Flexible Manufacturing System (FMS) in Penang (E&E) INDUSTRY

Flexible Manufacturing System (FMS) in Penang (E&E) INDUSTRY

1. FLEXIBLE MANUFACTURING SYSTEM (FMS) IN PENANG ELECTRONICS & ELECTRICAL (E&E) INDUSTRY International Conference on Technology Management and Technopreneurship , 2025 29 October 2025

2. Boon Cheong Chew 1,2 , Thivek P. Sinathamby 1 , Ganaga Laxamanan 1,2 , Bak Aun Teoh 3 , Syaiful Rizal Hamid 1,2 1 Fakulti of Technology Management and Technopreneurship , Universiti Teknikal Malaysia Melaka. 2 SOLVE Sustainable Orange-Tech Life Value Excellence, Universiti Teknikal Malaysia Melaka. 3 School of Economics and Management, Xiamen University Malaysia. FRGS/1/2023/FPTT/F00539  

3. Focus:   R eal FMS implementations within Penang's E&E sector. Research Objective:   To examine the real implementation of FMS in Penang E&E companies. Methods:  A qualitative study , semi-structured interview and observation (factory visit) with 8 factory managers from 8 different company types . (2 MNCs, 2 Large Malaysian Companies, 2 General Contractors, 2 Medium Sized Malaysian Companies). Significance:   Bridges the gap between FMS theories and actual FMS implementation.

4. Source: Invest Penang (2024)

5. Source: Invest Penang (2024)

6. Source: Invest Penang (2024)

7. What is a Flexible Manufacturing System (FMS)? Definition:  A computer-controlled production system designed to efficiently adapt to changes in product type , mix , and quantity . The Core Idea:  Produce different products on different machines across various stations , all integrated to form a single final product ."

8. What is a Flexible Manufacturing System (FMS)? Key Components: Workstations  ( Computer Numerical Control machines, perform automated operations) Automated Material Handling   (conveyors, rails that transport items in-out or between workstations) Skilful Human Resources   (personal for programming , operational planning and system maintenance ) Computer Control System  ( central brain that integrates and coordinates operations )

9. Why Shift to FMS? The Driving Forces Intense Global Competition:  Requires 24/7 operational capacity with minimal human intervention . Efficiency Gains: Maximized machine utilization and throughput Reduced factory workspace & inventory costs Shorter manufacturing lead times Enhance responsive to market changes Strategic Shift:  Evolving from low-tech assembly to high-value , sophisticated manufacturing .

10. Types of FMS in Practice Categorized by Scale: Single Machine Cell:   A single CNC machine integrated with automated handling. Flexible Manufacturing Cell:  A cluster of 2-3 CNC workstations operating. Full FMS:   Four or more workstations under central control system , capable of batch processing, flexible mode. "We have to tackle both facility and manufacturing process together in an integrated fashion."  – Factory Manager

11. Single Machine Cell:  One CNC with automated handling.

12. Single Machine Cell:  One CNC with automated handling. A single-machine CNC machining cell (photo courtesy of Cincinnati Milacron)

13. 2. Flexible Manufacturing Cell: 2-3 workstations with several CNCs.

14. 2. Flexible Manufacturing Cell: 2-3 workstations with several CNCs. A two-machine flexible manufacturing cell for machining (photo courtesy of Cincinnati Milacron)

15. 3. Full FMS:  Four or more workstations under central control, operating in batch/flexible mode. A five-machine flexible manufacturing system for machining (photo courtesy of Cincinnati Milacron)

16. Levels of Flexibility for FMS (1. Dedicated vs 2, Random-order) 1.Dedicated FMS - Designed to produce a limited variety , pre-defined set of part styles. - The complete product portfolio is known in advance , with stable design . - This contrasts with systems designed for high variability or new product introduction.  -Based on product commonality (parts used across multiple final products ) rather than geometric similarity. - This contrasts with the traditional approach of grouping parts based on geometric similarities, where parts with similar shapes and sizes are clustered.  Source: Student Mechanica : Flexible Manufacturing System

17. Levels of Flexibility for FMS (1. Dedicated vs 2. Random-order) 2.Random-order FMS - Appropriate for large part families (large collection of parts that are grouped together) - Production schedule is subject to daily changes . - H ighly flexible system that can produce a wide variety of parts in a random sequence . - Ideal for situations with high part variation and fluctuating production schedules .  - It uses general-purpose machines , a sophisticated computer control system, and processes parts in a non-fixed , random order to accommodate new part designs and frequent schedule changes .  Source: Student Mechanica : Flexible Manufacturing System

18. Levels of Flexibility for FMS (1. Dedicated vs 2. Random-order) Source: Student Mechanica : Flexible Manufacturing System

19. Five Types of FMS Layouts 1.In‑line 2.Loop 3.Ladder 4.Open field 5.Robot‑centered

20. In‑line • Straight line flow , well-defined processing sequence similar for all work units. •Work flow is from left to right through the same workstations. Source: Student Mechanica : Flexible Manufacturing System

21. Loop • One direction flow , but variations in processing sequence possible for different part types Source: Student Mechanica : Flexible Manufacturing System FMS Rectangular Layout

22. Ladder •Loop with rungs to allow greater variation in processing sequence. Instead of automatically moving from one item to the next, the "loop" transitions from one step to the next only when a specific condition is met . Non-linear flow:  The path through the loop is not fixed . Based on different conditions, the program can branch to different steps , skip steps , or repeat certain sequences. Source: Student Mechanica : Flexible Manufacturing System

23. Open field • Multiple loops and ladders, suitable for large part families . i t consists of multiple , interconnected material handling loops that link different workstations . t he network of paths allows for complex part routing . provides the greatest variation in processing sequences and allows parts to be sent to any machine in almost any order. this means that parts are not limited to a single, rigid sequence of operations. advanced , distributed computer control system is required to coordinate the activities of all components.

24. Open field Source: Student Mechanica : Flexible Manufacturing System

25. Robot- Centered •Suited to the handling of rotational parts and turning operations Source: Student Mechanica : Flexible Manufacturing System

26. The Challenges: High Costs & Complexity High Initial Investment:   Machinery , software , setup . Complexity:  Requires intricate planning , design , and integration . High Maintenance & Skilled Labour Need . Risk Aversion:  Many companies hesitate to operate outside established parameters (they want similar/stable/manufacture-able products)

27. Advanced Challenges - Multi-product scenarios risk  cross-contamination  (due to frequent changeovers , shared equipment , and multi-product operations that define their flexibility). -P roduction bottlenecks where a component or process that limits the overall production rate. Unlike traditional assembly lines where bottlenecks are often static, an FMS is more susceptible to  dynamic bottlenecks that shift depending on the specific mix of products , processing requirements , and routing decisions .

28. Solutions from Practitioners Segregation Strategy:   - Define and validate system closure (end) from the start. A segregation strategy involves  physically separating or isolating materials , products , or processes to prevent cross-contamination, ensure product quality and safety, and improve efficiency . -The specific strategies depend on the industry and potential hazards , such as chemical incompatibility, quality defects, or allergen cross-contact.  Process Modelling:   Simulate manufacturing to maintain efficiency during high traffic.

29. Solutions from Practitioners Integrated Interface Points:  Manage operational boundaries across different processes. Integrated Interface Points are specific junctures where different processes, teams, or systems interact, and managing them involves defining and controlling the operational boundaries at these points. Effective management is crucial for ensuring seamless and coordinated operations and preventing costly misalignment . 

30. The Human Factor & The Future Skilled Workforce Gap:  Targeted training for start-up and maintenance is essential. The MNC Advantage:  Using AI and robotics for "capability failover" – if one machine breaks down, another adapts. The Future:  Leveraging IoT , robotics, and cyber-connectivity (Industry 4.0) for a fully automated platform. Cloud manufacturing is  an advanced manufacturing model that applies cloud computing principles to integrate and share manufacturing resources, software, and services over the internet .

31. Key Takeaways & Conclusion No One-Size-Fits-All:  FMS implementation varies by company type (MNCs vs. local LM Companies). Holistic Strategy is Key:  Must address technical and human resource challenges . MNCs Lead the Way :  Best positioned to implement and extend FMS with advanced technology. Medium Sized Companies Face Higher Hurdles :  Costs, complexity, and skilled labour needs are major barriers due to limited resources.

32. Key Takeaways & Conclusion 5.FMS implementation is a strategic journey , not just a technical upgrade. 6. FMS contributes to SDG 8: Decent Work and Economic Growth: FMS can increase productivity, competitiveness, and create higher-skilled jobs. SDG 9: Industry, Innovation and Infrastructure: FMS is integral to sustainable industrialization, improving resilience and resource efficiency. SDG 12: Responsible Consumption and Production: By optimizing resource use, FMS reduces waste and environmental impact. SDG 17: Partnership for the Goals: FMS strengthening global cooperation on technology, innovation, and sustainable practices

33. SDGs Content Here Content Here Content Here Content Here Google “BC Chew Slideshare ”, thank you .