The flexible manufacturing system is one of those, and here we’ll look at what it is and businesses that use it, and discuss strengths and weaknesses and how it can help your business.
- Read more: The Modern Manufacturing Guide
What is the flexible manufacturing system?
Flexible manufacturing is all about adaptability – that is, the ability to adapt to changes in product requirements without compromising on quality. A flexible manufacturing system (FMS) is the production method that helps make this happen, and it can cut down both on production times and the amount of resources required.
The system is designed to adapt to changes like slight (or more significant) variations to a product, production volumes, or even the addition of entirely new products. It does this with the help of computers and machines that can automate key manufacturing processes, including machining and assembly, loading and unloading, and data processing.
It can cut and form metal, weld and join, and assemble, test, and inspect parts. It can also deburr, shave, and apply finishing treatments to pieces, making parts presentation-ready.
Because the system is automated, it relies less on human power than traditional manufacturing methods, which has both advantages and disadvantages. We’ll look at these below.
With the help of flexible manufacturing systems businesses can automate key manufacturing processes
What Are The Different Types of Flexible Manufacturing Systems?
here are five primary types of FMS, each offering different levels of adaptability and production capability:
Sequential FMS
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Produces one type of part at a time
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Switches to the next type in a pre-defined production sequence
Random FMS
- Manufactures a mixed variety of parts at any given time
- Machines can handle diverse configurations in random order
Dedicated FMS
- Produces a limited mix of parts continuously
- Designed for long production runs with high throughput
Engineered FMS
- Produces the same part repeatedly
- Focuses on consistency and stable, unchanging designs
Modular FMS
- Can switch between sequential, random, dedicated, and engineered modes.
- Supports flexible reconfiguration based on production needs
What is a flexible manufacturing cell?
A flexible manufacturing cell (FMC) comprises two or three machines including processing workstations and a parts handling capability. While it's less complex and sophisticated than an FMS, an FMC has flexible capabilities as well, including rerouting a product from one machine to another should one of them fail, and the ability to adapt to an increase in production volumes.
An FMS is larger than an FMC. It is made up of four or more machines and has more supporting parts, including wash stations for parts and pallets, and storage stations. It also has a more advanced computer system with a greater number of functions, such as monitoring and diagnostics.
If you’re looking for a flexible manufacturing solution for your business, you might consider both options depending on your size, resources, and space. An FMS is more flexible, but requires more space, and with its complexity, will require more training with a bigger learning curve. It also comes at a greater cost which will likely require a higher level of buy-in from senior staff and managers.
Flexible Manufacturing Examples – Companies That Use FMS
Flexible manufacturing systems are applied across a wide range of industries that require high precision, rapid retooling, and efficient production of variable parts. Below are 10 examples demonstrating how modern manufacturers use FMS to increase speed, reduce costs and respond quickly to design changes.
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Siemens uses FMs to produce Simatic controllers, enabling rapid configuration changes across circuit board assemblies.
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Ford Motor Company implements flexible robotic welding and tolling systems in their body shops to quickly shift production volumes between different vehicle models.
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General Electric uses FMS in turbine blades and compressor part fabrication to accommodate ongoing engineering changes.
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Boeing employs FMS for producing varied titanium and aluminium aircraft components requiring high-precision CNC machining.
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Medtronic uses modular FMS cells to rapidly adapt manufacturing for surgical device variations with short run lengths.
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Catapillar uses FMS for machining engine blocks, hydraulic components, and speciality parts with frequent design updates.
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Bosch deploys FMS for compressor and motor assembly lines, allowing rapid product variant switching.
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ABB Robotics uses FMS for robotic arm components, enabling efficient production of customised configurations.
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Intel applies FMS for precision metal parts used in chip-fabrication machinery requiring ultra-tight tolerances.
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John Deere implements FMS for drive systems, gear housing, and chassis components where seasonal demand fluctuates significantly.
Advantages of the flexible manufacturing system
The advantages of an FMS can be significant for the right company. If overall you’re producing a high volume of products with the potential for a significant number of variations in a competitive industry, FMS might be right for you. Let’s look at some of the benefits:
Flexibility
As the name suggests, flexibility is the name of the game with FMS. There are times companies will need to scale up production volumes at short notice, add entirely new products, or allow for variations in a specific line of products. The FMS is of course designed for just these scenarios, simplifying the process significantly with automated systems that can adapt to changes fluidly.
Customisation
The ability to modify products has become increasingly important, particularly as customers demand a greater say over their products and the option to tailor them to their style, taste and needs. But as most manufacturers know, customisation can be a complicated, time-consuming and expensive process. FMS comes into its own with the ability to modify and customise products easily.
Speed and efficiency
Automated systems and powerful machinery mean that the time it takes for a product to be made can be greatly reduced, thanks to quicker set-up and loading times, through to machining, tool-changing, unloading, and cleaning times.
But it’s not just about the amount you can get done in normal working hours. With an FMS, operations needn’t stop after hours, on weekends, or on holidays. This ability to work around the clock can have huge positive implications for a business looking to increase both its speed and volume of production.
Quality
Powerful and durable machinery with high-precision and testing capability can mean improved product quality and consistency, which of course helps keep customers happy with your products – and helps avoid potentially costly defaults downstream.
Improved intelligence
With the ability to collect data, monitor production, and test products, an FMS can be a valuable insight tool for your company, allowing you to understand your production capabilities and make plans and decisions with more confidence.
Labour
Implementing an FMS will mean you need fewer staff working to make products as the machines will replace the need for some of this labour. This will save you money of course, but there is a flip side to be considered, which we’ll look at below.
You’ll need to implement flexible manufacturing systems over the long run to reap the benefits
Disadvantages of the flexible manufacturing system
FMS won’t be right for every business, particularly if cash flow is an issue. Some of the downsides to FMS are:
Cost
While the long-term benefits may well make it worthwhile, implementing an FMS will require high up-front costs and associated maintenance costs which may be prohibitive for your business. Adapting equipment will likely be expensive as well. It won’t come as a surprise that financial forecasting will be crucial before committing to an FMS. It’s worth speaking to a range of providers beforehand to understand what the real value would be for your company.
Technical expertise
As we touched on above, an FMS should reduce the number of staff needed to run your production activity, but as a complex system, it will require technical expertise to operate and monitor it. You’ll also need staff for maintenance and repairs. This expertise will likely require higher salaries and could require a significant time investment in training, so it’s worth balancing out how much reduced labour will save, versus the cost of training or hiring technical operators.
Limited future changes
While it may sound counterintuitive, as flexible as an FMS is, the system you start with won’t necessarily be the right system for some of your future needs – and you won’t always be able to retool it to reflect those needs. This is another reason why thinking about your long-term plans will be important before making a final decision.
Complex planning
A sophisticated system like this won’t just run on its own. It will require detailed plans, designs, schedules, and instructions to get going – and these will require a decent investment in your time. This may be balanced out in the end, but it’s worth considering where the time investment will be shifted in your business and making sure you have the capacity and expertise for it.
For manufacturers like Ford, flexible manufacturing in the body shop can greatly boost efficiency
Does flexible manufacturing improve productivity?
Like any tool or system, whether flexible manufacturing can increase productivity for your business will depend on the type of products you make, the volume you produce, and the amount of variation and customisation required for them.
Flexible manufacturing systems are widely claimed to positively impact productivity and quality. Studies show that investing into a long-term FMS results in reduced labour costs, increased output, decreased manufacturing costs, increased flexibility, and reduced production lead time.
FMS components: what you need for flexible manufacturing
| FMS Components | Primary Function |
| Workstations | CNC machining, assembly, tool changing, inspection, loading/unloading, wash stations; core site of physical production. |
| Material Handling & Storage Systems | Move parts between stations using robots, pallet changers, conveyors, and AS/RS; ensure smooth part flow. |
| Computer Systems | Coordinate work station activities, collect data, monitor tools and workpieces, manage traffic and production control. |
| Managers & Operators | Skilled personnel responsible for supervision, technical operation, maintenance, and aligning production tasks with design specifications. |
Transform Your Production with Smarter Inventory Management
Implementing a flexible manufacturing system is only part of building a truly agile operation. To fully unlock the speed, accuracy, and adaptability that FMS offers, you need inventory software that keeps up – tracking materials in real-time, reducing stockouts, and giving you the visibility to make smarter, faster decisions.
That’s where Unleashed inventory management software comes in. With Unleashed, manufacturers can:
- Maintain real-time visibility of raw materials and finished goods
- Improve production planning with accurate materials availability
- Reduce waste and downtime through tighter stock control
- Confidently scale operations as product ranges grow
- Integrate seamlessly with existing manufacturing workflows.
Discover how Unleashed can power a more flexible, efficient production system today. Start your 14-day free trial.
