Imagine this: You’ve got a manufacturing line running at full speed, cranking out products to meet demand. Then, a sudden shift — maybe a last-minute design change or a surge in orders — throws everything off balance. Machines sit idle, deadlines get pushed, and efficiency takes a hit.
When production is rigid, even minor disruptions can throw everything off course. But what if your system could adapt on the fly?
A flexible manufacturing system (FMS) makes that possible. It allows you to pivot quickly and keep manufacturing operations running smoothly in spite of outside influences.
Let’s dive into what makes an FMS so powerful and how businesses use it to stay agile in a fast-moving market.
Flexible manufacturing system: An overview
Flexible manufacturing is a strategy that allows manufacturers to adapt to changes in real time. Rather than relying on fixed setups that struggle with demand fluctuations or product variations, an FMS combines automation, robotics, and computerized control to keep production lines running efficiently — no matter what comes their way.
Core components of a flexible manufacturing system
An FMS is about how all the parts work together to create a smooth, efficient, cost-effective process. Here are the core components that make it happen:
- Smart machines and robotics: Computer numerical control (CNC) machines, robots, and automated assembly systems are the backbone of an FMS. These machines are programmed to adjust on the go, making quick changeovers between different production processes without wasting time.
- Material handling system: Think of this as the factory’s circulatory system. Conveyors and automated guided vehicles (AGVs) move raw materials and finished goods across the factory floor, ensuring every machine gets what it needs, when it needs it.
- Computerized control systems: A computer system oversees every aspect of the manufacturing process, from scheduling and inventory management to quality control and real-time adjustments. If something needs tweaking, the system responds instantly.
- Human expertise: Even with automation in manufacturing, people still play a crucial role. Operators and engineers monitor, troubleshoot, and optimize the system so efficiency and quality stay on point.
Types of flexible manufacturing systems
Not all FMSs work the same way. Depending on what a company produces and how often demand shifts, different FMS setups can make or break efficiency. Here’s a breakdown of the five main types of FMS and how they help manufacturers stay competitive.
1. Sequential FMS
A sequential FMS follows a predefined sequence, producing one type of product before switching to another. Imagine a custom furniture factory — it produces one model of chair, then adjusts machinery to make another model based on a planned schedule.
Why it’s useful:
- Smooth transitions between different product types
- Efficient for predictable demand
- Reduces downtime by automating changeovers
Best for:
- Manufacturers with a structured production schedule (like furniture and home appliances)
Potential drawback:
- Less flexibility for unexpected demand changes
2. Random FMS
If your business frequently shifts between different product configurations, a random FMS is a helpful option. Unlike a sequential system, this FMS allows machines to switch between product types at any time rather than following a strict order.
Think of a high-tech electronics factory producing smartphones, tablets, and wearables — each with unique specs. Automated robots and computer-controlled systems manage the production flow, so changeover is efficient without stopping the assembly line.
Why it’s useful:
- Handles multiple product types at once
- Responds quickly to demand changes
- Reduces waste by optimizing material handling systems
Best for:
- Industries that produce a wide range of products (like consumer electronics and automotive parts)
Potential drawback:
- Requires high automation investment to manage complexity
3. Dedicated FMS
A dedicated FMS is designed for long-term, high-volume production of a limited set of products. Instead of frequently switching product types, this system produces a specific set of parts or items consistently.
A great example is medical device manufacturing. For a company that produces the same model of syringes, implants, or surgical tools every day, robots and CNC machines work together to ensure precise, large-scale production.
Why it’s useful:
- Maximizes production efficiency
- Reduces manufacturing costs through automation
- Ideal for industries with stable demand
Best for:
- Factories that produce a fixed range of products at high volume (like medical supplies and industrial tools)
Potential drawback:
- Limited ability to adapt to sudden market changes
4. Engineered FMS
An engineered FMS is custom-built to manufacture highly specialized parts. Unlike other systems, it doesn’t switch between different product types — it’s designed to continuously produce a specific component with extreme precision.
Think about aerospace companies that manufacture jet engine parts or satellite components. These parts require CNC machines, automated inspection, and precise material handling to meet strict quality standards.
Why it’s useful:
- Delivers consistent, high-quality output
- Optimized for precision-based manufacturing
- Reduces the risk of errors through automated control systems
Best for:
- Industries requiring specialized, high-precision production (like aerospace and semiconductor manufacturing)
Potential drawback:
- Not ideal for businesses that need frequent product changes
5. Modular FMS
A modular FMS is the most adaptable of all systems. It allows manufacturers to switch between sequential, random, dedicated, or engineered modes based on production needs.
One example is a car manufacturing plant that needs to produce different vehicle models and varying engine types based on market demand. A modular FMS uses advanced automation and AI-driven scheduling to make these transitions seamless.
Why it’s useful:
- Balances efficiency and flexibility
- Supports quick changeovers between product types
- Scales up or down depending on market demand
Best for:
- Businesses needing a mix of efficiency and adaptability (like consumer goods and machinery production)
Potential drawback:
- Requires high investment in automation and software
Benefits of a flexible manufacturing system
Whether demand spikes unexpectedly or a new product needs to hit the market fast, an FMS keeps manufacturers efficient and competitive. Here’s how.
Increased efficiency and productivity
Traditional manufacturing lines can be rigid and time-consuming, especially when switching between different products. An FMS streamlines the process with automation and computerized control, allowing for quick changeovers and minimal downtime.
Quick adaptation to market demand
Markets are unpredictable. One day, a product is flying off the shelves, and the next, sales slow down. A flexible production setup lets manufacturers scale up, scale down, or introduce new variations without significant disruptions. With an FMS, manufacturers can pivot quickly and keep customers happy, even in ever-changing conditions.
Lower operational costs
Setting up an FMS requires an investment, but the payoff is worth it. Here’s why:
- Fewer manual tasks: Automation takes over repetitive work, reducing labor costs.
- Less waste: Smarter material handling systems mean fewer mistakes and lower scrap rates.
- Better machine utilization: Computer-controlled production lines ensure equipment runs efficiently, reducing unnecessary downtime and maintenance costs.
Improved quality and consistency
Human error is inevitable. An FMS lessens these mistakes and helps every product meet high-quality standards. Unlike manual systems, which can be prone to errors, an FMS maintains consistency and reliability across production runs. This leads to better product quality and higher customer satisfaction.
Challenges of a flexible manufacturing system
The FMS process improves efficiency and adapts to changes, but it also has challenges. High costs, complex implementation, and the need for a skilled workforce make adoption difficult.
High initial costs
Setting up an FMS requires a significant investment in automated machinery, robotics, and computer-controlled systems. While the system pays off in the long run, the upfront costs are a major barrier — especially for small and mid-sized manufacturers.
Complex implementation and maintenance
Unlike traditional production lines, an FMS depends on computerized controls and automated workflows. Setting up these systems takes time, and once in place, regular maintenance and software updates are necessary to avoid costly downtime.
Skilled workforce requirements
An FMS process minimizes manual labor but requires highly trained engineers and technicians to manage automation, troubleshoot issues, and optimize production. Without the right talent, companies may struggle to fully benefit from the system’s capabilities.
Limited flexibility in some areas
While an FMS improves flexible production, some setups — like a dedicated FMS — are less adaptable. Switching between products still requires planning, and sudden shifts in market demand may slow down production instead of speeding it up.
Flexible manufacturing system examples
Many leading manufacturers rely on the FMS process to keep up with demand and stay ahead of the competition. Here are a few examples of companies using FMSs to make their operations more efficient and adaptable.
Toyota: Lean manufacturing and flexibility
Toyota has mastered the art of flexible manufacturing with its lean production system. By designing assembly lines that can quickly switch between different car models, Toyota reduces downtime and keeps up with changing consumer demands. This adaptability has helped Toyota maintain high production efficiency while keeping costs low.
LEGO: Automation enhancing productivity
Building toys might not seem complex, but LEGO has hundreds of thousands of pieces and variations to manufacture. It streamlined the process with automation and robotics, using machines to handle almost every step.
Streamline your flexible manufacturing system with Fishbowl
An FMS thrives on efficiency, but managing inventory and production schedules manually can slow you down. Fishbowl automates it all — seamlessly integrating with QuickBooks to track orders, update inventory in real time, and optimize production scheduling.
Stay ahead of demand and keep your operations running smoothly with Fishbowl. Book a demo today and see how Fishbowl can transform your manufacturing process.