakia

2. COMPANY: Tos Kurim

3. LOCATION:

4. DIVISION:

5. SUPPLIER: Tos Kurim

6. CLASS: MC

7. YEAR: 77

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: IVU 800 System

11. PRODUCTS: Machine tool parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE: 800 mm

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE: 25 maximum

20. MACHINE SET: 1 NM, 2 MC, 1 NB

21. MATL. HANDLING: Stacker crane, 2 carts

22. TOOLING: ATC

23. FEATURES:

24. REFERENCES: 41

1. COUNTRY: Czechoslovakia

2. COMPANY: Tos Kurim

3. LOCATION:

4. DIVISION:

5. SUPPLIER: Tos Kurim

6. CLASS: MC

7. YEAR: 77

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: IVU 1250 System

11. PRODUCTS: Machine tool parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE: 1250 mm

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE: 25 maximum

20. MACHINE SET: 1 NM, 1 NB, 2 NHM, 1 MC

21. MATL. HANDLING: Stacker crane, 2 carts

22. TOOLING: Manual

23. FEATURES:

24. REFERENCES: 41

46
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Czechoslovakia

Tos Olomonc

Olomonc

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

Vusco Research Institute

FMS

83

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

ADT 4500 (Czech.)

PVS 400 System, NS Series 750, 850, and 920 controls

Machine tool parts

Cast iron

40

8

52 parts/24 hours

400 mm Prismatic

Random flow of parts. One manned shift, 24 hour operation

Parallel machine centers.

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

8 MC, 2 CMM, 2 WS

Stacker crane, ASRS

ATC: tool magazines linked by automatic tool transfer

Adaptive control

41, 78

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Czechoslovakia

Unknown

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

SKODA

MC

77

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

SKODA-NC-N System

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

3.5 x 2.24 x 2 m Prismatic

24. REFERENCES: 86

47
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Czechoslovakia

2. COMPANY: Vuste Research Institute

3. LOCATION: Prague

4. DIVISION:

5. SUPPLIER: Vuste Research Institute

6. CLASS: FMS

~

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS: Steel, cast iron, and non-ferrous metals

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE: .25 m cube (prismatic), .16 m rd. x .38 m 1 (rotational

17. PART SHAPE: Prismatic and rotational

18. OPERATION Computer scheduling of work and material transport.

SCHEDULING: Central computer downloads NC programs.

19. LOT SIZE:

20. MACHINE SET: 2 MC, 2 NT

21. MATL. HANDLING: rail guided cart, robots

22. TOOLING:

23. FEATURES:

24. REFERENCES: 23

1. COUNTRY: Czechoslovakia

2. COMPANY: ZPS Gottwaldow

3. LOCATION:

4. DIVISION:

5. SUPPLIER: Tos Kurim

6. CLASS: MC

7. YEAR: 75

8. FINANCIAL DATA: 15 jobs eliminated, 90% machine utilization acheived

9. COMPUTER:

10. CONTROLS: IVU 400 System

11. PRODUCTS: Machine tool and shoe machinery parts

12. MATERIALS: Cast iron

13. NUMBER OF PARTS: 20,000

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE: 630 mm

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE: Average of 50, range of 10 to 100

20. MACHINE SET: 10 MC

21. MATL. HANDLING: Stacker Crane

22. TOOLING:

23. FEATURES:

24. REFERENCES: 41

48
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

East Germany

7 October

Niles Group

7 October

MC

71

Rota F125 System

Machine tool parts

Steel, cast iron

400

135,000/year

125 mm diameter

Rotational

Batch computer schedules with revisions by operator

1 NT (rough), 3 NT, 2 NM/D, 1 NGR

Overhead carousel (270 part capacity), manual load/unload

37, 38

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

East Germany

7 October

Zerbst

7 October

FMS

73

4-5 year payback, 270% increase in productivity

Robatron 4000

Rota FZ200 System

Gears for machine tools

Steel

2,000

310,000 parts/year

60-200 mm diameter

Rotational

Batch computer schedules with revisions by operator

Range 10 to 500

16 work stations: 3 NV, 1 NT, 2 NM, + ... Stacker crane, robots for machine loading

Manual, local to each machine

Gear hardening equipment planned for 1978

14, 37, 38, 39

49
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

East Germany

Fritz Heckert

Gruenbach

Fritz Heckert

MC

71

62.8 % cost reduction in sample of 21 parts

KRS 4200

Prisma 1 System

Machine tool components

Steel, cast iron

250 mm Prismatic

Fixed sequence of operations for each part

1 NHM, 1 NVM

Carosel at center of cell

40 per machine tool

14, 37, 38

1 . 2 . 3.

4.

5.

6 . 7.

8 . 9.

10 . 11 . 12 . 13.

14.

15.

16.

17.

18.

19.

20 . 21 . 22 . 23.

24.

COUNTRY: East Germany

COMPANY: Fritz Heckert

LOCATION: Auerbach

DIVISION: Karl-Marx-Stadt

SUPPLIER: Fritz Heckert

CLASS: FMS

YEAR: 72

FINANCIAL DATA: 5 year payback, 75 % machine utilization

COMPUTER:

CONTROLSPrisma 2 System

PRODUCTS: Machine tool parts

MATERIALS: Steel, cast iron

NUMBER OF PARTS: 12

PART FAMILIES:

PRODUCTION RATE: 8,000 parts/year

PART CUBE: 1 x 1 x 1 . 5 m PART SHAPE: Prismatic

OPERATION Multiple routings with alternate operations generated by

SCHEDULING: computer to balance the work load, crew of 11 LOT SIZE:

MACHINE SET: 1 NM (rough), 2 NVM, 3 MC, 2 CMM, 2 WS

MATL. HANDLING: Air cushion conveyor positions pallet to w/i 3 urn TOOLING: Local to MT, up to 138/MT

FEATURES: Adaptive control: tool wear, casting dim., pit. position

REFERENCES: 14, 37, 38, 39

50
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

East Germany

Herbert Warnke

Erfurt

Fritz Heckert

MC

78

PC 1 System

Very large parts for metal forming machines

Cast iron

Prismatic

2 NVM (200 mm spindle), 1 NVM (250 mm spindle)

Overhead crane

39

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

East Germany

Herbert Warnke

Erfurt

Fritz Heckert, Svoda

FMS

77

Labor savings of 55,000 man-hrs./year, 66% MT utilization

Robatron 4000

PC 3 System

Large parts for metal presses & brakes

Cast iron, steel

120

625 parts/ year

4 - 7 m Prismatic

Works to a monthly plan, infrequent changes made by the

operator, simulation is used in developing the schedule

5 NVM (250 mm & 160 mm spindles)

Rail guided cart with 57 m track and 14 stations

ATC for each machine

23, 38, 39

51
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

East Germany

Hermann Matern

Zerbst

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

7 October

FMS

73

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

2 - KRS 4201 's FZ 200 System

Spur gears for lathes

Steel

200

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

180,000 parts/year

60-200 mm round

Rotational

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

400 maximum

5 NT, 3 NGR, 1 Broaching MT, 9 NG, 1 Burnishing MT

24. REFERENCES: 86

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

East Germany

Saalfeld

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

MC

80

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

MAPK 500 System

Drill gearbox, spindle, and base

Steel, cast iron

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

500 mm Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

2 MC

1 Rail guided cart, 2 carousels

Head changer

24. REFERENCES: 39

52
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

East Germany

USSR Import

VEB Rawema

Fritz Heckert

FMS

85

FMS 1000 System

1000 mm Prismatic

19 MT

Robots

24

East Germany

Umformtechnik

Erfurt

Forschungszentrum

FMS

77

PC 3 System

1000 mm, 24000 kps

Prismatic

5 NVM

86
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: East Germany

2. COMPANY:

3. LOCATION: Dresden

4. DIVISION: Agricultural Machinery

5. SUPPLIER: Fritz Heckert

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA: 480 % increase in productivity

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Gear boxes

12. MATERIALS: Cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 8 MC, 1 WS

21. MATL. HANDLING: Rail guided cart, ASRS

22. TOOLING:

23. FEATURES:

24. REFERENCES: 24

1 . COUNTRY: East Germany

2. COMPANY: Veb Robur

3. LOCATION

4. DIVISION

5. SUPPLIER Comau

6. CLASS: FMS

7. YEAR: 83

8. FINANCIAL DATA:

9. COMPUTER

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

Prismatic

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

54
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

East Germany

Werkzeugmaschinenkombinat

7 October

FMS

73

Rotational

3 NV, 1 NT, 2 NM

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

France

Alsthom Atlantique

Saint Nazaire

Mandelli

FMS

84

Diesel engine parts

Cast iron, steel

Prismatic

2 MC, 1 MT, plus 2 auxilliary modules

14, 20

55
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: France

2. COMPANY: Alsthom Unelec

3. LOCATION: Orleans

4. DIVISION:

5. SUPPLIER: Mandelli

6. CLASS: FMS

7. YEAR: 83

8. FINANCIAL DATA:

9. COMPUTER: DEC PDP 11/24

10. CONTROLS:

11. PRODUCTS: AC electric motor parts

12. MATERIALS:

13. NUMBER OF PARTS: 12

14. PART FAMILIES: 4

15. PRODUCTION RATE: 7,000 parts/year

16. PART CUBE:

17. PART SHAPE: Rotational

18. OPERATION Crew of 2

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 3 MC, 1 WS

21. MATL. HANDLING: 1 rail guided cart

22. TOOLING: ATC 60 tool capacity

23. FEATURES: Probing

24. REFERENCES: 14, 15, 20

1. COUNTRY: France

2. COMPANY: Caterpillar

3. LOCATION: Grenoble

4. DIVISION:

5. SUPPLIER: Mandelli

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Track links

12. MATERIALS: Cast steel

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 2 MC

21. MATL. HANDLING: 2 rototraversing units

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14, 18

56
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

France

Caterpillar

Grenoble

Renault /Mandelli

FMS

84

Renault/Mandelli

Track roller frames

Steel

Prismatic

4 MC

Pallet transfer

Probing, adaptive control

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

France

Caterpillar

Grenoble

Wotan/Line

FMS

81

Bosh, Bendix

Track type loader frames

Steel

Prismatic

6 MC

14

57
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

France

Caterpillar

Grenoble

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

Pegard

FMS

85

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Siemens

Track type case & frame

Cast iron, steel

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

2 MC

Cart with tow line

23. FEATURES:

24. REFERENCES:

Probing, adaptive control

14, 18

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

France

Citroen

Meudon

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Comau

FMS

84

3.1 year payback period

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

Cylinder heads, transmission & differential housings

Steel, cast iron

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

3

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

2 MC (five axis), 1 CMM, 1 WS

4 AGV's

24. REFERENCES: 14, 69

58
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: France

2. COMPANY: Citroen

3. LOCATION: Meudon

4. DIVISION:

5. SUPPLIER: Automatique Industriel

6. CLASS: FMS

7. YEAR: 82

8. FINANCIAL DATA: Machine utilization 75-80 %

9. COMPUTER: Thompson (French Mfg.)

10. CONTROLS:

11. PRODUCTS: Automobile engine parts

12. MATERIALS: Cast iron, steel, aluminum

13. NUMBER OF PARTS: 80

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE: 500 mm

17. PART SHAPE: Prismatic

18. OPERATION 24 hour operation, parts may be processed in random order

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 2 MC (5 axis), surface treatment station, 1 CMM, 1 WS

21. MATL. HANDLING: AGV

22. TOOLING: ATC, central magazine with 600 tools

23. FEATURES:

24. REFERENCES: 65, 66

1. COUNTRY: France

2. COMPANY: Citroen Construction Mechanique

3. LOCATION:

4. DIVISION:

5. SUPPLIER: Automatique Industriel

6. CLASS: FMS

7. YEAR: 83

8. FINANCIAL DATA: Labor savings, 20 workers vs. 73

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Cylinder heads, gear, differential, and clutch housings

12. MATERIALS: Cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE: 500 mm

17. PART SHAPE: Prismatic

18. OPERATION 24 hour operation, third shift has 1 worker (10 hrs.),

SCHEDULING: random processing capability, crew size of 9, 8, and 1 19. LOT SIZE:

20. MACHINE SET: 3 MC, 1 WS, 1 CMM, 1 surface treating station

21. MATL. HANDLING: 5 AGV's

22. TOOLING: ATC, central magazine with 600 tools

23. FEATURES:

24. REFERENCES: 66

59
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

France

Iveco

Berardi S.P.A.

FMS

84

Prismatic

6 MC

14

France

Renault

Saint Priest

Vehicles Industriels

Renault

FMS

82

Prismatic

9 work stations

Roller conveyor

14, 18

60
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: France

2. COMPANY: Renault

3. LOCATION: Le Mans

4. DIVISION: Renault Materiel Agricole

5. SUPPLIER: Renault

6. CLASS: FMS

7. YEAR: 82

8. FINANCIAL DATA:

9. COMPUTER

10. CONTROLS:

11. PRODUCTS: Agricultural machinery parts

12. MATERIALS: Cast iron, steel

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 5 MT

21. MATL. HANDLING: Rail guided cart

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14, 18

1. COUNTRY: France

2. COMPANY: Renault Machines Outils

3. LOCATION: Boutheon

4. DIVISION: Renault Vehicles Industriels

5. SUPPLIER: Renault /Graf fens taden

6. CLASS: FMS

7. YEAR: 82

8. FINANCIAL DATA: Reduced WIP

9. COMPUTER: Solar 16.4

10. CONTROLS: Renault (SMC)

11. PRODUCTS: Gear boxes for trucks

12. MATERIALS: Cast iron, aluminum

13. NUMBER OF PARTS: 3

14. PART FAMILIES:

15. PRODUCTION RATE: 300/ day

16. PART CUBE: 600 mm

17. PART SHAPE: Prismatic

18. OPERATION Alternate routings for machine failure

SCHEDULING:

19. LOT SIZE: 100

20. MACHINE SET: 4 MC (4-axis), 1 NM, 1 WS

21. MATL. HANDLING: 8 AGV's

22. TOOLING: 2 Head changers

23. FEATURES: Adaptive control: tool wear adjustment

24. REFERENCES: 18, 19

61
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: France

2. COMPANY: Unic

3. LOCATION:

4. DIVISION:

5. SUPPLIER: Coraau

6. CLASS: FMS

7. YEAR: 85

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Engine base

12. MATERIALS: Steel

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 2 special machines

21. MATL. HANDLING: Cart with towline, robots

22. TOOLING:

23. FEATURES: Automated inspection

24. REFERENCES: 14

1 . COUNTRY: Hungary

2. COMPANY: Budapest Technical University

3.

4.

5.

LOCATION:

DIVISION:

SUPPLIER:

Budapest

6. CLASS: MC

7. YEAR: 83

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: CONY 16 System

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic & rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 4 MC, 4 NT, 1 CMM

21. MATL. HANDLING: 2 Robots

22. TOOLING:

23. FEATURES:

24. REFERENCES: 69

62
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Hungary

Csepel Machine Tool Company

Budapest

Csepel

MC

78

KFKI (Hungarian)

CONY 16 System

Machine tool parts

Cast iron, steel

33

Prismatic

Alternate routings

1 WS, 1 CMM, 2 NHM, 1 NVM, 1 NM

Rail guided cart, 30 queue buffer, ASRS (400 part cap.)

ATC

67, 86

I. . COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

II. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Hungary

EVIG

MC

79

Electric motor housings

Prismatic

4 MT

86

63
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Hungary

HAFE

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

HAFE

MC

82

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Gear boxes

Cast iron

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

8 MT

24. REFERENCES: 86

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Hungary

Szim

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

MC

81

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Machine tool parts

Steel, cast iron

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

4 MT

24. REFERENCES: 86

64
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Hungary

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS: MC

7. YEAR: 78

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: BME System

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 86

1 . COUNTRY : Hungary

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS: MC

7. YEAR: 81

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: Diagon 500 System

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 86

65
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Hungary

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS: MC

7. YEAR: 73

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: DNC-73 Syst

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 86

1. COUNTRY: Hungary

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS: MC

7. YEAR: 79

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: FIG System

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 86

66
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Hungary

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS: MC

7. YEAR: 80

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: IGYR 630 System

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 86

1. COUNTRY: Italy

2. COMPANY: Bonfiglioli

3. LOCATION: Bologna

4. DIVISION:

5. SUPPLIER: Comau

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Vehicle parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 2 NV

21. MATL. HANDLING: Cart with towline, robot

22. TOOLING:

23. FEATURES: Automated inspection

24. REFERENCES: 14

67
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Italy

2. COMPANY: Cessna

3. LOCATION: Treviglio

4. DIVISION:

5. SUPPLIER: Olivetti

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: Plasma

11. PRODUCTS: Engine Heads

12. MATERIALS: Cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE: 100,000 parts/year

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 4 MC, 1 NB, 1 WS

21. MATL. HANDLING: Robots

22. TOOLING:

23. FEATURES: Adaptive control, automated inspection

24. REFERENCES: 14

1. COUNTRY: Italy

2. COMPANY: Ferrari

3. LOCATION: Maranello

4. DIVISION:

5. SUPPLIER: Mandelli

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: Plasma

11. PRODUCTS: Automobile engine components

12. MATERIALS: Cast iron, steel

13. NUMBER OF PARTS: 29

14. PART FAMILIES:

15. PRODUCTION RATE: 13 engines/day

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 9 MC, 2 WS

21. MATL. HANDLING: 2 rail guided carts, 2 carousels (14 pall

22. TOOLING: ATC

23. FEATURES:

24. REFERENCES: 14, 20

68
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Italy

Fiat

Brescia

Iveco Truck Plant

Jobs

MC

81

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Drive Shafts

Steel

15. PRODUCTION RATE: 15 parts/hour

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Rotational

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

1 SP, 1 NB

Robot

24. REFERENCES: 14, 20

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Italy

Fiat

Turin

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Comau

FMS

84

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Wheel hubs

Cast iron

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Rotational

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

2 NV

Robot

23. FEATURES:

24. REFERENCES:

Automated inspection

14

69
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Italy

Fiat

Turin

Coraau

FMS

84

Universal joints

Steel

Rotational

6 NV

Robots, cart with towline

Automated inspection

14

1. COUNTRY

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Italy

Fiat Trattori

Modena

Coraau

FMS

84

Transmission housing

Steel

Prismatic

4 MC

Robots

Automated inspection

14

70
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Italy

Goldoni

Capri

Berardi

FMS

84

Tractor body parts

Steel, cast iron

9 parts/3.5 hours

Prismatic

2 MC

Roller conveyor

14

Italy

IBM Italia

Milan

Mandelli

FMS

83

Terminal parts

Prismatic

2 MC

14
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Italy

Iveco Brescia

Comau

FMS

82

Covers and gear boxes

Aluminum, cast iron

7

220 parts/15 hours

Prismatic

10 MT, 1 WS

Robots

Head changer

Automated inspection

14, 70

Italy

Lamborghini

Pieve di Centro

Berardi

FMS

84

Engine parts

Cast iron, steel

44

Prismatic

2 MC

AGV

14
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Italy

Mandelli

Mandelli

FMS

85

DEC PDP 11/23,24,34

Machine tool parts

62

1.85 x 1.2 x .45 m

Prismatic

Two shifts with crew of 4, one shift unmanned

5 MC, 1 WS, 1 CMM

1 rail guided cart, carousel with 20 pallet capacity

ATC: 120 tool capacity

Automated inspection

20

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Italy

Maserati

Modena

Olivetti

FMS

81

Engine components

Cast iron, steel

200 parts/day

Prismatic

10 MC, 1 WS

Rail guided cart

Automated inspection, probing

14

73
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Italy

Nuova Innocenti

Milan

Berardi

FMS

80

Engine heads

Cast iron

Prismatic

4 MC

Roller conveyor

Automated inspection,

14

Italy

Nuovo Pignone

Florence

Mandelli

FMS

84

Turbine impellers

17

1 part/3 hours

Prismatic

3 MC

14

probing

74
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Italy

OM

Brescia

Jobs

FMS

84

Beveling shaft gears

120 parts/hour

Rotational

3 SP

AGV, Robot

Automated inspection,

14

Italy

Piaggio Gilera

Genoa

Berardi

FMS

83

Motorcycle castings

Prismatic

3 MC, 1 WS

Roller conveyor

Probing

14

probing

75
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Italy

Piaggio Gilera

Genoa

Berardi

FTL

84

Engine heads

Cast iron

4

1

1 part/2 hours

Prismatic

8 MC

Roller conveyor

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Italy

Rockwell CVC Omevi

Cameri

Mandelli

FTL

84

Truck differential carriers

Cast iron

2

17.6/hour

Prismatic

4 MC, 1 CMM, 1 WS

2 rail guided carts, robots,

14, 20

carousel with 18 pallets

76
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Italy

Rockwell Iveco

Novara

Mandelli

FMS

85

Truck differential carriers

Cast iron

Prismatic

15

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Italy

Rockwell Italia

Cameri

Comau

FMS

84

Differential parts

Cast Iron

62,300 parts/year

Rotational

2 NV

Cart with towline, robot

Automated inspection

14

77
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Italy

2. COMPANY: Rockwell Italia

3. LOCATION: Cameri

4. DIVISION:

5. SUPPLIER: Coraau

6. CLASS: FMS

7. YEAR: 83

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Bearing boxes

12. MATERIALS: Cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE: 44,500 parts/year

16. PART CUBE:

17. PART SHAPE: Rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 2 NV

21. MATL. HANDLING: Cart with towline, r< 22. TOOLING:

23. FEATURES: Automated inspection

24. REFERENCES: 14

1. COUNTRY: Italy

2. COMPANY: Savio

3. LOCATION: Genoa

4. DIVISION:

5. SUPPLIER: Berardi

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 4 MC, 1 WS

21. MATL. HANDLING: Roller conveyor

22. TOOLING:

23. FEATURES: Cental coolant

24. REFERENCES: 14

78
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Italy

Di Toraazo

Berardi

FMS

82

Prismatic

8 MC

Roller conveyor, 8 robots

18

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Italy

VM

Ceto

Jobs

FMS

82

Drive shafts

Steel

4 parts/2.5 minutes

Rotational

2 NV, 2 NM

Robots

Automated inspection, probing

14

79
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Japan

Asian Kogyo

Anjyo

MC

82

6 NC piercing machines

2 robots

14

Japan

Atsugi Jidasha Buhin

Akita

FMS

81

Prismatic

1 MC, 2 MT

14

80
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Japan

Brother Industries

Toshiba

FMS

80

Typewriter, sewing machine parts

6

Prismatic

Crew of 2

50 average

22 DNC MT's

14, 86

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6 . CLASS

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Japan

Cannon

Okuma

MC

84

Camera and VCR parts

Aluminum

40

Rotational

6 NT (2 duplicate cells)

75

81
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY

Japan

2. COMPANY: Daifu Kiko

3. LOCATION: Osaka

4. DIVISION:

5. SUPPLIER:

6. CLASS: FMS

7. YEAR: 82

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 4 MC

21. MATL. HANDLING: AGV, ASRS

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

1. COUNTRY: Japan

2. COMPANY: Fuji Denki

3. LOCATION: Suzuka

4. DIVISION:

5. SUPPLIER:

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 2 NV, 1 MC

21. MATL. HANDLING: 3 automatic

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

82
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Japan

2. COMPANY: Fuji Xerox

3. LOCATION: Ebina

4. DIVISION:

5. SUPPLIER:

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Parts for copy machines

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 5 MC

21. MATL. HANDLING: Cart with towline

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

1 . COUNTRY: Japan

2. COMPANY: Fujitsu Fanuc

3. LOCATION: Fuji

4. DIVISION:

5. SUPPLIER: Fuji Electric

6. CLASS: FMS

7. YEAR: 80

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Robots, EDM machines, small CNC lathes

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

450

17. PART SHAPE: Prismatic and rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Unmanned night shift, crew of 4

20. MACHINE SET: 30 MT's, C02 laser for hardening

21. MATL. HANDLING:

22. TOOLING:

4 AGV's, ASRS, robots, and carousels

23. FEATURES: Probing, closed circuit TV

24. REFERENCES: 7, 12, 14, 18, 51

83
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Japan

Fujutsu Fanuc

Fuji

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Fanuc

FMS

82

$37 million plant, labor savings: 60 workers vs. 300

11. PRODUCTS:

12. MATERIALS:

Electric motors

13. NUMBER OF PARTS:

14. PART FAMILIES:

900

15. PRODUCTION RATE:

16. PART CUBE:

120,000 parts/year

17. PART SHAPE:

18. OPERATION

SCHEDULING:

Prismatic and rotational

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

Range of 20 to 1,000

60 MT’s

AGV’s, 52 robots (plus 49 used in assembly), ASRS

24. REFERENCES: 7, 12, 69

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Japan

Fujitsu Fanuc

Oshino

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Fanuc

FMS

84

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Plastic injection molding machine parts

Steel, cast iron

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

11 NHM (Makino), 2 NVM (Makino)

AGV’s

24. REFERENCES: 7, 14

84
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Japan

2. COMPANY: Fujitsu Fanuc

3. LOCATION: Oshino

4. DIVISION:

5. SUPPLIER: Fanuc

6. CLASS: FMS

7. YEAR: 81

8. FINANCIAL DATA: 90 % savings in number of MT’s and number of workers

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Plastic injection molding machine parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 6 NT, 1 GR, 1 NM, 1 SP, 1 ND

21. MATL. HANDLING: Robots, AGV's

22. TOOLING:

23. FEATURES:

24. REFERENCES: 7, 12, 14, 18

1. COUNTRY: Japan

2. COMPANY: Fukushimo Seisakusha

3. LOCATION:

4. DIVISION:

5. SUPPLIER: Hitachi Seiki

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Low pressure hydraulic devices

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Rotational and prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 3 MC, 1 NT, 1 NV, 1 NM

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

85
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Japan

Hitachi Seiki

Abiko

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

Hitachi Seiki

FMS

83

3.7 year payback period, jobs reduced from 9 to 4

NEC MS8

Fanuc 6MB CNC's

Machine tool parts

Steel

79

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

60 x 100 in plate

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

4 NHM (Hitachi, # 112 line)

1 rail guided cart

24. REFERENCES: 7, 14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Japan

Hitachi Seiki

Abiko

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Hitachi Seiki

FMS

83

4.1 year payback period, 4 MT's vs 8

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

Machine tool parts

Steel, cast iron

131

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

500 mm x 500 mm pallets

Prismatic

3 shift operation with 2,000 machine hours per month

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

2 NHM, 2 NVM (# 113 line)

AGV, ASRS

ATC with a robot, 528 tools in the system

24. REFERENCES: 7, 14

86
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Japan

2. COMPANY: Hitachi Seiki

3. LOCATION: Abiko

4. DIVISION:

5. SUPPLIER: Hitachi Seiki

6 . CLASS

FMS

7. YEAR: 83

8. FINANCIAL DATA: 3.6 year payback, 4 MT's vs.

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Machine tool parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS: 468

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Rotational

18. OPERATION 1600 machine hours per month

SCHEDULING:

19. LOT SIZE: Maximum of 20

20. MACHINE SET: 3 NT, 1 NHM (# 114 line)

21. MATL. HANDLING: 4 robots

22. TOOLING:

23. FEATURES:

24. REFERENCES: 7, 14

1. COUNTRY: Japan

2. COMPANY: Hitachi Seiko

3. LOCATION: Ebina

4. DIVISION:

5. SUPPLIER: Hitachi Seiki

6. CLASS: FMS

7. YEAR: 82

8. FINANCIAL DATA:

9. COMPUTER: Hitachi M1002H

10. CONTROLS:

11. PRODUCTS: Machine tool parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS: 10

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE: 500 x 500 mm pallet

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 1 NHM, 1 NVM

21. MATL. HANDLING: 1 rail guided cart

22. TOOLING: ATC with capacities of 40 and

23. FEATURES: Machine vision, pallet ID

24. REFERENCES: 7

jobs reduced from 12 to 5

87
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Japan

Ishikawajima Harima

FMS

84

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Japan

Japanese National Project

Tsukuba Science City

MITI - Agency of Science & Technology

FMS

84

Gearboxes, diesel engine components

Cast iron, steel

300 mm Prismatic

3 MC

77

88
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Japan

Kawakami Seisakusho

FMS

82

Rotational

4 GR, 1 NV, 1 power press

Robot for power press

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Japan

Kawaski Heavy Industries

Nishi-Kobi

FMS

75

Valve casting - radial piston engine

Rotational

1NV, 2 NT, 3NM, 4ND

14

89
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Japan

Kitagoe Kogyo

FMS

80

Compressor parts

Prismatic

2 MC

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Japan

Komatsu Seisakusho

Awazu

Komatsu

FMS

76

Bulldozer transmission parts

Steel

106

Rotational

Crew of 6

Average of 16

1 NM, 2 NV, 4 spline hobbing machines

14, 86

90
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Japan

2. COMPANY: Makino Milling Machine Co

3. LOCATION:

4. DIVISION:

Atsugi

5. SUPPLIER: Makino

6. CLASS: FMS

7. YEAR:

8. FINANCIAL DATA:

84

9. COMPUTER:

10. CONTROLS:

Univac AGS2400F

11. PRODUCTS: Machine tool parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

500

15. PRODUCTION RATE:

16. PART CUBE:

270 parts/day

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

3 shift operation

20. MACHINE SET: 10 MC (Makino)

21. MATL. HANDLING:

22. TOOLING:

5 AGV's, ASRS

23. FEATURES: Probing

24. REFERENCES: 7, 14

1. COUNTRY: Japan

2. COMPANY

Mike Pulley

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS: MC

7. YEAR: 79

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Conveyor parts

12. MATERIALS: Steel

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 1 NV, 1 GR

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

91
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6 . CLASS

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Japan

Mitsubishi Electric Co.

Inagwa

Mitsubishi

FMS

84

Machined sheet metal parts

Prismatic

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Japan

Mitsubishi Heavy Industries

Kyoto

FMS

84

Machine tool parts

Steel, cast iron

120

Prismatic

5 MC

Air cushion AGV, air cushion conveyor

ATC with capacities of 60 and 90, 100 tools in system

7

92
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1 . COUNTRY: Japan

2. COMPANY: Mitsubishi Heavy Industries

3.

4.

5.

LOCATION:

DIVISION:

SUPPLIER:

Kyoto

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Machine tool parts

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Steel, cast iron

17. PART SHAPE:

18. OPERATION

Rotational

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 12 CNC (boring, turning, and grinding operations)

21. MATL. HANDLING:

22. TOOLING:

Robots

23. FEATURES:

24. REFERENCES: 7

1. COUNTRY: Japan

2. COMPANY: Mori Seiki

3. LOCATION:

4. DIVISION:

Iga

5. SUPPLIER: Mori Seiki

6. CLASS: FMS

7. YEAR: 82

8. FINANCIAL DATA: Machine utilization 93%, 13 MT's vs. 54

9. COMPUTER:

10. CONTROLS:

Hitachi E800

11. PRODUCTS: Machine tool parts

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Steel, cast iron

17. PART SHAPE: Prismatic

18. OPERATION 22 24-hour days are scheduled every month, 3 workers

SCHEDULING:

19. LOT SIZE:

first shift, none on second or third

20. MACHINE SET: 9 NVM (Mori Seiki), 4 NHM (Toyada)

21. MATL. HANDLING:

22. TOOLING:

16 AGV's, ASRS, linear 14 station queue

23. FEATURES: Probing

24. REFERENCES: 7

93
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Japan

Murata Machinery

Nihon Denki

Tamagwa

Murata

FMS

84

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Sheet metal chasis cover

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

4 turret presses, 2 cutting machines

AGV, ASRS

24. REFERENCES: 14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Japan

Murata Machinery

Inuyama

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

FMS

81

260 % increase in productivity, 20 to 30 workers vs. 100

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Textile machinery, AGV’s

Steel, cast iron

150

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

2 10-hour shifts

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

3 NHM, 4 NVM

Robots, ASRS

24. REFERENCES: 7, 69

94
APPENDIX C. FMS IMPLEMENTATI ON DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

Japan

Niigata Engineering

Niigata

Diesel Engine Works

Niigata Engineering

FMS

79

9. COMPUTER: . 10. CONTROLS:

Hitachi

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

Cylinder heads

Cast iron

80

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

36 x 24 x 12 in

Prismatic

3 shifts, 21 hours per day, in event of machine breakdown

the computer assigns alternate operations in real time

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

5 MC

Roller conveyor, 1 rail guided cart

23. FEATURES:

24. REFERENCES:

Acoustic emmisions for adaptive control

7, 14, 45

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Japan

Niigata Engineering

Niigata

Niigata Machine Tool Works

Niigata

FMS

83

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Machine tool parts

Steel, cast iron

70

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

5 NHM, 1 NM, 1 NV (all Toshiba)

2 AGV's, ASRS

ATC with capacities of 60 & 90, 700 tools in system

24. REFERENCES: 7, 14

95
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Japan

2. COMPANY: Okuma

3. LOCATION: Oguchi

4. DIVISION:

5. SUPPLIER: Okuma

6. CLASS: FMS

7. YEAR: 82

8. FINANCIAL DATA: 1.9 year payback, 60% labor savings, 75 % utilization

9. COMPUTER: Campus 5000

10. CONTROLS:

11. PRODUCTS: Machine tool headstocks, taulstocks, and saddles

12. MATERIALS: Cast iron

13. NUMBER OF PARTS: 95

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION 3 shifts with crew of 3, 1 shift unmanned

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 7 MC (Okuma)

21. MATL. HANDLING: 1 AGV

22. TOOLING: ATC

23. FEATURES: Adaptive control

24. REFERENCES: 7, 51, 69, 75

1. COUNTRY: Japan

2. COMPANY: Osaka Kiko

3.

4.

5.

LOCATION:

DIVISION:

SUPPLIER:

Inuyama

6. CLASS: FMS

7. YEAR: 82

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Machine tool parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS: 65

14. PART FAMILIES

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION 2 shifts plus

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 2 NHM, 1 NVM, (all OKK)

21. MATL. HANDLING: 1 rail guided cart

22. TOOLING: ATC with capacity of 120 tools per machine

23. FEATURES: Acoustic emmissions monitoring for adaptive control

24. REFERENCES: 7

96
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Japan

Shin Nippon Koki

Osaka

Shinodayama Works

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

FMS

82

9. COMPUTER:

10. CONTROLS:

Mitsubishi Melcom 7030

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

Machine center and planner parts

Steel, cast iron

250

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE: 28 x 28 x 20 in

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

3 shifts, with unmanned night shift

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

2 NHM, 2 NVM, 1 CMM, (all SNK)

1 rail guided cart, ASRS

23. FEATURES:

24. REFERENCES:

Acoustic emraissions monitoring for adaptive control

7

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Japan

Shinmeiwa Kogyo

Takarazuka

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Shinmeiwa

FMS

82

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Robot and machine tool parts

Steel, cast iron

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

Unmanned night shift

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

2 MC

Rail guided cart

24. REFERENCES: 14, 51

97
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Japan

Shinraeiwa Kogyo

Takarazuka

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Shinraeiwa

FMS

82

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Machine tool, aircraft parts

Steel, cast iron, and aluminum

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

Unmanned operation at night

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

4 MC

Rail guided cart

23. FEATURES:

24. REFERENCES:

Adaptive control

14, 51

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Japan

Shinodayaraa

Osaka

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

Shi Nippon Koki

FMS

82

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Melcon 70/30

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

4 MC

Rail guided cart, ASRS

23. FEATURES:

24. REFERENCES:

Automated inspection

14

98
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Japan

2. COMPANY:

3. LOCATION: China

4. DIVISION:

5. SUPPLIER: Sunitomo Jyuki Kogyo

6. CLASS: FMS

7. YEAR: 79

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Power shovel parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 4 MC

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES: 1 welding robot

24. REFERENCES: 14

1. COUNTRY: Japan

2. COMPANY: Takisawa Machine Tool

3. LOCATION: Okayama

4. DIVISION:

5. SUPPLIER: Takisawa

6. CLASS: FMS

7. YEAR: 83

8. FINANCIAL DATA:

9. COMPUTER: IBM System 38

10. CONTROLS: IBM S-l Process Computer

11. PRODUCTS: Machine tool parts

12. MATERIALS

Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 3 MC (Takisawa)

21. MATL. HANDLING: 1 AGV

22. TOOLING:

23. FEATURES:

24. REFERENCES: 7

99
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Japan

2. COMPANY: Takisawa Machine Tool

3. LOCATION: Okayama

4. DIVISION:

5. SUPPLIER: Takisawa

6. CLASS: FMS

7. YEAR: 83

8. FINANCIAL DATA:

9. COMPUTER: IBM System 38

10. CONTROLS: IBM S-l Process Computer

11. PRODUCTS: Machine tool parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 2 MC (Takisawa)

21. MATL. HANDLING: 1 AGV, ASRS with 570 locations

22. TOOLING:

23. FEATURES:

24. REFERENCES: 7

1. COUNTRY: Japan

2. COMPANY: Tokyo Shibaura Denki

3. LOCATION: Fuchu

4. DIVISION:

5. SUPPLIER: Toshiba

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Switches

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

Prismatic and rotational

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 6 MC, 8 NV

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

AGV, robots, ASRS

24. REFERENCES: 14

100
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Japan

2. COMPANY: Toshiba Machine Co.

3. LOCATION: Fuchu

4. DIVISION:

5. SUPPLIER: Toshiba

6. CLASS: FMS

7. YEAR: 83

8. FINANCIAL DATA: Labor savings: 7 workers vs. 75

9. COMPUTER: Toshiba

10. CONTROLS:

11. PRODUCTS: Machine tool parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS: 3,000

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic and rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 6 MC, 8 NT

21. MATL. HANDLING: 1 AGV, 2 robots, ASRS

22. TOOLING:

23. FEATURES:

24. REFERENCES: 69

1. COUNTRY: Japan

2. COMPANY: Toshiba

3. LOCATION: Numazu

4. DIVISION:

5. SUPPLIER:

6. CLASS: FMS

7. YEAR: 82

8. FINANCIAL DATA:

9. COMPUTER

FMS T5003

10. CONTROLS: Tosunuc 500

11. PRODUCTS: Machine tool and textile parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARiS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 1 NHM, 1 NVM

21. MATL. HANDLING: ASRS, carousel (16 locations)

22. TOOLING:

23. FEATURES:

24. REFERENCES: 7, 51

101
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Japan

Toshiba Machine Company

Numazu

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

FMS

82

9. COMPUTER:

10. CONTROLS:

Toshiba

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

Machine tool parts

Steel, cast iron

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

1 m

Prismatic

20. MACHINE SET:

21. MAIL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

2 NHM, 1 CMM, 1 WS, honing machine

ASRS

ATC 120 tool capacity

Automated inspection

7

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Japan

Toshiba Machine Company

Numazu

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

FMS

82

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

Machine tool parts

Steel, cast iron

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

630 x 630 mm pallet

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

2 NHM, 1 NVM

AGV

24. REFERENCES: 7

102
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: Japan

2. COMPANY: Toshiba Machine Tool Company

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Numazu

6. CLASS: FMS

7. YEAR:

8. FINANCIAL DATA:

80

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

T-5003 System

16. PART CUBE: 630 x 630 mm pallet

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET: 2 NHM

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

Carousel with 20 positions

24. REFERENCES: 7

1. COUNTRY: Japan

2. COMPANY: Toshiba Machine Company

3. LOCATION: Numazu

4. DIVISION:

5. SUPPLIER: Toshiba Machine

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Injection molding machine

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Steel, cast iron

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET: 6 MC

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

Roller conveyor

24. REFERENCES: 14

103
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Japan

Toshiba Tungaloy Company

Toshiba Machine

FMS

80

6 MT vs. 50, 16 workers vs. 70, and 4 vs. 16 wk lead time

Carbide cutting tools

Carbide tool materials

3600

10

Prismatic and rotational

Crew of 8, unmanned night shift

Average of 5

4 MC, 1 GR, 1 NV

No inter-machine transfer, multiple pallets on machine

Automated inspection, tool wear monitoring

14, 19, 51, 86

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Japan

Toyada Machine Works

Kariya

FMS

86

Machine tool parts

Steel, cast iron

Prismatic

104
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1 . COUNTRY: Japan

2. COMPANY: Toyada Machine Works

3. LOCATION: Okazaka

4. DIVISION:

5. SUPPLIER:

6. CLASS: MC

7. YEAR: 81

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Machine tool parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

1,500

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

Crew of 12

19. LOT SIZE:

20. MACHINE SET:

Average of 5

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

15 DNC

24. REFERENCES: 7, 12, 86

1 . COUNTRY: Japan

2. COMPANY: Toyota Tipros

3. LOCATION:

4. DIVISION:

5. SUPPLIER: Toyota

6. CLASS: FMS

7. YEAR: 73

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Engine components

12. MATERIALS: Cast iron, steel

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE: 9,600 parts/year

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION Each part stops at each spur in the conveyor

SCHEDULING: Crew of 4

19. LOT SIZE: 100

20. MACHINE SET: 1 MC, 8 MT's

21. MATL. HANDLING: Roller conveyor

22. TOOLING:

23. FEATURES:

24. REFERENCES: 35, 38

105
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Japan

Tsugami

Nagaoka

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Tsugami

FMS

86

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Machine tool parts

Steel, cast iron

200

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

3 NHM (Tsugami)

Overhead conveyor

ATC with capacity of 164

24. REFERENCES: 7

1. COUNTRY:

2. COMPANY:

Japan

3. LOCATION:

4. DIVISION:

Inuyaraa

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Osaka Kiko

FliS

82

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

3 MC

Rail guided cart

23. FEATURES:

24. REFERENCES:

Probing

14

106
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Japan

Yamatake Honeywell

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Hitachi Seiki

FMS

72

Job reduction from 40 to 5

Fujutsu Fanuc

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

1.5-6 inch flow control valve housings

Cast iron, steel, stainless steel

400

15. PRODUCTION RATE: 4,000 parts/month

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

Prismatic

Parts designed for equal cycle times, fixed path flows

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

10

7 MC, 1 WS

Roller conveyor, ASRS

23. FEATURES:

24. REFERENCES:

Probing

14, 35, 51, 86

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Japan

Yamazaki Machinery

Aichi

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Yamazaki

FMS

82

2.5 year payback

DEC PDP 11

'

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Large MT parts for NT, MC

Cast iron, steel

74

15. PRODUCTION RATE: 5,400 parts/year

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

24 hour, 6 day schedule, with 3rd shift unmanned,

crew of 3

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

8 MT (A line)

2 AGV’s

ATC, 2 drums per MT

24. REFERENCES: 51, 69

107
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Japan

Yamazaki Machinery Works

Aichi

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Yamazaki

FMS

82

2.5 year payback

DEC PDP 11

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Large machine tool parts

Cast iron, steel

74

15. PRODUCTION RATE: 6,744 parts/year

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

24 hour, 6 day schedule with 3rd shift unmanned,

crew of 3

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

10 MT's (B line)

24. REFERENCES: 51, 69

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Japan

Yamazaki Machinery Works

Mino-Kamo

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Yamazaki

FMS

81

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

CNC lathes

Cast iron, steel

543

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic and rotational

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

88 MT, 60 of which are CNC

30 robots, AGV's

23. FEATURES:

24. REFERENCES:

Adaptive control using acoustic emmissions

7, 14, 69

108
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Japan

Yamazaki Machinery Works

Oguchi

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Yamazaki

FMS

81

75 % reduction in the number of MT’s needed

DEC PDP 11

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Headstocks for MC's

Cast iron

23

15. PRODUCTION RATE: 800 parts/month

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

40 x 40 in pallet

Prismatic

3 shift operation, 3rd shift unmanned, crew of 2

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

8 NHM (Yamazaki)

Rail guided carts, robots

24. REFERENCES: 7, 12, 14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Japan

Yamazaki Machinery Works

Oguchi

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

FMS

81

9. COMPUTER:

10. CONTROLS:

DEC PDP 11

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Beds, bases, columns for MT’s

Cast iron

350

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

650 parts/month

63 x 118 inch pallet

Prismatic

3 shift operation, crew of 4

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

7 NVM, 3 NHM, (all Yamazaki)

24. REFERENCES: 7, 14

109
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Japan

Yanmar Diesel

Araagaski

Hitachi Seiki

FTL

72

Labor reduction 12 to 1, cost reduction of 23 %

Fujitsu Fanuc T-0 K-0

Cylinder heads

Cast iron

8

110,800

2 x 1.5 x 2 ft

Prismatic

Fixed sequence determined by operator at time of loading,

crew of 1 Average of 3

5 MC

Roller conveyor loop with spurs

ATC with capacity of 160

35, 38, 86

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Japan

Yanmar Group

Makino

FMS

84

14
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Japan

Yanmar Group

6. CLASS:

7. YEAR:

8! FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

FMS

84

24. REFERENCES: 14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

Norway

University of Trondheim

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

SINTEF

University of Trondheim

MC

78

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic and rotational

Control computer attempts to optimize operations

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

1 MC, 1 NM, 1 NT, 1 ND

1 robot at the center of the cell

24. REFERENCES: 52

111
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Poland

Stalowa Wola

7 October

FMS

81

Rota FZ200

Gears for trucks, construction, and agricultural uses Steel

400,000 parts/year

Rotational

52 work stations (see East German Rota FZ200 systems)

Stacker crane, roller conveyor

37, 86

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Poland

CBKO (Design & Research Center for Machine Tools)

MC

77

KOR-1 System

Machine tool parts

Steel, cast iron

Prismatic

2 to 5 MC's

86

112
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Poland

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

7 October

FMS

80

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Rota FZ200 System

Gears

Steel

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Rotational

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

(See East German Systems)

24. REFERENCES: 37

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Poland

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

CBKO (Design & Research Center for Machine Tools)

MC

79

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

TOR-1 System

Shafts

Steel

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Rotational

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

3 NT

24. REFERENCES: 86

113
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Poland

CBKO (Design & Research Center for Machine Tools)

MC

78

T0R-1M System

Shafts

Steel

Rotational

2 NT

86

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Rumania

Bucharest R & D Institute for Automation

Bucharest

Bucharest R & D Institute

FMS

79

Felix C32 (Rumanian under French license)

AEC, GE, Cesla, and Sperry

7 MT

86

114
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: South Korea

2. COMPANY: Tongil Company

3. LOCATION: Kyungnam

4. DIVISION:

5. SUPPLIER: Fanuc

6. CLASS: FMS

7. YEAR: 85

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: Fanuc

11. PRODUCTS: Machine tool and automative parts

12. MATERIALS: Cast iron

13. NUMBER OF PARTS: 30

14. PART FAMILIES:

15. PRODUCTION RATE: 4,500 parts/year

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING: Roller conveyor

22. TOOLING:

23. FEATURES: Probing, self contained coolant

24. REFERENCES: 14

1. COUNTRY: Sweeden

2. COMPANY: AB Hydron

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS: MC

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS: 50

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE: 175 minimum

20. MACHINE SET: 2 NT, 2 ND, 1 WS, 1 Press

21. MATL. HANDLING: Robot, conveyor

22. TOOLING:

23. FEATURES:

24. REFERENCES: 69

115
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Sweeden

ASEA

Ludvika

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

FMS

84

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

6 MC

24. REFERENCES: 23

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Sweeden

ASEA

Vastarras

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

FMS

79

11. PRODUCTS:

12. MATERIALS:

Electric motor parts

13. NUMBER OF PARTS:

14. PART FAMILIES:

18

3

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

Rotational

1 manned shift, 2 unmanned shifts

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

200 minimum

1 NT, 1 rotary grinder, 2 turret drills

Conveyor with internal storage, 1 robot

24. REFERENCES: 14, 52

116
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Sweeden

Alo-Maskiner

FMS

84

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Sweeden

Atlas-Copco

FMS

84

14

117
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Sweeden

BT (AB BYGG-och Transport)

Mjolby

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

FMS

83

9. COMPUTER:

10. CONTROLS:

DEC PDP 11

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

Materials handling, ASRS, and AGV systems

Steel

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

Pallets enter system following operator request via CRT

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

20 NC MT's, 23 CNC MT's

Stacker crane, ASRS

24. REFERENCES: 3, 4, 69

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Sweeden

Benzler Production AB

Norrkoping

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Sajo, Benzler provided the systems integration

FMS

84

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

2 MC, 1 MT, 1 cutting machine

Benzler AGV

24. REFERENCES: 14, 69

118
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Sweeden

Bofors

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

FMS

84

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

4 MC

24. REFERENCES: 23

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Sweeden

Bygg & Transportekonomi DB BT

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

Japanese MC’s, West German NV's

FMS

78

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Saab

Material handling systems parts

Steel

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

3 MC, 1 NV

Roller conveyor, stacker crane

24. REFERENCES: 14

119
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Sweeden

C. E. Johansson Aktiebolag FFV-CEJ

FMS

84

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Sweeden

Electrolux AB

FMS

84

14

120
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Sweeden

Esab AB

Laxa

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

FMS

80

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic and rotational

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

2 MC, 2 NT, 2 NM

AGV, ASRS

24. REFERENCES: 3, 4, 14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Sweeden

Hiab Foco

Skelleftea

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

SMT Machine Company

MC

81

45 % cost reduction

No host

NC for each machine

Cylinder heads, pistons

Cast iron, steel

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

22 parts/hour

45-160 mm Rotational

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

175 minimum

2 NT, 1 ND, 1 WS, 1 CMM, 1 hydraulic press

Conveyor, Electrolux robots

23. FEATURES:

24. REFERENCES:

Press fit of bearing

31

121
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Sweeden

Kochums Mekaniska Verkstads AB

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

FMS

84

24. REFERENCES: 14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Sweeden

Saab-Scania AB

Sodertal je

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

FMS

82

3 year payback

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Gearbox mainshafts

Steel

8

17. PART SHAPE:

18. OPERATION

SCHEDULING:

Rotational

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

300-700

1 NT, 2 ND, 2 NG

Conveyor system

24. REFERENCES: 14, 31

122
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Sweeden

Samefa

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Niigata

FMS

84

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

2 MC, 1 MT, 1 cutting machine

BT AGV

24. REFERENCES: 14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Sweeden

Seco Tools

Arbogo

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Saab

MC

84

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Special tool for external turning

17. .PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

1 MC

Rotary table, robot for deburring

23. FEATURES:

24. REFERENCES:

Probing

14

123
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY

Sweeden

2. COMPANY: Sundsvalle Verkstader

3. LOCATION: Orebo

4. DIVISION:

5. SUPPLIER: Japanese MT’s, BT installation

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Glass making machinery

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 3 MC

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14, 69

y

1. COUNTRY: Sweeden

2. COMPANY: Volvo

3. LOCATION: Koping

4. DIVISION: Heavy Engineering Division

5. SUPPLIER: Volvo

6. CLASS: FMS

7. YEAR: 79

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Truck transmission parts

12. MATERIALS: Cast iron

13. NUMBER OF PARTS: 22 transmissions

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE: Range from 200 to 600

20. MACHINE SET: 4 MC, 1 NM, 1 multi-headed

21. MATL. HANDLING: Rail guided cart

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

124
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Sweeden

Volvo

Skovde

Components Division

Japanese Firm

FMS

84

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Intake Manifold

Cast iron

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

2 SP, 3 MC, 1 ND, drying station

22. TOOLING:

23. FEATURES:

2 head indexers

24. REFERENCES: 14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

Sweeden

Volvo

Skovde

Components Division

Volvo

FTL

82

9. COMPUTER:

10. CONTROLS:

DEC PDP 11

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Heavy diesel crank shafts

Steel

2

17. PART SHAPE:

18. OPERATION

SCHEDULING:

Rotational

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

2,000

3 NT, 2 NM, balancing machine (4 cells)

3 AGV's, 3 gantry cranes

24. REFERENCES: 14, 47, 69

125
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Switzerland

Bobst & Fils SA

Pausanne-Prilly

Forest (French)

FMS

84

Printing & packaging machine parts

Steel

Prismatic

5 MT

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Switzerland

Brown Boveri

Scharmann

FMS

85

DEC PDP 11/44

Sinumeric 8MC

Turbocharger parts

Cast iron, aluminum

100

5

1 x 1 x 1 .2 m Prismatic

3 shift operation, 1 man crew

2 MC, 1 WS

2 AGV

ATC with capacity of 80

14, 79

126
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Switzerland

Sulzer Brothers

Zuchwil

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Fischer, Burkhardt & Weber

FMS

84

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

High speed weaving machine parts

Steel

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

12 MC

24. REFERENCES: 14, 69

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

Taiwan

Lian Feng Machine

Feng Yuan

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

FMS

85

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Fanuc

Machine tool parts

Steel, cast iron

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

2 MC

Rail guided cart

24. REFERENCES: 14

127
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Taiwan

Mechanical Industries Research Laboratory

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

Mechanical Industries Research Laboratory

FMS

84

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

Allen Bradley

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

2 NHM

AGV

23. FEATURES:

24. REFERENCES:

Probing, automated inspection, part washing

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

Taiwan

ORC Speicer

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Speicer

FMS

83

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

2 MC

2 carriers

23. FEATURES:

24. REFERENCES:

Probing

14

128
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1 . COUNTRY: Taiwan

2. COMPANY: Taichung Precision Machinery

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS: FMS

7. YEAR: 87

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Machine tool parts

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Steel, cast iron

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic and rotational

20. MACHINE SET: 4 NT, 2 NVM, 1 NHM

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

1 robot, conveyor

24. REFERENCES: 14

1 . COUNTRY: UK

2. COMPANY: Anderson Strathclyde PLC

3. LOCATION: Motherwell, Scotland

4. DIVISION:

5. SUPPLIER: Giddings & Lewis, Fraser

6. CLASS: FMS

7. YEAR: 83

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Coal cutters

12. MATERIALS: Steel castings

13. NUMBER OF PARTS: 14

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE: 4 x 6 ft pallet

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 6 MC

21. MATL. HANDLING: AGV

22. TOOLING: ATC with capacity of 100

23. FEATURES:

24. REFERENCES: 14, 58, 60

129
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

UK

Babcock Bristol

Croydon

Yamazaki

FMS

83

Signature transmitter parts

100

Rotational

1 NV, 1 MC

Robot, conveyor, carousel

14, 58

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

UK

Black & Decker

Spennymoor, County Durham

Fairey Automation

FMS

84

14

130
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: UK

2. COMPANY: British United Shoe Company

3. LOCATION: Leicester

4. DIVISION:

5. SUPPLIER: KTM

6. CLASS: FMS

7. YEAR: 86

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: Siemens

11. PRODUCTS: Shoe machinery parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS: 4-5,000

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 4 MC

21. MATL. HANDLING: Rail guided cart

22. TOOLING:

23. FEATURES: Automated inspection

24. REFERENCES: 14, 58

1. COUNTRY: UK

2. COMPANY: Caterpillar

3. LOCATION: Glasgow

4. DIVISION:

5. SUPPLIER: Scharmann

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Tractor gearbox parts

12. MATERIALS: Cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

9

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET: 4 MC

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

Rail guided cart

24. REFERENCES: 14

131
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1 . COUNTRY: UK

2. COMPANY: Caterpillar

3. LOCATION: Glasgow

4. DIVISION:

5. SUPPLIER: Scharmann

6. CLASS: FMS

7. YEAR: 83

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Large tractor parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

8

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

2 MC

24. REFERENCES: 14, 58

1. COUNTRY: UK

2. COMPANY: Caterpillar

3. LOCATION: Glasgow

4. DIVISION:

5. SUPPLIER: Comau

6. CLASS: FMS

7. YEAR: 85

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Tractor track parts

12. MATERIALS: Steel

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 2 specially designed MT*

21. MATL. HANDLING: Robot, cart with towline

22. TOOLING:

23. FEATURES: Automated inspection

24. REFERENCES: 14

132
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1 . COUNTRY: UK

2. COMPANY: Cessna

3. LOCATION: Glenrothes, Scotland

4. DIVISION: Fluid Power

5. SUPPLIER: Olivetti

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

Pump gear housing

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

18

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET: 3 MC

21. MATL. HANDLING:

22. TOOLING:

2 robots

23. FEATURES: Automated inspection

24. REFERENCES: 14, 58

1. COUNTRY: UK

2. COMPANY: Cincinnati Milicron

3. LOCATION: Birmingham

4.

5.

DIVISION:

SUPPLIER: Cincinnati Milicron

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Machine tool parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

13

21. MATL. HANDLING:

22. TOOLING:

AGV

23. FEATURES: Probing, adaptive control

24. REFERENCES: 14

part washing

133
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: UK

2. COMPANY: Colechester Lathe

3. LOCATION: Colechester

4. DIVISION: 600 Group

5. SUPPLIER: Scamp Systems Limited

6. CLASS: FMS

7. YEAR: 83

8. FINANCIAL DATA: Leadtime reduced from 3 months to 3 days

9. COMPUTER: Dual DEC PDP 11/60's

10. CONTROLS: 5000E

11. PRODUCTS: Shafts, discs, and gears for machine tools

12. MATERIALS: Steel

13. NUMBER OF PARTS: 46

14. PART FAMILIES: 3

15. PRODUCTION RATE:

16. PART CUBE: 220 mm round x 420 mm long

17. PART SHAPE: Rotational

18. OPERATION Computer assisted scheduling

SCHEDULING:

19. LOT SIZE: 25-100

20. MACHINE SET: 4 NT, 3 NG, 1 NGR, 1 SP

21. MATL. HANDLING: 8 Fanuc robots, roller conveyor

22. TOOLING:

23. FEATURES: Automated inspection

24. REFERENCES: 14, 57, 68, 69

1. COUNTRY: UK

2. COMPANY: Deep Sea Seals

3. LOCATION: Havant

4. DIVISION:

5. SUPPLIER: TI Matrix

6. CLASS: MC

7. YEAR: 84

8. FINANCIAL DATA: 60 % reduction in machining time

9. COMPUTER: DEC PDP 11/23

10. CONTROLS: Fanuc 6MB, Fanuc 6T

11. PRODUCTS: Ship propeller shaft seals

12. MATERIALS: Gunraetal bronze

13. NUMBER OF PARTS: Custom designs

14. PART FAMILIES: 20

15. PRODUCTION RATE:

16. PART CUBE: 1.5 m round

17. PART SHAPE: Rotational

18. OPERATION 16 hours per day

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 1 NVM (Matrix V50LR) , 1 NV (Web. & Ben.)

21. MATL. HANDLING: AGV - Babcock FATA

22. TOOLING: ATC for NVM with 30 tool magazine

23. FEATURES:

24. REFERENCES: 85

134
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

UK

Dowty Mining Equipment

Tewkesbury

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

K & T

FMS

83

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

DEC

Gemini

Hydraulic valve manifolds

Cast iron

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

30

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

4 MC

AGV

23. FEATURES:

24. REFERENCES:

Automatic inspection, probing, and adaptive control

14, 58

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

UK

Ford Motor Company

Halewood

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

FMS

85

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Cluster gear for automobile transportation

Steel

9

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Rotational

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

9 NT, 2 ND

AGV

24. REFERENCES: 14, 58

135
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

UK

J. C. Bamford

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

Scharmann

FMS

84

24. REFERENCES: 14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

UK

L. Gardner & Sons

Barton Hall

Engine Works

KTM

FMS

82

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Diesel engine blocks

Cast iron

4

13parts/hour

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

Prismatic

24. REFERENCES: 14, 16

136
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: UK

2. COMPANY: Leyland Bus

3. LOCATION: Farington

4. DIVISION:

5. SUPPLIER: KTM

6. CLASS: FMS

7. YEAR: 82

8. FINANCIAL DATA:

9. COMPUTER: DEC PDP 11/24

10. CONTROLS:

11. PRODUCTS: Hydraulic transmissions

12. MATERIALS: Aluminum

13. NUMBER OF PARTS: 28

14. PART FAMILIES: 2

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 3 NHM (KTM)

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14, 63

1. COUNTRY: UK

2. COMPANY: Lucas Electrical

3. LOCATION: Telford

4. DIVISION:

5. SUPPLIER: KT

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER: DEC

10. CONTROLS: Gemini

11. PRODUCTS: Automotive electrical parts

12. MATERIALS: i 13. NUMBER OF PARTS: 130

14. PART FAMILIES:

15. PRODUCTION RATE: 130,000 parts/year

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 7 MC

21. MATL. HANDLING: Rail guided cart

22. TOOLING:

23. FEATURES: Probing, adaptive control

24. REFERENCES: 14, 75

137
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

UK

Normalair Garret

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

KTM

FMS

81

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Aircraft components

Aluminum

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

2 MC

24. REFERENCES: 14, 16, 86

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

UK

Rolls Royce

Derby

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

FMS

85

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Jet engine parts

Nickle alloys, stainless steels

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

Prismatic

24. REFERENCES: 49

138
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Allis Chalmers

Milwaukee , WI

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

KT

FMS

71

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Inter Data, Bendix

Tractor parts

Cast iron

48

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

23,600

3 ft

Prismatic

Computer dynamically assigns work stations, product mix

changed significantly during implementation, crew of 9

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

5 MC, 1 NM

23 carts with towline, complex network

4 duplex multi-spindle head indexers, 864 tools, 73 heads

24. REFERENCES: 18, 38, 52, 61

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Allison-Detroit Diesel

Hamtrack, MI

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

White Sunstrand

FMS

83

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

DEC

Omni

Large transmission housings

Cast iron

40

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

8 MC

Cart with towline

23. FEATURES:

24. REFERENCES:

Probing

14, 22

139
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: USA

2. COMPANY: Avco Lycoming

3. LOCATION: Stratford, Conn

4. DIVISION: Lycoming

5. SUPPLIER: KT

6. CLASS: FMS

7. YEAR: 81

8. FINANCIAL DATA:

9. COMPUTER: 2 Interdata 8/16E

10. CONTROLS: Allen Bradley 7320's

11. PRODUCTS: XM-1 Tank engine parts

12. MATERIALS: Stainless steel castings

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION 2 shifts, 3 shifts planned in late 85

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 7 MC, 3 NV, 4 more MC's planned

21. MATL. HANDLING: Cart with towline

22. TOOLING: ATC with 70 tool magazines, 1,000 + tools in system

23. FEATURES: Probing

24. REFERENCES: 14, 46, 49

1. COUNTRY: USA

2. COMPANY: Avco Lycoming

3. LOCATION: Williamsport, PA

4. DIVISION: Lycoming

5. SUPPLIER: KT

6. CLASS: FMS

7. YEAR: 76

8. FINANCIAL DATA: 9 MC's replaced 67 MT's

9. COMPUTER: 2 Microdata Model 70 's 10. CONTROLS:

11. PRODUCTS: Aircraft engine crank cases

12. MATERIALS: Aluminum

13. NUMBER OF PARTS: 6

14. PART FAMILIES: 2

15. PRODUCTION RATE: 2,000 parts/month

16. PART CUBE: 4 ft square pallet

17. PART SHAPE: Prismatic

18. OPERATION Computer dynamically assigns work stations, each

SCHEDULING: operation has alternates, crew of 9

19. LOT SIZE:

20. MACHINE SET: 9 MC

21. MATL. HANDLING: Cart with towline, simple loop with short spurs

22. TOOLING: 2 simplex & 1 duplex multispindle head changers

23. FEATURES: Probing

24. REFERENCES: 14, 38, 52, 61, 17, 43, 45

140
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: USA

2. COMPANY: Boeing Aerospace

3. LOCATION: Kent, WA

4. DIVISION:

5. SUPPLIER: White Sunstrand

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA: 61 % reduction in machine hours

9. COMPUTER: DEC PDP 11/44

10. CONTROLS: Omni Microswinc M23

11. PRODUCTS: Housings, covers, fittings, and links for airframes

12. MATERIALS: Aluminum (6061-T6), stainless steel 15-5ph, 13-8mo

13. NUMBER OF PARTS: 15

14. PART FAMILIES:

15. PRODUCTION RATE: 6,000 parts/year

16. PART CUBE: 30 x 20 x 22 in

17. PART SHAPE: Prismatic

18. OPERATION Crew of 1 SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 3 MC, 1 WS

21. MATL. HANDLING: 195 ft roller conveyor with 5 pallet transfer units

22. TOOLING: ATC with capacity of 48

23. FEATURES:

24. REFERENCES: 14, 59

1. COUNTRY: USA

2. COMPANY: Boeing Aerospace

3. LOCATION: Seattle, WA

4. DIVISION:

5. SUPPLIER: Shin Nippon Koki

6. CLASS: FMS

7. YEAR: 85

8. FINANCIAL DATA:

9. COMPUTER: DEC

10. CONTROLS:

11. PRODUCTS: Airframe parts

12. MATERIALS: Aluminum (6061-T6), stainless steel 15-5ph, 13-8mo

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 5 MC

21. MATL. HANDLING: AGV, ASRS

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

141
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Borg-Warner

York, PA

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

Comau

FMS

84

Replaced 14 MT's

Dual DEC PDP 11/44’s

Allan Bradley

Air conditioner compressor parts

13. NUMBER OF PARTS:

14. PART FAMILIES:

85

7

15. PRODUCTION RATE: 38,500 parts/year

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

1300 mm Prismatic

Random sequencing possible

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

4 MC, 1 NV

Roller conveyor, ASRS, stacker crane ATC 2 tool magazines with 70 tools, 572 tools in system

Robotic wash station, adaptive control

14, 70, 71, 75

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Caterpillar

Aurora, IL

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER

10. CONTROLS:

Giddings & Lewis

FMS

79

Labor reduction from 18.7 to 6.4 hours per piece

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

3 tractor loader frames

Steel

3

14. PART FAMILIES: 1 15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:.

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

2 NM, 4 ND

Cart with towline

Head indexer

Automated inspection

14

142
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Caterpillar

Aurora, IL

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

Cincinnati Milicron

FMS

86

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Milicron

Excavator sticks & booms

Steel

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

2 MC

23. FEATURES:

24. REFERENCES:

Automated inspection, probing, and adaptive control

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Caterpillar

Davenport, 10

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

Cincinnati Milicron

FMS

85

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Milicron

Tracked loader frames

Steel

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

100 machining steps

20. MACHINE SET:

21. MATL. HANDLING:

3 MC, 1 NB

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Head indexer

Adaptive control, part washing

14

143
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Caterpillar

Decatur , IL

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

Dearborn

FMS

84

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Allen Bradley

Truck axle banjo housings

Cast iron

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

3 NB, 5 MC, 1 ND, 1 NM

24. REFERENCES: 14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Caterpillar

East Peoria, IL

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

White Sunstrand

FTL

74

Labor reduced from 13 to 7, machine utilization doubled

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Omnicontrol DNC

Case & cover for tractor transmissions

Cast iron

6

15. PRODUCTION RATE: 1,200 parts/year

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

3 ft

Prismatic

Fixed sequence, worked to monthly master schedule, crew of 7

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

5 MC, 2 NV, 1 CMM, 3 ND

2 rail guided carts

350 tools in system

24. REFERENCES: 18, 38, 52, 61, 84

144
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

Caterpillar

East Peoria, IL

White Sunstrand

FMS

83

Omnicontrol DNC

Transmission cases & covers

Cast iron

Prismatic

8 MC, 2 NV, 1 WS, 1 CMM

Shuttle car

Automated inspection, probing

14, 84

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

Caterpillar

Peoria, IL

Mazak (Yamazaki's US subsidiary)

FMS

84

Mazak

Sprocket segments

Steel

Rotational

3 MC, 1 SP

Robots

Automated inspection, probing, and part washing

14

145
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Cincinnati Milicron

Cincinnati, OH

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Cincinnati Milicron

FMS

85

Leadtime 20 days to 1 day

DEC PDP 11/44

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

Plastic injection molding machine parts

Steel, cast iron

3,500

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE: 3 ft

17. PART SHAPE:

18. OPERATION

SCHEDULING:

Prismatic

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

1 possible

4 MC, 1 CMM

3 Eaton AGV’s

23. FEATURES:

24. REFERENCES:

Part washing

14, 62, 75

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Cummins Engine

Columbus, IL

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

KT

FMS

84

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

DEC

DEC, Gemini

Brake parts

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

6 MC

AGV

23. FEATURES:

24. REFERENCES:

Probing, adaptive control

14

146
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

Department of Commerce

Gaithersburg, MD

National Bureau of Standards

Integration by NBS

FMS

83

Reaseach facility

DEC VAX

Hewlett Packard, Allen Bradley, GE

Aluminum, brass, steel

Prismatic and rotational

Real time scheduling of machines, robots, and AGV

1 NHM, 1 NVM, 1 NT, 1 CMM

AGV, robot, gantry robot

ATC

Robotic deburring station

1, 25, 33

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

FMC

Aiken, SC

Cincinnati Milicron

FMS

84

Leadtime reduced from 90 to 5 days

DEC PDP 11/44

Acramatic 900

Gear housings for the IFV drive train

Aluminum

16

15 parts/week

30 in

Prismatic

Crew of 5

4 MC, 1 CMM

3 AGV’s (Eaton Kenway), 2 10-position carousels

ATC with capacity of 90

14, 75, 80

147
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

USA

FMC

San Jose, CA

Ordinance

Cincinnati Milicron

FMS

85

9. COMPUTER:

10. CONTROLS:

DEC PDP 11/24

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Infantry Fighting Vehicle drive train & chasis parts

Steel

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

4 MC, 1 CMM

24. REFERENCES: 13, 14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

USA

GMC

Hamtrack, MI

Chevrolet Gear & Axle Plant

Coraau

FMS

82

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Dif. housing, suspension tubes, cylinder heads, manifolds

Cast iron, steel

15. PRODUCTION RATE: 70 parts/15 hours

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

3 MC, 1 WS

Roller conveyor, robots

23. FEATURES:

24. REFERENCES:

Automated inspection, part washing

12, 14, 70

148
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

GMC

Indianapolis, IN

Allison Gas Turbine

FMS

87

MAP system

Precision gears

Steel

30

3 - 14.5 in round

Rotational

10 NT, 1 MC, 11 NGR, 8 NG, 1 Broaching MT

2

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

GMC

Indianapolis, IN

Detroit Diesel Allison

White Sunstrand

FMS

80

Replaced 35 MT’s

Omnicontrol DNC

Diesel transmissions

Cast iron

44

40 x 30 x 18 in

Prismatic

Supervisory computer receives input at load/unload sta.

3 shift operation, crew of 5

4 NHM, 4 NVM, 1 CMM

2 rail guided carts, 240 ft track, 15 stations

43, 52, 61, 84

149
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: USA

2. COMPANY: General Dynamics

3. LOCATION: Fort Worth, TX

4. DIVISION:

5. SUPPLIER: Westinghouse/Devlieg

6. CLASS: FMS

7. YEAR: 86

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Aircraft parts

12. MATERIALS: Aluminum

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 6 MC

21. MATL. HANDLING: AGV, robots

22. TOOLING:

23. FEATURES: Automated inspection

24. REFERENCES: 14

1. COUNTRY: USA

2. COMPANY: General Dynamics

3. LOCATION: Fort Worth, TX

4. DIVISION:

5. SUPPLIER: Cincinnati Milicron

6. CLASS: FMS

7. YEAR: 85

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Aircraft & missle parts

12. MATERIALS: Aluminum

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 6 MC

21. MATL. HANDLING: Power shuttle

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

150
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: USA

2. COMPANY: General Dynamics

3. LOCATION: Lynburg, CA

4. DIVISION: Convair

5. SUPPLIER: Cincinnati Milicron

6. CLASS: FMS

7. YEAR: 82

8. FINANCIAL DATA:

9. COMPUTER

10. CONTROLS: Allen Bradley

11. PRODUCTS: Aircraft & missle parts

12. MATERIALS: Aluminum

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 4 MC

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES: Probing

24. REFERENCES: 14

1. COUNTRY: USA

2. COMPANY: General Dynamics

3. LOCATION: Lynburg, CA

4. DIVISION: Convair

5. SUPPLIER: Cincinnati Milicron

6. CLASS: FMS

7. YEAR: 82

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: Allen Bradley

11. PRODUCTS: Aircraft & missle parts

12. MATERIALS: Aluminum

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 2 MC

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES: Part washing

24. REFERENCES: 14

151
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

General Dynamics

Lynburg, CA

Convair

Cincinnati Milicron

FMS

84

Allen Bradley

Aircraft & missle parts

Aluminum

Prismatic

6 MC

Part washing

14

USA

General Dynamics

Convair

White Sunstrand

FMS

80

Aircraft & missle parts

Aluminum

4 ft

Prismatic

8 MC

Rail guided cart

52
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

General Electric

Erie, PA

Erie Works

Giddings & Lewis

FMS

83

Leadtime from 16 to 1 day

Dual DEC PDP 11/44's

GE 1050 CNC

Locomotive motor frames and gear boxes

Steel

6

1

1 part/hour, 5,500 parts/year

4 x 4 x 5 ft

Prismatic

Computer schedules in real time, can reschedule around

down unit, crew of 2

12 NVM, 4 NB, 3 NHM, 1 SP

Cart with towline, robot, ASRS

ATC

Automated inspection, probing

8, 12, 14, 49, 69

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

General Electric

Evandale, OH

Cincinnati Milicron

FMS

85

Rotational

4 NT

Robots

Automated inspection

14

153
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: USA

2. COMPANY: General Electric

3. LOCATION: Pittsfield, MA

4. DIVISION: Ordinance Systems

5. SUPPLIER: Ex-Cell-0

6. CLASS: FMS

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

82

11. PRODUCTS: Infantry Fighting Vehicle

12. MATERIALS: Steel

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

11

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

5 MC

24. REFERENCES: 22, 52, 53

1. COUNTRY: USA

2. COMPANY: Georgetown Manufacturing

3. LOCATION:

4. DIVISION:

Georgetown, KY

5. SUPPLIER: KT

6. CLASS: FMS

7. YEAR:

8. FINANCIAL DATA:

84

9. COMPUTER: DEC

10. CONTROLS: Gemini

11. PRODUCTS: Manifolds, spindl es, hous.

12. MATERIALS: Cast iron, steel

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

150

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET: 6 MC

21. MATL. HANDLING:

22. TOOLING:

Stacker crane

23. FEATURES: Adaptive control. probing

24. REFERENCES: 14, 53

154
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: USA

2. COMPANY: Harris Press

3. LOCATION: Fort Worth, TX

4. DIVISION:

5. SUPPLIER: Harris Press

6 . CLASS

FMS

7. YEAR: 81

8. FINANCIAL DATA: Cost reduction of from 25 - 57 %

9. COMPUTER: DEC

10. CONTROLS:

11. PRODUCTS: Precision printing press cylinder parts

12. MATERIALS: Steel

13. NUMBER OF PARTS: 700

14. PART FAMILIES: 1 15. PRODUCTION RATE:

16. PART CUBE: 1.5 - 8 in round x 120 in long

17. PART SHAPE: Rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: NC saw, 2MC, 2NT, 1 MC, 2NGR, balancing , straightening

21. MATL. HANDLING: 3 robots, roller conveyor

22. TOOLING:

23. FEATURES: Automated inspection, part washing, inertial welding sta.

24. REFERENCES: 14, 55, 69

1. COUNTRY: USA

2. COMPANY: Hughes Aircraft

3. LOCATION: El Segundo, CA

4. DIVISION: Electro-Optical & Data Systems Group

5. SUPPLIER: KT

6. CLASS: FMS

7. YEAR: 82

8. FINANCIAL DATA: 9 MT's vs. 25, 87 % labor savings

9. COMPUTER: Dual DEC PDP 11/44’s

10. CONTROLS: KT, Gemini DNC

11. PRODUCTS: Housings for laser range finder

12. MATERIALS: Aluminum

13. NUMBER OF PARTS: 5

14. PART FAMILIES: 1 15. PRODUCTION RATE: 1,200 + parts/year

16. PART CUBE: 24 x 24 in pallet

17. PART SHAPE: Prismatic

18. OPERATION Crew of 3

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 9 MC, 1 CMM

21. MATL. HANDLING: Cart with towline

22. TOOLING:

23. FEATURES: Automatic inspection, adaptive control, and probing

24. REFERENCES: 14, 29, 44, 50, 69

155
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: USA

2. COMPANY: Ingersol Rand

3. LOCATION: Roanoke, VA

4. DIVISION:

5. SUPPLIER: White Sunstrand

6. CLASS: FMS

7. YEAR: 72

8. FINANCIAL DATA: Labor savings of 50 %, cost savings of 70 %

9. COMPUTER: IBM 360/30

10. CONTROLS: Omnicontrol DNC

11. PRODUCTS: Housings for industrial hoists

12. MATERIALS: Cast iron, steel, aluminum

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE: 3 ft

17. PART SHAPE: Prismatic

18. OPERATION Fixed sequence within system, multiple alternate

SCHEDULING: routings, 4 man crew, foreman dispatches jobs

19. LOT SIZE:

20. MACHINE SET: 5MC, 2ND

21. MATL. HANDLING: Roller conveyor with buffer at each MT

22. TOOLING: 360 tools in system

23. FEATURES:

24. REFERENCES: 38, 61, 84

1. COUNTRY: USA

2. COMPANY: Ingersoll Milling Machine

3. LOCATION: Rockford, IL

4. DIVISION:

5. SUPPLIER: Ingersoll Milling

6 . CLASS

FMS

7. YEAR: 83

8. FINANCIAL DATA: Eliminated 17 MT's

9. COMPUTER: DEC VAX 750

10. CONTROLS: Allan Bradley 8200

11. PRODUCTS: Machine tool parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE: 25,000 parts/year

16. PART CUBE: 1 m

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE: 1 (75 % of the time)

20. MACHINE SET: 5 MC, 1 WS, 2 CMM

21. MATL. HANDLING: AGV

22. TOOLING:

23. FEATURES: Automated inspection, part washing

24. REFERENCES: 14, 32, 42

156
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: USA

2. COMPANY: Ingersoll Milling Machine

3. LOCATION: Rockford, IL

4. DIVISION:

5. SUPPLIER: Ingersoll Milling

6. CLASS: FMS

7. YEAR: 87

8. FINANCIAL DATA:

9. COMPUTER: VAX 750

10. CONTROLS: Allen Bradley 8200

11. PRODUCTS: Machine tool parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 3 MC

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

1. COUNTRY: USA

2. COMPANY: Ingersoll Milling Machine

3. LOCATION: Rockford, IL

4. DIVISION:

5. SUPPLIER: Ingersoll Milling

6. CLASS: FMS

7. YEAR: 87

8. FINANCIAL DATA:

9. COMPUTER: VAX 750

10. CONTROLS: Alen Bradley 8200

11. PRODUCTS: Machine tool parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 4 NV

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

157
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

J. I. Case

Racine , WI

Components

Imgersoll Milling

FTL

78

Agricultural tractor transmission cases Gray iron castings

2

Prismatic

Fixed path sequencing

2 MC, 1 NM, 1 NB

Roller conveyor, cart with towline for heads

2 head changers, 22 heads in system

Automated inspection

14, 43, 45

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

John Deere & Company

Moline, IL

Masch. Diedesheim

FMS

80

DNC network

Allan Bradley

Farm tractor parts

Cast iron, steel

Rotational

3 NT, 2 MC (WCI)

2 Uniraate robots

54

158
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: USA

2. COMPANY: John Deere & Company

3. LOCATION: Waterloo, 10

4. DIVISION:

5. SUPPLIER: KT

6. CLASS: FMS

7. YEAR: 79

8. FINANCIAL DATA:

9. COMPUTER: DEC

10. CONTROLS: DEC, KT, CNC

11. PRODUCTS: Transmission & clutch housings

12. MATERIALS: Cast iron

13. NUMBER OF PARTS: 8

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 11 MC

21. MATL. HANDLING: Cart with towline

22. TOOLING: 5 Head indexers

23. FEATURES: Part washing

24. REFERENCES: 14

1. COUNTRY: USA

2. COMPANY: John Deere & Company

3. LOCATION: Waterloo, 10

4. DIVISION:

5. SUPPLIER: Burkhardt & Weber

6. CLASS: FMS

7. YEAR: 78

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Agricultural machinery parts

12. MATERIALS: Cast iron, steel

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 2 MC

21. MATL. HANDLING:

22. TOOLING: Head changer

23. FEATURES:

24. REFERENCES: 14, 53

159
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

John Deere & Company

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

Burkhardt & Weber

FMS

84

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

USA

LTV

Dallas, TX

Vought Aero Products

Cincinnati Milicron

FMS

84

3 year return on investment

DEC PDP 11/70,44,24

Acramatic 900, DEC, Allen Bradley

B1 bomber airframe components

95 % aluminum, 5% steel

540

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

30 x 32 x 36 in

Prismatic

Simulation used to aid in computerized scheduling

Average crew size of 5.6

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

8 MC, 1 WS, 2 CMM

4 AGV’s, ASRS, 2 carousels with 10 stations each

ATC with capacity of 45

Automatic inspection, probing, and part washing

14, 21, 45, 75

160
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CUSS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

Mack Truck

Haggerstown, MD

KT

FMS

83

Labor reduction from 20 to 5

DEC PDP 11/44

Gemini

Truck transmission castings

Aluminum

7

1

Prismatic

4 MC, 1 NB

Cart with towline

2 head changers

Adaptive control, probing, auto.

14

insp.part washing

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

Massey Ferguson

Detroit, MI

Transmission & Axle Plant

Massey Ferguson and Unimate

MC

79

1.5 year payback, 25 % increase in productivity

Planetary pinion gears

Steel

4 sizes

3.5 - 7 in round

Rotational

Alternate part programs for MT's and robots, graceful

degradation in the event of MT failure

2 NV, 6 NG

3 Unimate robots, custom design conveyor

45, 52, 54, 69

161
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

McDonnel Douglas

Saint Charles, MO

Astronautics

Giddings & Lewis

FMS

85

60 % reduction in machining costs

DEC VAX 11/780

G & L CNC 8000

Missle body sections

Aluminum

72

134,800 parts/year

33 in round x 60 in long

Rotational

Real time scheduling & control, average crew size of 2.5

3 MC, 2 NV, 2 NH, 1 CMM, 1 WS

AGV, robots, 3 deburring stations, ASRS

ATC with 80 tool magazines

Auto, insp., probing, adaptive control, part washing

14, 27

1. COUNTRY: USA

2. COMPANY: Mercury Marine

3. LOCATION: Fond Du Lac, WI

4. DIVISION:

5. SUPPLIER: KT

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER: DEC

10. CONTROLS: Gemini

11. PRODUCTS: Outboard marine engine block

12. MATERIALS: Aluminum

13. NUMBER OF PARTS: 6

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 9 MC, 1 NB

21. MATL. HANDLING: Rail guided cart

22. TOOLING: Head indexer

23. FEATURES: Adaptive control, probing

24. REFERENCES: 14

and crank case parts

162
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

New York Air Brake

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Cincinnati Milicron

FMS

86

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

Prismatic

24. REFERENCES: 14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

North American Rockwell

Newark , OH

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

KT

FMS

73

Reduced WIP and setup costs

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Bendix

Truck differential housings

Cast iron

33

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

24,000 parts/year

1.5 ft

Prismatic

Computer dynamically assigns work stations

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

10 - 50

8 MC, 1 NV, 1 WS, 1 CMM

Cart with towline

Local to MT's

Automated inspection

14, 18, 38, 61

163
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Onan

Minneapolis, MN

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER

KT

FMS

84

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

KT, CNC

Generator frames

Steel

12

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

1 NV, 1 MC

AGV planned for 88

23. FEATURES:

24. REFERENCES:

Adaptive control, probing

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Rigid tool

Elyria, OH

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

KT

FMS

84

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Pipe fitting hand tools

Steel

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

Prismatic

24. REFERENCES: 75

164
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

Rock Island Arsenal

(Proposal)

FMS

(Proposal)

Prismatic

22

USA

Rockwell Motch

New Castle, PA

Oerlikon/Motch

FMS

85

Steering knuckles

Steel

22

Rotational

2 NV, 1 ND

Automated inspection

14
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Smith Tool

Irvine, CA

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

Okuma

FMS

84

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Okuma

Okuma

Oil fiels parts

Steel

54

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Rotational

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

4 MC, 2 NT

2 robots, conveyor

23. FEATURES:

24. REFERENCES: 75

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Sunstrand Aviation

Rockford, IL

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

White Sunstrand

FMS

67

Alternative was 100 MT's

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

Omnicontrol DNC

Pump & aircraft parts

Aluminum, Magnesium

70

2

24,000 parts/year

16 in

Prismatic

Fixed sequence, unidirectional flow, crew of 8

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

Range of 25 to 300

8 MC, 2 ND, 1 WS, 1 CMM

Roller conveyor, ASRS

Local to MC, 39 max

24. REFERENCES: 38, 61, 84

166
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Sunstrand Aviation

Rockford, IL

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

KT

FMS

85

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

DEC

Gemini

Aircraft parts

Aluminum

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

2 MC

AGV, ASRS

23. FEATURES:

24. REFERENCES:

Automated Inspection, probing, and adaptive control

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Union Special

Huntley, IL

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

KT

FMS

84

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

Sewing machine parts

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

Prismatic

24. REFERENCES: 75

167
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: USA

2. COMPANY: Vickers

3. LOCATION: Omaha, NE

4. DIVISION:

5. SUPPLIER: Acme Cleveland

6. CLASS: FMS

7. YEAR: 84

8-. FINANCIAL DATA: Replaced a transfer line

9. COMPUTER:

10. CONTROLS: Westinghouse

11. PRODUCTS: Pump blocks

12. MATERIALS: Cast iron, steel

13. NUMBER OF PARTS: 25-30

14. PART FAMILIES:

15. PRODUCTION RATE: 35-135 parts/hour

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 5 MC, 3 NT, 2 vertical broaching machines

21. MATL. HANDLING: Roller conveyor, 11 ASEA robots

22. TOOLING:

23. FEATURES: Automated inspection

24. REFERENCES: 14, 82

1. COUNTRY: USA

2. COMPANY: Warner Ishi

3. LOCATION: Shelbyville, IL

4. DIVISION:

5. SUPPLIER: KT

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER: DEC

10. CONTROLS: Gemini

11. PRODUCTS: Turbo charger housings

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 2 MC, 2 NT

21. MATL. HANDLING: Robots

22. TOOLING:

23. FEATURES: Automated inspection, adaptive control

24. REFERENCES: 14

168
APPENDIX C. FMS IMPLEMENTATI ON DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

Watervliet Arsenal

Watervliet, NY

White Sunstrand

FMS

85

Omnicontrol DNC

Gun tubes

Steel

6

Rotational

8 MC, 2 NV, 2 CMM, 1 WS

AGV

Automated inspection

14, 84

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6 . CLASS

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

USA

Westinghouse

Cheswick, PA

Electro-Mechanical

White Consolidated

FMS

84

Nuclear pump parts

Stainless steel, inconnel

63

1

1.5 ft round x 1.5 ft long

Rotational

JIT, real time scheduling & inventory control

1 MC, 2 NT, 1 CMM

1 gantry robot, ASRS

5

169
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USA

Xerox

Rochester, NY

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

Unimate

FMS

79

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

Unimate, central control to robots

Fuser rolls for copy machines

Copper

14. PART FAMILIES: 1 15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Rotational

Frequent model changes

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

3 NT, 1 brazing station, 1 NGR, 1 broaching MT

3 robots, conveyor

24. REFERENCES: 52

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER

10. CONTROLS:

USA

Yamazaki Machinery Works (Mazak)

Florence, KY

Mazak

Yamazaki

FMS

81

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

Machine tool frames & beds

Cast iron

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

4 MC

AGV

ATC

Probing

12, 14, 49, 69

170
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

USA

Yamazaki Machinery Works (Mazak)

Florence, KY

Mazak

Yamazaki

FMS

81

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

Gear boxes and small MT parts

Cast iron, steel

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic and rotational

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

4 MC, 1 NM, 1 NV, 1 NT

AGV

23. FEATURES:

24. REFERENCES:

Probing

14, 49

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USSR

Ceboksary

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Comau

FMS

78

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

Farm tractor cases and frames

Cast iron, steel

14. PART FAMILIES:

15. PRODUCTION RATE: Plant produces 5,000 tractors per year

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

2 SP, 1 CMM

Cart with towline, robot

1 head changer

24. REFERENCES: 14, 53

171
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: USSR

2. COMPANY:

3. LOCATION:

4. DIVISION:

Ceboksary

5. SUPPLIER: COMAU

6. CLASS: FMS

7. YEAR:

3. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

82

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

Prismatic

24. REFERENCES: 14

1 . COUNTRY: USSR

2. COMPANY: ENIMS (United R & D Center for Machine

3. LOCATION: Regional Centers

4. DIVISION:

5. SUPPLIER: ENIMS

6. CLASS: MC

7. YEAR: 76

8. FINANCIAL DATA: Productivity increase of 3-4 times

9. COMPUTER

CNC, PC's

10. CONTROLS: ASK 1, ASK 2, and ASK 3, Systems

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE: 250 - 1600 mm

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

Prismatic

21. MATL. HANDLING:

22. TOOLING:

Manual part handling, ASRS

23. FEATURES: Adaptive control

24. REFERENCES: 86

172
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: USSR

2. COMPANY: ENIMS (United R & D Institute for Machine

3. LOCATION: Moscow

4. DIVISION:

5. SUPPLIER: ENIMS

6. CLASS: MC

7. YEAR: 71

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: AU-1 System

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 86

1. COUNTRY: USSR

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS: FMS

7. YEAR: 82

8. FINANCIAL DATA:

9. COMPUTER: USSR manufacture

10. CONTROLS: ACB-20 System

11. PRODUCTS: Machine tool parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE: 250 mm round x 750 mm long

17. PART SHAPE: Rotational

18. OPERATION Parts may enter the system in random order

SCHEDULING: operation

19. LOT SIZE: as small as 10, about 150 half of the time

20. MACHINE SET: 6 NT, 3 NVD, 1 NVM, 1 NHM, 1 CMM

21. MATL. HANDLING: Gantry cranes, conveyors, robots, AGV’s

22. TOOLING:

23. FEATURES:

24. REFERENCES: 81

24 hour

173
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USSR

Strankokonstruktsiya

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

ENIMS (United R & D Institute for Machine Tools)

MC

76

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

M6000, Minsk 32

ASV-20 System

Machine tool parts

Steel, cast iron

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Rotational

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

6 NT, 3 ND, 1 NVM, 1 NHM, 1 CMM

24. REFERENCES: 86

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

USSR

Strankostroenie

Moscow

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

ENIMS (United R & D Institute for Machine Tools)

FMS

79

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

API System

Machine tool parts

Steel, cast iron

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

500 mm Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

6 MC, 1 CMM

Automated materials handling, ASRS

24. REFERENCES: 23, 69, 86

174
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: West Germany

2. COMPANY: Brown Boveri

3. LOCATION

4. DIVISION

5. SUPPLIER: Trumph

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

1. COUNTRY: West Germany

2. COMPANY: Brown Boveri

3. LOCATION:

4. DIVISION:

5. SUPPLIER: Trumph

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

175
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1 . COUNTRY: West Germany

2. COMPANY: Eberhard Bauer

3. LOCATION: Esslingen

A. DIVISION:

5. SUPPLIER: Fritz Werner

6. CLASS: FMS

7. YEAR: 79

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS: Fritz Werner

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

195 electric geared motors

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET: 9 NVM

21. MATL. HANDLING:

22. TOOLING:

Roller conveyor

23. FEATURES: Part washing

24. REFERENCES: 14, 36

1. COUNTRY: West Germany

2. COMPANY: Friedrich Deckel AG

3. LOCATION: Munich

4. DIVISION:

5. SUPPLIER: Friedrich Deckel

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Machine tool parts

12. MATERIALS: Steel, cast iron

13. NUMBER OF PARTS:

14. PART FAMILIES: 5

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION 16 hours with operator, 5.

SCHEDULING: Crew of 15

19. LOT SIZE: 100

20. MACHINE SET: 8 MC

21. MATL. HANDLING: 2 AGV’s

22. TOOLING: ATC with capacity of 80

23. FEATURES:

24. REFERENCES: 14, 73

unmanned hours,

176
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

West Germany

Gebr. Heller Maschinenf abrik

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Heller

FMS

77

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

Machine tool parts

Cast iron

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

1 .5 x 2 x 3 ft

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

4 MC

Stacker crane, roller conveyor

24. REFERENCES: 14, 36, 38

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

West Germany

Hieldelberger Druckmaschinenfabrik

Hiedelberg

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

Hieldelberger Druckmaschinenfabrik, U. of Stuttgart

FMS

69

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Printing press precision parts

Steel

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

13 MC, 1 WS

Stacker crane, roller conveyor

Automated tool flow

Automated inspection

14, 36, 38, 52

177
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1 . COUNTRY: West Germany

2. COMPANY: Holder

3. LOCATION:

4. DIVISION: Friedrich Deckel

5. SUPPLIER:

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

West Germany

Kloeckner Humboldt Deutz AG

Burkhardt & Weber

FMS

84

Siemens 300

Sinuraeric 8

Crank case, differential, clutch, and trans. housings

Cast iron

4

Prismatic

Crew of 5

4 MC, 1 WS

Rail guided cart

14, 72

178
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: West Germany

2. COMPANY: Linde Aschaff enburg

3. LOCATION:

4. DIVISION:

5. SUPPLIER: Scharmann

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES: 14

1. COUNTRY: West Germany

2. COMPANY: Messerschmitt Boelkow Blohm

3. LOCATION: Augsburg

4. DIVISION: Military Aircraft

5. SUPPLIER:

6. CLASS: FMS

7. YEAR: 85

8. FINANCIAL DATA:

9. COMPUTER

DFU Nabern

10. CONTROLS:

11. PRODUCTS: Aircraft parts

12. MATERIALS: Aluminum

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE: Prismatic and rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 2 MC, 2 NT

21. MATL. HANDLING: AGV's, ASRS

22. TOOLING:

23. FEATURES:

24. REFERENCES: 9

179
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

West Germany

Messerschmitt Boelkow Blohm

Augsburg

Military Aircraft

Burkhardt & Weber

MC

80

52.6 % reduction in MT's and labor

Siemens 330, 3 DEC PDP 11/34’s

Aircraft parts

Titanium

Prismatic

1 MC, 1 NM

AGV, ASRS

Overhead conveyor & ASRS for tools on pallets

26, 30, 36, 38, 69

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

West Germany

Moteren Turbinen Union (MTU)

FMS

81

Cylinder heads

Cast iron

4

Prismatic

5 MC

Stacker crane, 4 roller conveyors

86

180
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1 . COUNTRY: West Germany

2. COMPANY: Oberkochen

3. LOCATION:

4. DIVISION:

5. SUPPLIER: Carl Zeiss

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER: DEC PDP 11/24

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

Prismatic

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 4 MC

21. MATL. HANDLING:

22. TOOLING:

Rail guided cart

23. FEATURES: Automated inspection

24. REFERENCES: 14

1. COUNTRY: West Germany

2. COMPANY: Robert Bosch

3. LOCATION:

4. DIVISION:

5. SUPPLIER: Steinel

6. CLASS: MC

7. YEAR: 82

8. FINANCIAL DATA: Labor reduced from 18 to 5, cost 20 %, LT from 6wks to 1 9. COMPUTER:

10. CONTROLS: 4 Bosch CNC Micro # 8

11. PRODUCTS: Power tool gearboxes, housings for hand tools

12. MATERIALS: Aluminum

13. NUMBER OF PARTS:

14. PART FAMILIES: 4

15. PRODUCTION RATE: 300,000 parts/year

16. PART CUBE: 12 x 8 x 8 in

17. PART SHAPE: Prismatic

18. OPERATION 4 independent 'CNC machines in parallel,

SCHEDULING: crew of 2

19. LOT SIZE: Small & medium

20. MACHINE SET: 4 CNC

21. MATL. HANDLING: 4 robots, 2 conveyor belts (50 ft each)

22. TOOLING: ATC with capacity of 60

23. FEATURES:

24. REFERENCES: 48

181
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

West Germany

Robert Bosch

Steinel

FMS

82

Bosch CNC Micro # 8

ABS anti-skid system

Aluminum

400 x 250 mm pallet

Prismatic

Medium & large

8 MC, 1 CMM

Belt conveyor, 8 Bosch robots

ATC with capacity of 30

Pallet coding with pin system

48

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

West Germany

SEW

Friedrich Deckel

FMS

84

14

182
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

West Germany

Scharmann GmbH & Co.

Scharmann

FMS

84

Machine tool parts

Steel, cast iron

Prismatic

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

West Germany

Trumph

Friedrich Deckel

FMS

84

Machined sheet metal products

Prismatic

2 MC

Automated inspection, part washing

34

183
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

West Germany

University of Berlin

Berlin

University of Berlin

FMS

76

Prismatic and rotational

1 NT, 1 NM

Roller conveyor, overhead conveyor,

36, 38, 52

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

West Germany

University of Stuttgart

Stuttgart

University of Stuttgart

FMS

76

University of Stuttgart

Prismatic

4 MC, 1 CMM

2 stacker cranes, rack at each MC

Tooling under computer control

Automated inspection

14, 36, 38, 52, 72

2 robots

184
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

West Germany

Bauer Plant

Burkhardt & Weber

FMS

81

Prismatic

9 MC

Roller conveyor

18

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

West Germany

VFW - Fokker

FMS

81

Toranado aircraft parts

Aluminum

Prismatic

8 MC

Rail guided cart

18, 69, 86
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

West Germany

Vereinigte Flugtechnische Werke

Heller and Heyligenst.

FMS

77

Airframe parts

Aluminum

9

Prismatic

8 MC, 1 WS

Automated inspection

14

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

West Germany

Volkswagen

Burkhardt & Weber

FMS

80

Transmission and rear axle housings

Cast iron

7

Prismatic

8 MC

14, 53

186
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY: West Germany

2. COMPANY: Werkzeugmaschinenlabor

3. LOCATION: Aachen

4. DIVISION:

5. SUPPLIER:

6. CLASS: FMS

7. YEAR: 83

8. FINANCIAL DATA:

9. COMPUTER

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE: 50 - 250 mm round

17. PART SHAPE: Rotational

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET: 1 MC, 2 NT

21. MATL. HANDLING: 1 robot in an orbital layout

22. TOOLING: ATC with 20 tool magazine on

23. FEATURES:

24. REFERENCES: 14

1 . COUNTRY: West Germany

2. COMPANY: Westfalia Separator

3.

4.

LOCATION:

DIVISION:

Oelde

5. SUPPLIER: Dixi (Swiss)

6. CLASS: FMS

7. YEAR: 84

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS: Machine tool parts

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

Steel, cast iron

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

Prismatic

20. MACHINE SET: MC's

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

AGV's, ASRS

24. REFERENCES: 45

187
APPENDIX C. FMS IMPLEMENTATION DATA BASE

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

West Germany

Zahnradfabrik Friedrichshafen

Zahnradfabrik Friedrichshafen

FMS

82

DEC PDP 11/44

7 of 13 NC MT's DNC

Gears

Steel

100 +

4

16,000 parts/month

280 mm round x 80 mm thick

Rotational

Range of 50 to 500

1 NC, 4 NT, 3 SP, 5 NG

Robots, gantry crane

Automated inspection, part washing

14, 34, 86

1. COUNTRY:

2. COMPANY:

3. LOCATION:

4. DIVISION:

5. SUPPLIER:

6. CLASS:

7. YEAR:

8. FINANCIAL DATA:

9. COMPUTER:

10. CONTROLS:

11. PRODUCTS:

12. MATERIALS:

13. NUMBER OF PARTS:

14. PART FAMILIES:

15. PRODUCTION RATE:

16. PART CUBE:

17. PART SHAPE:

18. OPERATION

SCHEDULING:

19. LOT SIZE:

20. MACHINE SET:

21. MATL. HANDLING:

22. TOOLING:

23. FEATURES:

24. REFERENCES:

Yugoslavia

Ljublana University

Ljublana

Ljublana University

FMS

81

DEC PDP 11/70

Miscellaneous parts for local industry

Steel, cast iron

Prismatic and rotational

1 NT, 1 MC (3 additional MT's planned by 82)

86

188
APPENDIX D. BIBLIOGRAPHY

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189
APPENDIX D. BIBLIOGRAPHY

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20. Egalini, P., and A. Ferrari, "An FMS for Mandelli Production,” Proceedings

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21. Ennis, G. E., "Flexible Machining Cell (FMC)," Paper presented at Flexible

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23. "Flexible Manufacturing Systems - State of the Art and Trends in Their

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24. "FMSs are Widespread at GDR Show,” American Machinist , (May 1985),

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25. Furlani, Cita M. , Ernest W. Kent, Howard M. Bloom, and Charles R. Mclean,

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26. Gans, G., "Flexible Manufacturing at Messerschmitt-Bolkow-Blohm, " Paper

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27. Germann, Michael J., "Advanced Flexible Manufacturing Systems for Tactical

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28. Gindy, M. N. Z., and S. K. Ghosh, " Flexible Manufacturing for Mixed Metal

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Conference on Flexible Manufacturing Systems , September 11-13, 1984,

Boeblingen, West Germany, North Holland Publishing Company, New York,

pp. 455-465.

29. Graf, Henry R., "Flexible Manufacturing System for the Fabrication of

Precision Components with Real Time Simulation," Proceedings of CASA/SME

Cincom '84 Conference, March 14, 1984, Washington.

30. Handke, Gunter, "Design and Use of Flexible Automated Manufacturing

Systems," Proceedings of the 2nd International Conference on Flexible

Manufacturing Systems , October 26-28, 1983, London, UK, North Holland

Publishing Company, New York, pp. 485-504.

31. Helliwell, John R., "Flexible Turning Cells by SMT Machine Co. AB Sweden,"

Proceedings of the 2nd European Conference on Automated Manufacturing , May 16-19, 1983, Birmingham UK, North Holland Publishing Company, New

York, pp. 427-442.

32. Hess, George J., "Computer Integrated Flexible Manufacturing - 1985

(CIFM-85) , " CIMC0M '85, April 15-18, 1985, Anaheim.

33. Hocken, Robert J., and Philip Nanzetta, "Research in Automated

Manufacturing at NBS," Manufacturing Engineering , (October 1983),

pp. 68-69.

190
APPENDIX D. BIBLIOGRAPHY

34. Hoerl, A., and S. C. Vaughan, "FMS at ZF Friedrichshafen - a Case Study,"

Proceedings of the 2nd International Conference on Flexible Manufacturing

Systems , October 26-28, 1983, London, UK, North Holland Publishing

Company, New York, pp. 799-809.

35. Hutchinson, G. K., "Flexible Manufacturing Systems in Japan," NTIS

PB 288000, (November 1977).

36. Hutchinson, G. K., "Flexible Manufacturing Systems in the Federal Republic

of Germany (BRD) , " NTIS PB 288193 (December 1977).

37. Hutchinson, G. K., "Flexible Manufacturing Systems in the German

Democratic Republic (DDR)," Management Research Center, University of

Wisconsin, (April 1978).

38. Hutchinson, G. K., "Advanced Batch Manufacturing Systems, Proceedings of

the 16th Numerical Control Society Annual Meeting and Technical

Conference, March 25-28, Los Angeles, pp. 118-146.

39. Hutchinson, G. K., "An Update on ABMS’s in the German Democratic Republic

(DDR)," Management Research Center, University of Wisconsin, (May 1982).

40. Hutchinson, G. K., "Messerschmitt-Bolkow-Blohm GMBH," Management Research

Center, University of Wisconsin, (May 1982).

41. Hutchinson, G. K., "ABMS's in Czechoslovakia," Management Research Center,

University of Wisconsin, (May 1982).

42. "Ingersoll Spending $20M for In-House FMS," Automation News , Vol. 2, No.

8, (August 6, 1984), p. 1,5.

43. Jablonski, Joseph, "Aiming for Flexibility in Manufacturing Systems,"

American Machinist , (March 1980), pp. 167-182.

44. Jablonski, Joseph, "Deciding on an FMS," American Machinist , (May 1983),

pp. 109-111.

45. Jablonski, Joseph, "Reexamining FMSs," American Machinist , (March 1985),

pp. 125-140.

46. Jablonski, Joseph, "Keeping an FMS up to Date," American Machinist , (August, 1985), pp. 76-78.

47. Johansson, Stig, "An FMS at Volvo Components for Machining Crank Shafts,"

Proceedings of the 2nd European Conference on Automated Manufacturing , May 16-19, 1983, Birmingham UK, North Holland Publishing Company, New

York, pp. 388-391.

48. Kief, Hans B., "FMS at Bosch: An Experience Report," Flexible

Manufacturing Systems ’85, March 11-14, 1985, Dallas, SME Technical Paper

MS85-159.

49. Kinnucan, Paul, "Flexible Systems Invade the Factory," High Technology,

(July 1983), pp. 32-42.

50. Knabb, William F., "Implementing an FMS at Hughes Aircraft Company,"

Proceedings of CAM-I International Spring Seminar, May 3-5, 1983, St.

Louis, pp. 121-123.

51. Knight, J. A. G., "The Latest Developments of FMS in Japan," Proceedings

of the 1st International Conference on Flexible Manufacturing Systems , October 20-22, 1982, Brighton, UK, North Holland Publishing Company, New

York, pp. 31-36.

52. Larsen, Raymond J., "Flexible Manufacturing: The Technology Comes of Age,"

Iron Age , (September 7, 1981), pp. 82-97.

53. Larsen, Raymond J., "Flexible Manufacturing: More Companies Make

Competition Intense," Iron Age , (September 28, 1981), pp. 85-95.

54. Larsen, Raymond J. , "Japan on First, Europe on Second in Battle for

Rotational Systems Market," Iron Age , (February 19, 1982), pp. 61-73.

191
APPENDIX D. BIBLIOGRAPHY

55. Larsen, Raymond J., "U. S. Plays Catch Up in the Development of

Rotational Systems," Iron Age , (March 1, 1982), pp. 58-67.

56. Larsen, Raymond J., "The Technology of ’Change' Will Highlight the Growth

of FMS in World Market," Iron Age , (April 23, 1982), pp. 76-81.

57. Long, Peter A., "SCAMP," Proceedings of the 2nd European Conference on Automated Manufacturing , May 16-19, 1983, Birmingham UK, North Holland

Publishing Company, New York, pp. 371-374.

58. "Major UK FMS Installations Under Construction," Financial Times, (January

12, 1984).

59. Martell, R. P., "Bringing an FMS "On-Line" in an Aerospace Company,"

Flexible Manufacturing Systems '85, March 11-14, 1985, Dallas, SME

Technical Paper MS85-150.

60. McBean, D. J., "Practical Applications of F.M.S.," Proceedings of the 2nd

International Conference on Flexible Manufacturing Systems , October 26-28,

1983, London, UK, North Holland Publishing Company, New York, pp. 477-484.

61. Meade, William P., "Flexible Manufacturing Systems in the United States,"

a report prepared for the French government by the Management

Collaborative Group, Chapel Hill, NC, (November 1978).

62. "Milacron Installing FMS to Aid Plastics Unit," Automation News , Vol. 2, No.

8, (August 6, 1984), pp. 1,17.

63. Morgan, T. K., "Planning for the Introduction of FMS," Proceedings of the

2nd International Conference on Flexible Manufacturing Systems , October

26-28, 1983, London, UK, North Holland Publishing Company, New York, pp.

349-357.

64. Percival, I. W. , "A Flexible Computer Controlled Production System,"

Proceedings of the 2nd International Conference on Flexible Manufacturing

Systems , October 26-28, 1983, London, UK, North Holland Publishing

Company, New York, pp. 515-524.

65. Purdom, Peter A., and Tony Palazzo, "The Citroen (CCM) Flexible

Manufacturing Cell," Proceedings of the 1st International Conference on Flexible Manufacturing Systems , October 20-22, 1982, Brighton, UK, North

Holland Publishing Company, New York, pp. 151-169.

66. Purdom, Peter A., "The Citroen Flexible Manufacturing Cell," Proceedings

of the 2nd International Conference on Flexible Manufacturing Systems , October 26-28, 1983, London, UK, North Holland Publishing Company, New

York, pp. 93-103.

67. Ranky, P. G., "The FMS in Cespel Machine Tool Company," Proceedings of the

1st International Conference on Flexible Manufacturing Systems , October

20-22, 1982, Brighton, UK, North Holland Publishing Company, New York,

pp. 141-150.

68. Rathmill, K., N. Greenwood, and M. Houshmand, "Computer Simulation of

FMS," Proceedings of the 2nd International Conference on Flexible

Manufacturing Systems , October 26-28, 1983, London, UK, North Holland

Publishing Company, New York, pp. 251-280.

69. "Recent Trends in Flexible Manufacturing," Economic Commission for

Europe, United Nations Economic and Social Council, (December 4, 1484).

70. Romanini, S., "FMS That Reach Their Goal," Proceedings of the 2nd

International Conference on Flexible Manufacturing Systems , October , 1983, London, UK, North Holland Publishing Company, New York, pp. 81-92.

192
APPENDIX D. BIBLIOGRAPHY

71. Roraanini, S., "Automated Factory: Science Fiction or Reality?,"

Proceedings of the 3rd International Conference on Flexible Manufacturing

Systems , September 11-13, 1984, Boeblingen, West Germany, North Holland

Publishing Company, New York, pp. 73-84.

72. Schmidt, J., "Flexible Manufacturing Systems Applied in Volume Production,"

Proceedings of the 3rd International Conference on Flexible Manufacturing

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Publishing Company, New York, pp. 133-142.

73. Schmoll, P. , and F. Popplewell, "Flexible Automation Made to Measure,"

Proceedings of the 3rd International Conference on Flexible Manufacturing

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74. Sizemore, Richard G., "LTV's $10-Million FMS Comes On-Line," Automation

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76. Storr, A., and S. Chmielnicki, "Proving of Simulation Programs with the

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May 3-5, 1983, St. Louis, pp. 27-35.

77. Suzuki, T., et. al., "Present State of the Japanese National Project,"

Proceedings of the 2nd International Conference on Flexible

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Publishing Company, New York, pp. 19-30.

78. Tomek, Pavel, and Jaromir Zeleny, "Machining Technology in Flexible Manufacturing Systems for Prismatic Parts with Automated Flow of Tools,"

Proceedings of the 2nd International Conference on Flexible

Manufacturing Systems , October 26-28, 1983, London, UK, North Holland

Publishing Company, New York, pp. 57-68.

79. Umbricht, F,, and C. R. Boer, "TUGEFA: Manufacturing of Turbocharger

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80. Vaccaro, Salvatore M. , "FMC's Venture into FMS: A Case Study," Flexible

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81. Vasiliev, V. N., V. A. Kudinov, and S. V. Vasiliev, "FMS in the U.S.S.R.:

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193
APPENDIX D. BIBLIOGRAPHY

85. Wilcox, D. J. t "FMS Linking Machining Center with Lathe for Small Batch

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194
MBS-114A (REV. 2-80

U.S. DEPT. OF COMM.

BIBLIOGRAPHIC DATA

SHEET (See instructions)

1. PUBLICATION OR 2. Performing Organ. Report No. 3. Publication Date REPORT NO.

NBSIR 86-3413 AUGUST 1986

4. TITLE AND SUBTITLE

A Survey of Flexible Manufacturing Systems Implementations

5 . author(S) Dr . william P. Darrow

Guest Worker from Towson State University

6. PERFORMING ORGANIZATION (If joint or other than NBS, see instructions)

NATIONAL BUREAU OF STANDARDS

DEPARTMENT OF COWERCE

GAITHERSBURG, ND 20899

7. Contract/Grant No.

8. Type of Report & Period Covered

9.

SPONSORING ORGANIZATION NAME AND COMPLETE ADDRESS (Street. City, State, ZIP)

National Bureau of Standards

Building 220, Room A-127

Gaithersburg, Mary], and 20899

10.

SUPPLEMENTARY NOTES

I I Document describes a computer program; SF-185, FIPS Software Summary, is attached.

11.

ABSTRACT (A 200-word or less factual summary of most significant information. If document includes a significant

bi bliography or literature survey, mention it here)

This report presents descriptive data on three hundred manufacturing

facilities that are using computer integrated manufacturing (CIM)

techniques to machine component parts for commercial, industrial, and

military products. Of these 258 were categorized as Flexible

Manufacturing Systems (FMS) . Key descriptive statistics were gathered

for each system. The data is organized into records by the user's

country, company, and geographic location. Each record is made up of

24 fields that describe the facility, the product, and the operating

parameters, as well as providing a reference to the source (s) of

information. In many instances the information has proven to be

sparse. Nevertheless, taken in aggregate, a picture of the state of

the art for FMS has emerged from the study. This picture is reflected

in the graphical summaries of the data, which are presented by region

for Eastern Europe, Western Europe, Japan, and the United States. An

analysis of trends in FMS implementation, product and material

characteristics, and materials handling technology is made for each

of the above regions.

12.

KEY WORDS (Six to twelve entries; alphabetical order; capitalize only proper names; and separate key words by semicolon s)

Database, Conputer Integrated Manufacturing, International, Flexible Manufacturing, Survey,

’ Statistics, World-wide

13.

availability

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I I For Official Distribution. Do Not Release to NTIS

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20402.

X, Order From National Techn ical Information Service (NTIS), Springfield, VA. 22161

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PRINTED PAGES

202

15. Price

$22.95

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