Unlock Flexible Production Lines With Industrial Automation

A flexible manufacturing system (FMS) is an advanced, computer-controlled production setup that combines efficiency with adaptable manufacturing capabilities. It consists of three components:

Automated processing stations

• Computer numerical control (CNC) machines
• Automated workstations
• Robotic systems

Material handling system

• Automated material transportation
• Storage and retrieval systems
• Real-time tracking capabilities

Central control system

• Integrated computer control
• Storage and retrieval systems
• Real-time tracking capabilities

The system provides two primary types of flexibility: Machine flexibility, which is the ability to process different products and handle varying production requirements; and routing flexibility, which is the capability to use alternative paths through the system for production.

FMS is particularly valuable for manufacturers dealing with varying production volumes, frequent product changes and high customization requirements while maintaining efficient production standards.

By 2030, AMRs will be the cornerstone technology of flexibility on the factory floor, with a forecasted market size of $15 billion. The adoption of AMRs is steadily growing within factories and gradually supplanting traditional conveyor systems.

This establishes a modular and seamless production process – that accommodates customer-specific manufacturing requirements – while reducing reliance on rigid, maintenance-intensive conveyors. The transition enhances agility and efficiency while mitigating scrap, contamination risks, waste and losses.AMR integration allows production lines to be adapted to accommodate production changes such as product type and assortment size. In addition to rapid and efficient changeovers, seamless AMR integration supports the modular reconfiguration of lines to maintain quality and improve productivity.

The 3DEXPERIENCE platform's integrated 3D modeling capability enables line builders to virtually model and simulate production lines from concept to operations. This allows AMR movements, line layouts and plant ergonomics to be optimized virtually before deployment on the factory floor.

The 3DEXPERIENCE platform offers comprehensive visibility into the operational status of the AMR fleet and production lines. Real-time access to operational data enables proactive maintenance scheduling to ensure optimal performance and continuous improvement of service operations.

The platform facilitates advanced predictive maintenance through the integration of virtual twin technology, which leverages AI and machine learning to analyze equipment behavior patterns. The platform will streamline asset tracking, maintenance and repair processes – allowing for preventive identification of issues and improving overall equipment efficiency (OEE).

A manufacturer should consider implementing a flexible production line when:

• Product variety is high: The need to manufacture multiple product variants or entirely new products on the same line
• Market demands fluctuate: Frequent changes in customer demand require quick adjustments to production volumes
• Customization is critical: Customers increasingly request personalized or customized product variations
• Innovation cycles accelerate: Shorter product lifecycles and frequent new product introductions demand rapid manufacturing adaptability
• Operating costs need optimization: Looking to reduce inventory costs, minimize downtime during changeovers, and improve resource utilization
• Competitive pressure increases: Market competition requires faster time-to-market and more efficient production methods
• Automation integration is planned: Implementing technologies like autonomous mobile robots (AMRs) or other automated systems to enhance manufacturing flexibility
• Quality standards are rising: Need for consistent quality across different product variants while maintaining efficiency
• Space optimization is required: Limited factory floor space necessitates more efficient, adaptable production methods

Investing in flexible production lines becomes particularly valuable when manufacturers encounter several of these challenges simultaneously, as it offers a comprehensive solution for future-proofing operations.