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Lecture 9 and 10

The document discusses material handling and describes it as the movement, storage, protection and control of materials throughout the manufacturing and distribution process. It states that material handling accounts for 25% of factory employees, 55% of factory space, and 87% of production time. The goal of material handling is the least cost delivery of undamaged material in a timely manner. The document also outlines various types of material handling equipment and considerations for designing material handling systems.

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Philani Xaba
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
27 views

Lecture 9 and 10

The document discusses material handling and describes it as the movement, storage, protection and control of materials throughout the manufacturing and distribution process. It states that material handling accounts for 25% of factory employees, 55% of factory space, and 87% of production time. The goal of material handling is the least cost delivery of undamaged material in a timely manner. The document also outlines various types of material handling equipment and considerations for designing material handling systems.

Uploaded by

Philani Xaba
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Material Handling Technologies

Material Transport Systems

Storage Systems
Material Handling Systems

“The movement, storage, protection and control of materials


throughout the manufacturing and distribution process including
their consumption and disposal”

• Estimated to represent 20-25% of total manufacturing labor cost


• The proportion varies depending on type of production and degree of automation

• Material Handling accounts for:


– 25% of all employees,
– 55% of all factory space,
– 87% of production time

• 3-5% of all material handled becomes damaged


Material Handling

 Handling of materials must be performed


 Safely
 Efficiently
 At low cost
 In a timely manner
 Accurately (the right materials in the right quantities to the right
locations)
 And without damage to the materials

 Material handling is a means by which:


 Total manufacturing costs are reduced through
 Reduced inventory
 Improved safety
 Improved material control.
 Manufacturing quality is improved by:
 Reducing damage
Material Handling Overview

 Concept
 Best Material Handling is No Material Handling
 Except for Delivery to Customer, Material Handling Adds No Value to
Product

 Can be 10 to 80% of Cost of Product

 Goal
 Least Cost Delivery of Undamaged Material in a Timely
Manner
Material Handling Overview

 On Machines/Equipment
 Transfer devices, Setup and Part Positioning etc.

 Within and/or Between Cells/Machines


 Fixed Path (Conveyors, Robots*)

 Variable Path (AGVs, Forktrucks)

 Hoists/Assists

 Between Floor and Storage (WIP, Finished)


 Location Information, Status, and Control
Material Handling and Storage Principles

 Orientation Principle:  Facilitate Next Operation

 Planning Principle:  Establish Plan, Contingencies

 Systems Principle:  Integrate into Rational System

 Unit Load Principle: Always transport the Largest Load Possible

 Space Utilization Principle:  Use All (Cubic) Space


 Standardization Principle:  Maximize Similarity of Solutions
 Ergonomic Principle:  Make Human Compatible (Specialist Fixtures
and Product Support)

 Energy Principle:  Minimize Energy (Potential/Kinetic)


Material Handling and Storage Principles

 Mechanization Principle:  Mechanize Wherever Possible

 Flexibility:  Use Equipment Across Part Families

 Simplification Principle:  Eliminate/Simplify/Reduce


 Gravity Principle:  Use Gravity (Cheap!) Whenever Possible

 Safety Principle:  Meet Codes

 Computerization Principle:  Use Automation Wherever Applicable

 System Flow Principle:  Integrate Data and Material Flow


Material Handling and Storage Principles

 Layout Principle:  Synchronize Processing and Layout

 Cost Principle:  Investigate Alternatives

 Maintenance Principle:  Ability/Cost to Service and Maintain

 Obsolescence Principle:  Long Range Life Cycle Plan


Material Handling Equipment

1. Material transport equipment - to move materials inside a factory, warehouse,


or other facility
2. Storage - to store materials and provide access to those materials when required
3. Unitizing equipment - refers to (1) containers to hold materials and (2)
equipment used to load and package the containers
4. Identification and tracking systems - to identify and keep track of the
materials being moved and stored

Design Considerations in Material Handling


• Material characteristics
• Flow rate, routing, and scheduling
• Plant layout
• Unit load principle
Flow Rate, Routing, and Scheduling

• Flow rate - amount of material moved per unit time


• Whether the material must be moved in individual units, as batches, or
continuously
• Routing - pick-up and drop-off locations, move distances, routing
variations, conditions along the route
• Scheduling - timing of each delivery
• Prompt delivery when required
• Use of buffer stocks to mitigate against late deliveries
Unit Load Principle
In general, the unit load should be as large as practical for the material handling system
that will move and store it
 A unit load is the mass that is to be moved or otherwise handled at one time

 Reasons for using unit loads in material handling:


 Multiple items handled simultaneously
 Required number of trips is reduced
 Loading/unloading times are reduced
 Product damage is decreased
Material Transport Equipment
Five categories:
1. Industrial trucks
2. Automated guided vehicles
3. Monorails and other rail guided vehicles
4. Conveyors
5. Cranes and hoists

Industrial Trucks
Two basic categories:
1. Non-powered
• Human workers push or pull loads
2. Powered
• Self-propelled, guided or driven by human
• Common example: forklift truck
Powered Trucks
 Widely used in factories and warehouses because pallet loads are so common
 Capacities from 450 kg (1000 lb) up to 4500 kg (10,000 lb)
 Power sources include on-board batteries and internal combustion motors

 Designed to pull one or more trailing


carts in factories and warehouses, as
well as for airport baggage handling
 Powered by on-board batteries or IC
engines
Automated Guided Vehicles
An Automated Guided Vehicle System (AGVS) is a material handling system
that uses independently operated, self-propelled vehicles guided along
defined pathways in the facility floor
 Types of AGV:
 Driverless trains
 Pallet trucks
 Unit load AGVs

 First type of AGVS introduced around 1954


 Common application is moving heavy payloads over long distances in warehouses
and factories without intermediate stops along the route
Automated Guided Vehicles
Pallet Truck
 Used to move palletized loads along
predetermined routes
 Vehicle is backed into loaded pallet by
worker; pallet is then elevated from floor
 Worker drives pallet truck to AGV guide
path and programs destination

Unit Load Carrier


 Used to move unit loads from station to
station
 Often equipped for automatic
loading/unloading of pallets and tote pans
using roller conveyors, moving belts, or
mechanized lift platforms
AGVS Applications
1. Driverless train operations - movement of large quantities of material over long distances
2. Storage and distribution - movement of pallet loads between shipping/receiving docks
and storage racks
3. Assembly line operations - movement of car bodies and major subassemblies (motors)
through the assembly stations
4. Flexible manufacturing systems - movement of work-parts between machine tools

Vehicle Guidance Technology


• Method by which AGVS pathways are defined and
vehicles are controlled to follow the pathways
• Guide wires - guide wires in the floor emit
electromagnetic signal that the vehicles follow
• Paint strips - optical sensors on-board vehicles track
the white paint strips
• Self-guided vehicles - vehicles use a combination of
• Dead reckoning - vehicle counts wheel turns in
given direction to move without guidance
• Beacons located throughout facility - vehicle
uses triangulation to compute locations
Vehicle Management
Two aspects of vehicle management:
 Traffic control - to minimize interference between vehicles and prevent collisions
1. Forward sensing
2. Zone control
 Vehicle dispatching
1. On-board control panel
2. Remote call stations (Distributed Framework)
3. Central computer control

Zone Control
Analysis of Material Transport Systems

 Analysis of vehicle-based systems


 From-to charts and network diagrams
 Types of systems: industrial trucks, AGVS,

Modeling
𝐿𝐿𝑑𝑑 𝐿𝐿𝑒𝑒
• 𝑇𝑇𝑐𝑐 = 𝑇𝑇𝐿𝐿 + + 𝑇𝑇𝑈𝑈 + (min/del)
𝑣𝑣𝑐𝑐 𝑣𝑣𝑐𝑐

• 𝐴𝐴𝐴𝐴 = 60𝐴𝐴𝐹𝐹𝑡𝑡 𝐸𝐸𝑤𝑤 (Available time per vehicle)


𝐴𝐴𝐴𝐴
• 𝑅𝑅𝑑𝑑𝑑𝑑 = (Hourly delivery rate per vehicle)
𝑇𝑇𝑐𝑐
• 𝑊𝑊𝑊𝑊 = 𝑅𝑅𝑓𝑓 𝑇𝑇𝑐𝑐 (Workload required by the system, 𝑅𝑅𝑓𝑓 =required flow
rate (del/hr))
𝑊𝑊𝑊𝑊 𝑅𝑅𝑓𝑓
• 𝑛𝑛𝑐𝑐 = = (Number of vehicles required)
𝐴𝐴𝐴𝐴 𝑅𝑅𝑑𝑑𝑑𝑑
Network Diagram Showing Deliveries between Load/Unload Stations

Loads per
hour/distance
between nodes
Eg.
9 loads per
hour/50 metres

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