Supply Chain Management

(MS-409)

Lecture – 5

Supply Chain Management

Drivers
Logistics

Course Instructor: Dr. Ammar ul Hassan

Email Id: [email protected]

Department of Mechanical Engineering,

University of Engineering & Technology,
Taxila
 MATERIAL HANDLING AND
IDENTIFICATION TECHNOLOGIES
 Material Transport Systems
 Material Storage Systems
 Automatic Identification and Data Capture
 Material Handling Defined

“The movement, storage, protection and control of

materials throughout the manufacturing and
distribution process including their consumption
and disposal”
 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
 The cost of material handling is a significant portion of total
production cost, estimates averaging around 20-25% of
total manufacturing labor cost in the US.
 Logistics
Concerned with the procurement, movement, storage, and
distribution of materials and products as well as the planning and
control of these operations to satisfy customer demand

 Two categories of logistics:

 External logistics – transportation of Goods and Services and

related activities that occur outside of a facility.
Five traditional modes of transportation: rail, truck, air, ship, and
pipeline

 Internal logistics - material handling and storage within a facility

External Logistics
External Logistics
Internal Logistics
 Categories of
Material Handling Equipment

1. Material transport equipment - to move materials

inside a factory, warehouse, or other facility
2. Material Storage Equipment - 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
 Material Characteristics

 Material characteristics affect type of transport and storage

equipment required
 Solid, liquid or gas
 Size
 Weight
 Shape - long, flat, bulky
 Condition - hot, cold, wet, dirty
 Risk of damage - brittle
 Safety risk - explosive, flammable, toxic, corrosive
 Flow Rate, Routing, and Scheduling
 Flow rate - amount of material moved per unit time
 Examples: pieces/hr, pallet loads/hr, tons/hr
 Whether the material must be moved in individual units,
as batches, or continuously (pipe line)

 Routing - pick-up and drop-off locations, move distances,

routing variations, conditions along the route (surface, traffic,
elevation)

 Scheduling - timing of each delivery

 Quick delivery when required
 Use of buffer stocks to mitigate against late deliveries
 Plant Layout
 Material handling equipment considerations must be
included in the plant layout design problem

 Correlation between layout type and material handling

equipment:

Plant layout type Material handling equipment

Fixed-position Cranes, hoists, industrial trucks/ fork
lifters
Process Hand trucks, forklift trucks, AGVs
Product Conveyors for product flow
Trucks to deliver parts to stations
 Plant Layout

In a fixed-position layout, the project/ product remains in

one place, and workers and equipment come to that one
work area. Examples of this type of project are a ship, a
highway, a bridge, a house, and an operating table in a
hospital operating room.
Plant layout type Material handling equipment
Fixed-position Cranes, hoists, industrial trucks
 Plant Layout
In process layout, the quantity of raw material is supplied to a machine,
located anywhere in the factory, that conducts the first operation. For the
next operation, the half-processed goods are taken to another machine
for further processing, which is located in another part of the factory. In
this way, the goods travel long distances, in a twisted path. And so the
distance between the department should be less, to save time and
efforts.
Plant layout type Material handling equipment
Process Hand trucks, forklift trucks, AGVs
 Plant Layout
Product layout, otherwise called as straight line layout or flow
shop layout, is a layout design in which the resources, i.e.
workstations, tools and equipment, which are to be used in the
process of production are organized sequentially in a straight line of
production, on the basis of the sequence of operations.
Plant layout type Material handling equipment
Product Conveyors for product flow
Trucks to deliver parts to stations
 Unit Load Principle (unitizing)
 A unit load is the mass that is to be moved or otherwise
handled at one time

 In general, the unit load should be as large as practical for

the material handling system that will move and store it

 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
 Unit Load Containers

(a) Wooden pallet, (b) pallet box, (c) cart box

 Material Transport Equipment

Five categories:
1. Industrial trucks
2. Automated guided vehicles (AGVs)
3. Monorails and other rail guided vehicles
4. Cranes and hoists
5. Conveyors
 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
 Nonpowered Industrial Trucks
(Hand Trucks)

(a) Two-wheel hand truck, (b) four-wheel dolly,

(c) hand-operated low-lift pallet truck
 Powered Trucks:
Walkie Truck

 Wheeled forks insert into pallet openings

 truck is steered by worker using control handle at front of
vehicle
 Powered Trucks:
Forklift Truck
 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
engines
 Powered Trucks:
Towing Tractor

 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 (AGVs)

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
 Automated Guided Vehicles:
Driverless Automated Guided Train
 First type of AGVs to be
introduced around 1954

 Common application is
moving heavy payloads
(freight, shipment etc)
over long distances in
warehouses and factories
without intermediate
stops along the route
 Automated Guided Vehicles:
AGV 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
 Automated Guided Vehicles:
Unit Load Carrier

 Used to move unit loads from station to station

 Often equipped for automatic loading/unloading of pallets
and tote pans (carts) 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 ports 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 workparts
between machine tools
5. Miscellaneous - mail delivery and hospital supplies
 AGVs Working
 AGVs are self-propelled vehicles with movement guided by
software and sensors. Most AGVs move along defined
pathways

 AGV navigation may be guided using one or more of the

following mechanisms:

 Magnetic guide tape — some AGVs have magnetic sensors

and follow a track using magnetic tape.
 Wired navigation — some AGVs follow wire paths embedded
into the facility floor. The wire transmits a signal that AGVs
detect via an antenna or sensor.
 Vehicle Guidance Using Guide Wire

The guide wire is

connected to a
frequency generator
which emits low voltage,
low current signal, this
induces a magnetic field
along the pathway that
can be followed by
sensors on board of
each vehicle.
 AGVs Working
 Laser target navigation — with this method, reflective tape is
mounted on objects such as walls, fixed machines and poles. AGVs
are equipped with a laser transmitter and receiver. The lasers
reflect off of the tape within the line of sight and used to calculate
the object’s angle and distance from the AGV.

 Inertial (gyroscopic) navigation — some AGVs are controlled by a

computer system with the aid of transponders (device) embedded
into the facility floor to verify that the AGV is on the proper course.

 Vision guidance — No modification is required to the infrastructure

for vision-guided AGVs. Cameras record the features along the
route, and AGVs rely on these recorded features to navigate.
 AGVs Working
 LiDAR — LiDAR (Light Detection and Ranging) is a
sophisticated navigation technology utilizing sensors that
transmit laser pulses to measure the distance between the
robot and objects in its environment. This data is compiled to
create a 360-degree map of the environment, allowing robots to
navigate the facility and avoid obstacles without the need for
any additional infrastructure.
 Vehicle Management

Two aspects of vehicle management:

 Traffic control - to minimize interference between vehicles
and prevent collisions
1. Forward (on-board vehicle) sensing
2. Zone control
 Vehicle dispatching
1. On-board control panel
2. Remote call stations
3. Central computer control
 Zone Control

Zone control to implement blocking system. Zones A, B,

and D are blocked. Zone C is free. Vehicle 2 is blocked
from entering Zone A by vehicle 1. Vehicle 3 is free to
enter Zone C.
 Vehicle Safety

 Travel velocity of AGV is slower than typical walking speed of human

worker

 Automatic stopping of vehicle if it strays from guide path

 Obstacle detection system (ultrasonic sensors) in forward direction

 Emergency bumper - brakes vehicle when contact is made with forward

object

 Warning lights (blinking or rotating red lights)

 Warning sounds of approaching vehicles

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 https://www.youtube.com/watch?v=S8zDRu72HD0
Conveyor Systems
Overhead Monorail
 Conveyor Systems

Large family of material transport equipment

designed to move materials over fixed paths, usually
in large quantities or volumes
1. Non‑powered
 Materials moved by human workers or by gravity
2. Powered
 Power mechanism for transporting materials is
contained in the fixed path, using chains, belts,
rollers or other mechanical devices
 Conveyor Types

 Roller
 Skate‑wheel
 Belt
 In‑floor towline
 Overhead trolley conveyor
 Cart-on-track conveyor
 Roller Conveyor

 Pathway consists of a
series of rollers that are
perpendicular to direction
of travel
 Loads must possess a flat
bottom to span several
rollers
 Powered rollers rotate to
drive the loads forward
 Un-powered roller
conveyors also available
 Skate-Wheel Conveyor

 Similar in operation to
roller conveyor but use
skate wheels instead of
rollers
 Lighter weight and
unpowered
 Sometimes built as
portable units that can be
used for loading and
unloading truck trailers in
shipping and receiving
 Belt Conveyor

 Continuous loop with

forward path to move
loads
 Belt is made of reinforced
elastomer
 Support slider or rollers
used to support forward
loop
 Two common forms: (Support frame not shown)
 Flat belt (shown)
 V-shaped for bulk
materials
 In-Floor Tow-Line Conveyor

 Four-wheel carts powered

by moving chains or cables
in trenches in the floor
 Carts use steel pins (or
grippers) to project below
floor level and engage the
chain (or pulley) for towing
 This allows the carts to be
disengaged from towline
for loading and unloading
 Overhead Trolley Conveyor

 A trolley is a wheeled
carriage running on an
overhead track from which
loads can be suspended
 Trolleys are connected and
moved by a chain or cable
that forms a complete loop
 Often used to move parts
and assemblies between
major production areas
 Cart-On-Track Conveyor

 Carts ride on a track

above floor level
 Carts are driven by a
spinning tube
 Forward motion of
cart is controlled by a
drive wheel whose
angle can be
changed from zero
(idle) to 45 degrees
(forward)
 Powered Conveyor
Operations and Features
 Types of motions
1. Continuous - conveyor moves at constant velocity
2. Asynchronous - conveyor moves with stop-and-go
motion
 They stop at stations, move between stations
 Another classification of conveyors:
1. Single direction
2. Continuous loop
3. Recirculating
 (a) Single-Direction Conveyor and
(b) Continuous Loop Conveyor

(a) Single direction

conveyor

(b) Continuous loop

conveyor
 Cranes and Hoists

Handling devices for lifting, lowering and transporting

materials, often as heavy loads
 Cranes
 Used for horizontal movement of materials
 Hoists
 Used for vertical lifting of materials
 Cranes usually include hoists so that the crane-and-hoist
combination provides
 Horizontal transport
 Vertical lifting and lowering
 Hoist

Hoist with mechanical

advantage of four:
(a) sketch of the hoist
(b) diagram to
illustrate mechanical
advantage

(a) (b)
Bridge Crane
 Gantry Crane

A half-gantry crane
Jib Crane
 Analysis of
Material Transport Systems
 Analysis of vehicle-based systems
 From-to charts and network diagrams
 Types of systems: industrial trucks, AGVS, rail-guided
vehicles, and asynchronous conveyor operations
 Conveyor analysis
 Single-direction conveyors
 Closed loop conveyors
 Recirculating conveyor systems
Thanks
Supply Chain Management
(MS-409)

Lecture – 6

Supply Chain Management

Drivers
Logistics Problems

Course Instructor: Dr. Ammar ul Hassan

Email Id: [email protected]

Department of Mechanical Engineering,

University of Engineering & Technology,
Taxila
 Problem 1
 A network of one-way of
traffic flow in England is
shown in the figure.
 Assume that traffic must
travel in the directions as
shown.
 Find the general solution
of the network flow.
 Find the smallest value for
the x6.
 Solution
 A, B, C, D, E and F are
called nodes or junctions.

 Basic assumptions:

Total flow in = total flow out

Solution
Solution
Solution
Solution
 Problem 2
 A network of one-way
streets is shown in the
accompanying diagram.
 The rate of flow of cars
into intersection A is 500
cars per hour, and 400 and
100 cars per hour emerge
from B and C respectively.
 Find the possible flows
along each street.
 Solution
 Suppose the flows along
the streets are f1, f2, f3, f4,
f5, and f6 cars per hour in
the directions shown.

 Then, equating the flow in

with the flow out at each
intersection, we get
Solution
 Solution
 These give four equations
in the six variables f1,f2,
…,f6.
 Solution

 Impose constraints on the flows: f1 ≥ 0 and f3 ≥ 0

Thanks