Tactics for FMS Implementation

Straightforward steps to take a FMS from initial design to lean operation

Through decades of experience on dozens of FMS projects, we have developed a series of 8 steps that take a FMS from initial concept to a low-cost, efficient, well-run factory cell. Motivated by these tactics, we have a series of software tools designed together with engineers and operators to assist with all phases of cell operation.

Step 1: Planning and Justification

Goals for this step:

  • Forecast total amount of capital and labor.
  • Compare manufacturing scenarios between standalone machines and automation.
  • Predict cost per piece.
  • See simulation-based animation of predicted cell operation.

Before purchasing an FMS, the simulation-based SeedTactic: Planning and SeedTactic: Designer software is used by engineers in the office to predict and understand the future cell.

Step 1: Planning and Justification

Step 2: Flexibility Review

Goals for this step:

  • Decide part, pallet, and machine assignments.
  • Understand expected load operator activity.
  • Ensure current flexibility keeps the machines busy over a range of predicted daily production quantities.

The simulation-based SeedTactic: Planning and SeedTactic: Designersoftware allow you to decide on a flexibility plan and predict the cell's operation, even before the cell is installed.

Step 2: Flexibility Review

Step 3: Initial FMS Install

Goals for this step:

  • Start proving out parts.
  • Educate operators and managers about their tasks.
  • Gain confidence in operating the cell in automatic mode with enough flexibility to keep machines busy.

The free and open-source SeedTactic: FMS Insight runs on the cell controller and disseminates information about the cell throughout the factory. It provides helpful displays for the operators, floor supervisors, engineering, quality, and management. FMS Insight helps during the initial install and prove-out by exposing data about the cell in useful and targeted reports.

Step 3: Initial FMS Install

Step 4: Orders and Automatic Data Creation

Goals for this step:

  • Set up automatic data entry into the cell controller.
  • Reduce tedious manual management of the cell.
  • Gain confidence in operating the cell in automatic mode with enough flexibility to keep machines busy.

Manually entering data into the cell controller is tedious and error-prone. SeedTactic: OrderLink is our software product which automatically enters (and keeps up to date) part, pallet, and machine assignments into the cell controller. For production quantities, initially OrderLink will read orders from a CSV file, allowing simple manual control of orders and production.

Step 4: Orders and Automatic Data Creation

Step 5: Part Tracking and Marking

Goals for this step:

  • Mark each piece of material with a unique serial.
  • Install barcode scanners throughout the factory to allow display of data about the specific material.
  • Gain confidence in operating the cell in automatic mode with enough flexibility to keep machines busy.

SeedTactic: FMS Insight supports custom plugins and we can develop a plugin customized to your specific situation which can output a sub-program to scribe a barcode on the part inside the machine or print a label at the load station. The resulting barcode can then be scanned into FMS Insight to provide the history of the specific piece of material.

Step 5: Part Tracking and Marking

Step 6: Inspection Plan

Goals for this step:

  • Decide on inspection frequency for each part.
  • Ensure each combination of pallet and machine is periodically inspected.
  • Collect a pass/fail result for each inspection.
  • Gain confidence in operating the cell in automatic mode with enough flexibility to keep machines busy.

OrderLink and FMS Insight work together to ensure the inspection frequencies are kept up to date in the cell controller. FMS Insight will track and count each piece of material by pallet and machine, signaling that a specific serial should be inspected. FMS Insight can then display data about the specific serial under test, record a pass/fail result, and provide weekly and monthly inspection reports.

Step 6: Inspection Plan

Step 7: ERP Connection and Advanced AI

Goals for this step:

  • Automatically import orders from your ERP.
  • Upload to your ERP a completed workorder report consisting of actual machine hour and labor use for each completed order.
  • Develop a customized algorithm to ensure machines stay busy no matter the daily mix.
  • Gain confidence in operating the cell in automatic mode with enough flexibility to keep machines busy.

OrderLink supports plugins for order import and scheduling. We can work with you to develop a custom plugin which loads orders from your specific ERP automatically. Also, we will use our expertise on many different cells to develop a customized scheduling and allocation strategy which automatically keeps the machines busy no matter the daily mix.

Step 7: ERP Connection and Advanced AI

Step 8: Continuous Improvement

Goals for this step:

  • Once a month, review the operation of the cell and suggest future improvements.
  • Reduce overall cost per piece.
  • Adapt to changing part demand.

FMS Insight supports continuous improvement by providing monthly reports highlighting the cell's operation and locations for improvement.

Step 8: Continuous Improvement

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Get Started Today

Contact our integration experts at CMS Research to obtain a free customized quote, see live demos, arrange a visit to one of our customers, obtain expert advice, receive training, and more. CMS Research has decades of experience managing a flexible manufacturing system all the way from initial design to optimized production.

Email cms@cmsres.com or call 1-920-235-3356.