Flexible Manufacturing Systems (FMS)

A Flexible Manufacturing System (FMS) is a production approach that uses programmable, often automated equipment and interconnected workstations to switch rapidly between different products or product variants. Designed for adaptability, FMS supports make-to-order strategies, enables customization, and reduces inventory and setup downtime while increasing overall production agility.

Key takeaways

• FMS enables rapid changeover between product types and quantities, supporting customization and make-to-order production.
• Automation in FMS can reduce per-unit labor costs and downtime, but requires significant upfront investment.
• Successful FMS implementation demands skilled technicians, careful system design, and planning for future flexibility.
• The FMS concept traces to Jerome H. Lemelson’s mid-20th-century work on robot-based manufacturing systems.

How FMS improves efficiency

• Reduced changeover time: Automated programming and tooling changes eliminate long shutdowns for reconfiguration.
• Lower inventory needs: Make-to-order capability cuts the need to hold large finished-goods inventories.
• Consistent quality and testing: Integrated inspection and data collection improve product quality and traceability.
• Higher utilization: Interconnected workstations and automated material handling optimize throughput and reduce idle time.

Typical FMS configuration

An FMS can take many forms depending on product mix and volume but commonly includes:
* A set of flexible machine tools or robotic workstations for machining, assembly, welding, etc.
* Automated material handling (conveyors, automated guided vehicles, or robotic transfer systems).
* Intermediate storage (e.g., automated storage/retrieval systems) to buffer work between stations.
* Central control and scheduling computers that manage part routing, tool changes, and production batches.
* Integrated inspection and data-logging systems for quality control.

Pros and cons

Pros
* Faster response to changing demand and product customization.
* Reduced downtime from setup and changeovers.
* Potential long-term cost savings through higher automation and lower labor per unit.
* Improved consistency and traceability of production.

Cons
* High initial capital expenditure for equipment and software.
* Longer lead time for design and system specification to ensure future flexibility.
* Requires specialized technicians for operation and maintenance, increasing staffing and training needs.
* Complexity in planning and integration—poor design can negate expected benefits.

Historical note

The FMS concept was developed in the mid-20th century by American inventor Jerome H. Lemelson, who envisioned robot-based systems capable of welding, riveting, conveying, and inspecting manufactured goods. Although early implementations were limited by technology, FMS began appearing on factory floors in the late 1960s and expanded through the 1970s as automation matured.

Implementation considerations

Before adopting an FMS, evaluate:
* Return on investment horizon and expected production volumes.
* Product mix variability and the degree of customization required.
* Availability of skilled staff and training programs for operation and maintenance.
* Scalability and modularity to accommodate future product lines or capacity changes.
* Integration with existing ERP, CAD/CAM, and quality-management systems.

Conclusion

FMS offers a practical path to flexible, efficient manufacturing for companies needing quick product changeovers and customization. While it delivers reduced downtime, improved quality, and potential long-term cost savings, it demands substantial upfront investment, careful design, and skilled personnel. When aligned with production strategy and long-term volume expectations, FMS can be a powerful enabler of competitive, responsive manufacturing.