Automation of Flexible Manufacturing System

Project Overview

This project involved the strategic integration of advanced automation technologies into a Flexible Manufacturing System (FMS) to achieve lights-out manufacturing. The primary aim was to significantly enhance production flexibility, operational efficiency, and sustainability through state-of-the-art automation equipment and renewable energy solutions.

Objectives

• Develop and integrate a comprehensive multi-part machining strategy using CNC technologies
• Implement Automated Guided Vehicles (AGVs) for efficient material handling and warehouse operations
• Design and deploy an Automated Storage and Retrieval System (AS/RS) tailored for optimized inventory management
• Integrate automated tool management systems to minimize production downtime
• Adopt renewable energy sources (solar and wind) to reduce environmental impact and operational costs

Methodology

A systematic approach was utilized for this integration, focusing on:

• Analysis of existing manufacturing systems to identify automation potential
• Selection and deployment of advanced AGVs (EKS-215a from Jungheinrich)
• Installation of Automatic Tool Changers (HYCNC) to enhance CNC machining efficiency
• Implementation of AS/RS systems to streamline inventory management and reduce storage space
• Integration of renewable energy solutions (solar panels and wind turbines) to support sustainability and cost reduction
• Cost-benefit analysis for validating the economic viability of automation investments

Results

The integration of advanced automation and renewable energy solutions delivered substantial benefits:

• Improved production efficiency through automation, significantly reducing manual labour requirements
• Annual labour cost savings of approximately £188,000
• Energy savings through renewable energy:
  • Solar Power savings: £11,645 annually
  • Wind Energy savings: £128,772 annually
• Enhanced sustainability with reduced carbon footprint and reliance on traditional energy sources
• Projected maximum payback period of 5 years

Key Technologies and Innovations

The project implemented several cutting-edge technologies to achieve optimal automation:

• Automated Guided Vehicles (AGVs):
  • Jungheinrich EKS-215a self-supported stacker with automated charging, cloud-based interfaces, and advanced safety scanners
  • Load Capacity: 1500 kg, high flexibility, and extended battery life
• Automated Tool Changer:
  • HYCNC Automatic Tool Changer capable of handling up to 10 tools simultaneously
  • Benefits include reduced downtime and increased production consistency
• Automated Storage and Retrieval System (AS/RS):
  • Selection of advanced Robotic Cube Storage System for optimal space utilization, efficiency, and scalability
  • Enhanced accuracy, safety, and significantly reduced manual inventory handling
• Renewable Energy Integration:
  • Solar Panel System: 62 panels, 420W each, generating approximately 47,523 kWh annually
  • Wind Turbine System: Capable of significantly offsetting traditional energy consumption

Skills Applied