Post on 06-Jul-2018
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MODELING AND ANALYSIS OF
MANUFACTURING SYSTEMS
Session 13
MATERIAL HANDLING
SYSTEMS
E. Gutierrez-MiraveteSpring !!"
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MATERIAL HANDLING
SYSTEM TAS#S• DISTRI$UTE %ITAL MATERIALS TO
THE &LANT'S CELLS
• IM&LEMENT FLO( &ATHS &LANNED
IN THE FACILITY LAYOUT
• CONTROL THE FLO( OF &ARTS)
TOOLS AND (ASTES (ITHIN AND$ET(EEN DE&ARTMENTS
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MHS DESIGN GOALS
• TO CONTRI$UTE TO THE
EFFECTI%ENESS AND
EFFICIENCY OF THE &LANT
• USUALLY) LESS IS $ETTER
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MHS FEATURES
• CORRECT &RODUCT *(HAT+
• LOCATION *(HERE+
• TIMING *(HEN+
• METHOD *(HO , HO(+
•CONDITION *HO(+
• ORIENTATION *HO(+
• UANTITY *HO( MUCH+
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UESTIONS
• (HAT IS &OINT OF USE STORAGE
• (HAT IS A UNIT LOAD
• (HY IS NOT AL(AYS TRUE THAT
LESS IS $ETTER
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MHS EUI&MENT TY&ES
• CON%EYORS *Fig. /.0+
• CRANES AND HOISTS
• AUTOMATED STORAGE1RETRIE%AL
SYSTEMS *AS1RS+ *F/.2+
• INDUSTRIAL TRUC#S
• AUTOMATED GUIDED %EHICLES
*AG%+
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MHS OTHER COM&ONENTS
• CONTAINERS
• RO$OTS
• $AR CODES
• RADIO FREUENCY SYSTEMS
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MHS &RINCI&LES
".- ORIENTATION
.- &LANNING
0.- SYSTEMS
2.- UNIT LOAD
3.- S&ACE USE
4.- STANDARDI5E6.- ERGONOMIC
7.- ENERGY
/.-ECOLOGY
"!.- MECHANI5E
"".- FLE8I$ILITY
".- SIM&LIFY
"0.-GRA%ITY
"2.- SAFETY"3.- COM&UTERI5E
"4.- SYSTEM FLO(
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MHS &RINCI&LES
"6.- LAYOUT
"7.- COST
"/.- MAINTENANCE!.- O$SOLESCENCE
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EUI&MENT SELECTION
• NUM$ER OF EUI&MENT TY&ES
A%AILA$LE *M+
•NUM$ER OF &RODUCT MO%ES&LANNED *N+
• EUI&MENT i MA#ES MO%E 9
• ASSUME THAT THE FREUENCYAND DISTANCE FOR EACH MO%E
ARE ALREADY #NO(N
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EUI&MENT SELECTION
• %ARIA$LE COST &ER &ERIOD :i9
• FI8ED COST &ER UNIT-&ERIOD Ci
• TIME &ER MO%E ti9
• A%AILA$LE TIME &ER UNIT-&ERIOD Ti
• NUM$ER OF UNITS OF EUI&MENT i
ACUIRED Yi
• DECISION %ARIA$LES 8i9
• See E;. /.") p. /6
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DECISION MODEL
• MINIMI5E *:
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T(O #EY FEATURES OF
MODERNS MHS
• FLE8I$ILITY• MODULARITY
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$UL# LOAD RECEI%AL
• NUM$ER OF LOADS1ARRI%AL *+
• LOAD ARRI%AL RATE *λ
+
• LOAD SER%ICING RATE *µ
+• A%ERAGE NUM$ER OF LOADS
(AITING TO $E SER%ICED *L+
• A%ERAGE TIME $ET(EEN LOADARRI%AL AND SER%ICE
COM&LETION *W +
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$UL# LOAD RECEI%AL
• (ITH A SINGLE SER%ER AND
&OISSON ARRI%ALS) SYSTEM
$EHA%ES AS AN M1M1"1inBUEUE
• En. /.0• E;. /.3
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CON%EYOR ANALYSIS
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CON%EYOR DESIGN GOAL
• TO &RO%IDE THE DESIRED
LE%ELS OF &ERFORMANCE IN
THE INTENDED EN%IRONMENT
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DECISION %ARIA$LES
• S&EED
•
LENGTH• CARRIER S&ACING
• CARRIER CA&ACITY
• NUM$ER OF LOAD AND
UNLOAD STATIONS
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CLOSED LOO&
CON%EYORS• RE%OL%E AT CONSTANT S&EED
ALONG A FI8ED &ATH (ITH
&ART CARRIERS EUALLY
S&ACED ALONG THE
CON%EYOR LENGTH
• See Fig. /.3 E;. /.4
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CLOSED LOO& CON%EYOR
ANALYSIS• NUM$ER OF LOADING STATIONS *MC+
• NUM$ER OF UNLOADING STATIONS
*Mu+
• NUM$ER OF (OR#STATIONS *MI+
• CON%EYOR %ELOCITY *v+
• NUM$ER OF CARRIERS *N+
• NUM$ER OF &ARTS1CARRIER *:+
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CON%EYOR
LOAD1UNLOAD CA&ACITY• UNITS ARRI%E AT A SINGLE
LOADING STATION (ITH
FREUENCYλ
DETERMINISTIC)
• EACH CARRIER HOLDS ONE UNIT
• CARRIERS ARE A DISTANCE >
A&ART ON CON%EYOR
• UNLOADING FREUENCYµ
IS
ALSO DETERMINISTIC
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UESTIONS
• (HAT HA&&ENS IF UNITS ARRI%E
FASTER THAN THEY CAN $E
LOADED
• (HAT HA&&ENS THE FIRST TIME A
UNIT &ASSES AN IDLE UNLOAD
STATION
• (HAT HA&&ENS IF ALL UNLOADING
STATIONS ARE $USY *$LOC#ING+
• E;. /.4) p. 0!2
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CRITERIA
• FOR $LOC#ING
J λ >1v K "
• FOR SUCCESSFUL HANDLING OF
CON%EYOR TRAFFIC THROUGH
UNLOADING
Mu µ K λ1J
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CARRIER CA&ACITY
SETTING• ASSUME %OLUME AND TIMING OF
LOAD1UNLOAD REUEST ARE
#NO(N• AMOUNT OF MATERIAL LOADED
ONTO THE 9-t CARRIER ON
&ASSING STATION i *B i*9++• LOAD1UNLOAD &ERIOD *p+
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CARRIER CA&ACITY
• FOR CON%EYOR STA$ILITY O%ER
THE CYCLE p NEED
• LOADING UNLOADING
Σi Σ 9 B i*9+ !
•See Fig. /.4 E;. /.6
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&ATH FLE8I$ILITY
• CON%EYORS FI8ED &ATH
• MANNED TRUC#S FLE8I$LE &ATH
• AG%'S SEMI-FLE8I$LE &ATH
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AUTOMATED GUIDED
%EHICLES• USEFUL FOR THE SU&&ORT OF
ASYNCHRONOUS ASSEM$LY
• CAN &RO%IDE CONTROL IN
ADDITION TO TRANS&ORT
• CAN FUNCTION TO &IC# U& AND
DRO& OFF LOADS ONLY
• CAN FUNCTION AS MO$ILE &ART
FI8TURES
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UESTIONS
• HO( ARE AG%S CONTROLLED
– CENTRAL COM&UTER , LOCAL
CONTROLLERS
• HO( DO AG%'S NA%IGATE
– INDUCTI%E GUIDE&ATHS
– OTHER SYSTEMS
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AG%S FOR &IC# U&1DRO&
OFF EN%IRONMENT• DESIGN ISSUES
– NUM$ER OF &IC# U& &OINTS *&+
– NUM$ER OF DRO& OFF &OINTS *D+
– &ATH CONNECTING & AND D
• O&ERATIONAL ISSUES
– NUM$ER OF %EHICLES IN SYSTEM
– ROUTES THE %EHICLES TA#E
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AG% SYSTEM DESIGN
ISSUES• LOCATION OF & AND D
• GUIDE &ATH AND FACILITY
LAYOUT
• DECISION &RO$LEM FIND SET OF
ARCS CONNECTING & AND D THAT
MINIMI5E LOADED TRA%EL
• See Fig. /.6 Tae /.0
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&ATH DESIGN RULES
".- TRA%EL SHOULD $E
UNIDIRECTIONAL UNLESS TRAFFIC
IS %ERY LIGHT *(HY+
.- &IC#U& STATIONS SHOULD $E
DO(NSTREAM OF DRO&-OFF
STATIONS *(HY+
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&ATH DESIGN RULES
0.- FOR EACH &IC#U& &OINT ALONG A
SEGMENT) TOTAL DRO&-OFFS FROM
THE START OF THE SEGMENT TO
THIS &IC#U& SHOULD $E AT LEAST
AS LARGE AS TOTAL &IC#U&S TO
THIS &OINT IN THE SEGMENT
*(HY+
2.- LOCATE & AND D ON LO( USAGE
SEGMENTS *(HY+
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&ATH DESIGN RULES
3.- IF EM&TY %EHICLES ENTER AND
STO& ON A SEGMENT TO &IC# U&)
THEN NO %EHICLES SHOULDLEA%E THE SEGMENT EM&TY
AFTER DRO&&ING A LOAD IN THE
SEGMENT4.- $Y&ASSES AND SHORTCUTS MAY
$E CONSIDERED
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&ATH DESIGN
• MATERIAL HANDLING &ATHS *See
E; /.7+
• TANDEM A&&ROACH *See Fig /.7+
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%EHICLE REUIREMENTS
• HO( MANY %EHICLES ARE NEEDED
TO &ERFORM HANDLING
• %EHICLE UTILI5ATION TIME – LOADED TRA%EL TIME
– UNLOADED TRA%EL TIME
– $LOC#ED TIME – LOAD TIME
– UNLOAD TIME
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%EHICLE REUIREMENTS
• FINDING LOADING) UNLOADING
AND LOADED TRA%EL %EHICLE
TIME *See E;. /./+• HO( A$OUT EM&TY TRA%EL TIME
– TRANS&ORTATION MODELING *E. /.6+
– See E;. /."! *O+
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%EHICLE REUIREMENTS
• (HAT A$OUT $LOC#ING
– DI%IDE &ATH INTO 5ONES
– &RE%ENT T(O %EHICLES FROM
$EING IN SAME 5ONE
– See E;. /."" *O+
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AG% O&ERATION
• &IC#U& AND DELI%ERY DEMANDS
MUST $E MET AT EACH & AND D
• T(O CASES
– STATIC SITUATION *CONSTANT
DEMAND RATE FOR &IC#U& AND
DELI%ERY+ – DYNAMIC SITUATION
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STATIC FLO( O&ERATION
• ROUTES SHOULD $E SELECTED SO
THAT THEY RE&EAT
CONTINUOUSLY SATISFYING THES&ECIFIED DEMANDS
• (HAT IS A CYCLE *p. 0"7+
• See E;. /."
• See Tae /.3a T/.3) T/.4
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DYNAMIC FLO(
• &RIORITI5E &IC#U&S $ASED ON
– FCFS (OR#STATION REUESTS
– NUM$ER OF REMAINING S&ACESA%AILA$LE IN OUT&UT UEUE
• CYCLES MAY $E USED *@O$ SHO&+
• IM&LEMENT DEMAND DRI%ENMO%E &RIORITIES *@IT+
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&ALLET SI5E AND
LOADING