A Pattern Recognition Approach for Manufacturing Facility Compaction by Machining Function Combination Using Flexible Manufacturing Modules

Facility layout and flexible automation are two approaches for reduction of material handling costs and space requirements in a machining facility that have always been implemented independently of each other. This paper describes an integrated approach to compaction of existing machining facilities using machine grouping algorithms and multi-function machining centers, also referred to as Flexible Machining Modules (FMMs). First, we decompose a facility into a network of layout modules to reduce product travel distances and simplify material flow control. Then, subject to design feasibility, we identify those sets of machines in each module that could be replaced by multi-function FMMs that could be linked into a Flexible Machining System (FMS). The proposed approach uses a combination of pattern recognition and graph theory algorithms utilized for facility layout. The paper concludes with a description of a validation study conducted in an aerospace machining jobshop.