Challenges and Opportunities in the Adoption of Flexible Manufacturing Systems in Indian Manufacturing Industries

The manufacturing sector is increasingly adopting automation technologies to enhance productivity and flexibility. Among these technologies, Flexible Manufacturing Systems (FMS) offer substantial benefits, such as reduced lead times, improved production flexibility, and lowered operational costs. Despite its advantages, FMS adoption in Indian manufacturing industries has been slow due to several barriers, including high capital costs, technological complexity, and inadequate government support. This study investigates the current status of FMS adoption in India, identifies the key barriers hindering its implementation, and proposes a decision-making model to facilitate its wider adoption. The research gap highlights the lack of a comprehensive framework to quantify the barriers and assess the performance of FMS adoption. To address this, a two-phase Analytic Hierarchy Process (AHP) and Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) methodology was used. This approach allowed for the classification and prioritization of barriers, as well as the development of a model for FMS selection based on statistical analysis. A case study was conducted using this methodology to evaluate various FMS models and provide a systematic decision-making framework for manufacturers. The results revealed that the most significant barriers to FMS adoption in India include high upfront costs, insufficient infrastructure, and the challenges posed by rapidly advancing FMS technology. By applying the AHP-TOPSIS approach, this study offers insights into overcoming these barriers and presents actionable recommendations for manufacturers and policymakers. The findings emphasize the need for increased government support and industry collaboration to accelerate FMS adoption in India. This research contributes to the development of a structured decision-making framework, which could help manufacturers implement FMS more effectively, thereby enhancing competitiveness in an increasingly dynamic global market.