Reconfigurable manufacturing system having a production capacity method for designing same and method for changing its production capacity

Abstract

A reconfigurable manufacturing system (RMS) having an adjustable structure is designed based upon market demand and can be readily changed from a first desired production capacity to a second desired production capacity to manufacture a desired amount of products from a family of products. The RMS includes a plurality of workstations with reconfigurable machines and computerized numerically controlled (CNC) machines, a control system including a plurality of reconfigurable controllers, as well as a reconfigurable material handling system. The reconfigurable machines may be reconfigurable machine tools having reconfigurable hardware that enables conversion of the machines by, for example, relocating their spindle units. The RMS production capacity is quickly adjusted to market fluctuations in product demand. The RMS functionality is easily adapted to fabrication of new products of the same product family. The RMS possesses certain key characteristics (i.e., modularity, integrability, customization, convertability, and diagnosability) that are needed for rapid and cost-effective reconfiguration. A methodology for the design of an RMS, and a complementary methodology for changing the production capacity including reconfiguration and ramp-up of the RMS are also provided.