Material handling automation and warehouse execution systems
- Material Handling Systems
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Transcript of - Material Handling Systems
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Material Handling Systems
Forexploiting productivity potential in logistics
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Material Handling
Material handling is the function ofmoving the right material to the right
place in the right time, in the rightamount, in sequence, and in the rightcondition to minimize production cost.
The cost of MH estimates 20-25 of totalmanufacturing labor cost in the UnitedStates [The Material Handling Industry of America (MHIA)]
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Goals of Material Handling
The primary goal is to reduce unit costsof production
Maintain or improve product quality, reduce damage ofmaterials
Promote safety and improve working conditions
Promote productivity
material should flow in a straight line
use gravity! It is free power
move more material at one time
mechanize material handling
automate material handling
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Material Handling
Lifting/Lowering
Pushing/Pulling
Carrying Weights and Forces
Frequency of Activities
Load Center of Gravity
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Job Risk Factors
Weight of the Object
Location (position of load
w.r.t. worker) Frequency of Lifts
Stability of the Load
Hand Coupling Workplace Geometry
Twisting/Stooping
Environmental Factors
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Personal Risk Factors
Gender
Age
Lift technique Attitude
Strength
Training
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Calculator for Analyzing Lifting Operations
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Considerations in Material
Handling System Design1. Material Characteristics
Category Measures
Physical state
Size
Weight
ShapeCondition
Safety risk and risk ofdamage
Solid, liquid, or gas
Volume; length, width, height
Weight per piece, weight per unit
volumeLong and flat, round, square, etc.
Hot, cold, wet, etc.
Explosive, flammable, toxic; fragile,
etc.
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Considerations cont.
2. Flow rate
Manual handling
Hand trucks
Powered trucks
Unit load AGV
Conveyors Conveyors
AGV trainHigh
Low
LongShort Move Distance
Quantity of
material
moved
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Considerations cont.
3. Plant LayoutLayout Type Characteristics Typical MH Equipment
Fixedposition
Process
Product
Large product size, lowproduction rate
Variation in product andprocessing, low and medium
production rates
Limited product variety, highproduction rate
Cranes, hoists, industrialtrucks
Hand trucks, forklift trucks,AGVs
Conveyors for product flow,trucks to deliver componentsto stations.
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Manual
Mechanical
Semi-automatic
Automatic
Information guides
Material Handling Systems
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Volumes to be handled
Speed in handlingProductivityProduct characteristics
(weight, size, shape)
Nature of the product(hazardous, perishable, crushable)
Selection Criteria:Material Handling Systems
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Material Handling
Manual TrolleyVersatileFor smaller loadsFor short distance
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Material Handling
ForkliftManual or mechanizedPortableLarge distance travelMedium & large loads handlingVertical movement
Intermittent duty
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Material Handling
Overhead CraneCarry heavy loads
Continuous dutySize shape no bar
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Material Handling
Material handlingat sea ports
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Advanced MaterialHandling Systems
Pneumatic tube systemFor handling material in powered form
Semi-automatic system
Sorting devicesRobotics
Automatic guided vehicle systemMaterial handling on a fixed path
computer operated guided vehicleSpeed of operation 150-250 feet per minute
Automatic systemHuman factor eliminated
Operator required for to programming and controls
Productivity
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Standard equipment should be preferred to keep low capitalinvestments
Equipment designed for maximum continuous flow should bepreferred
Portable or movable equipment to be preferred
Ratio of dead weight to pay load should be minimum forhandling equipment
Gravity flow should be incorporated in the system design
Material Handling Guidelines
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Top 10 Principles of MaterialHandling
Principle 1. Planning Principle
All material handling should be the result of a deliberate plan where the needs,
performance objectives and functional specification of the proposed methods are
completely defined at the outset. The plan should be developed in consultation
between the planner(s) and all who will use and benefit from the equipment to be
employed.
Principle 2. Standardization Principle
Material handling methods, equipment, controls and software should be standardized
within the limits of achieving overall performance objectives and without sacrificing
needed flexibility, modularity, and throughput. Standardization means less variety
and customization in the methods and equipment employed.
Principle 3. Work Principle
Material handling work should be minimized without sacrificing productivity or the
level of service required of the operation.
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Top 10 Principles of Material Handling(cont.)
Principle 4. Ergonomic Principle
Human capabilities and limitations must be recognized and respected in the design
of material handling tasks and equipment to ensure safe and effective operations.
Ergonomics is the science that seeks to adapt work or working conditions to suit the
abilities of the worker.
Principle 5. Unit Load Principle
Unit loads shall be appropriately sized and configured in a way which achieves the
material flow and inventory objectives at each stage in the supply chain. A unit load
is one that can be stored or moved as a single entity at one time, such as pallet,
container or tote, regardless of the number of individual items that make up the
load.
Principle 6. Space Utilization Principle
Effective and efficient use must be made of all available space. Space in material
handling is three dimensional and therefore is counted as cubic space.
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Top 10 Principles of Material Handling(cont.)
Principle 7. System Principle
Material movement and storage activities should be fully integrated to form a
coordinated, operational system that spans receiving, inspection, storage,
production, assembly, packaging, unitizing, order selection, shipping, transportationand the handling of returns.
Principle 8. Automation Principle
Material handling operations should be mechanized and/or automated where feasible
to improve operational efficiency, increase responsiveness, improve consistency and
predictability, decrease operating costs, and eliminate repetitive or potentially unsafemanual labor.
Principle 9. Environmental Principle
Environmental impact and energy consumption should be considered as criteria
when designing or selecting alternative equipment and material handling systems.
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Top 10 Principles of Material Handling(cont.)
Principle 10. Life Cycle Cost Principle
A thorough economic analysis should account for the entire life cycle of all material
handling equipment and resulting system. Life cycle costs include all cash flows that
occur between the time the first dollar is spent to plan or procure a new piece ofequipment, or to put in place a new method, until that method and/or equipment is
totally replaced. Life cycle costs include capital investment, installation, setup and
equipment programming, training, system testing and acceptance, operating (labor,
utilities, etc.), maintenance and repair, reuse value, and ultimate disposal.
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Material Handling Checklist
Is the material handling equipment more than 10 years old?
Do you use a wide variety of makes and models which require a high spare parts
inventory?
Are equipment breakdowns the result of poor preventive maintenance?
Do the lift trucks go too far for servicing?
Are there excessive employee accidents due to manual handling of materials?
Are materials weighing more than 50 pounds handled manually?
Are there many handling tasks that require 2 or more employees?
Are skilled employees wasting time handling materials? Does material become congested at any point?
Is production work delayed due to poorly scheduled delivery and removal of
materials?
Is high storage space being wasted?
Are high demurrage charges experienced?
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Material Handling Checklist (cont.)
Is material being damaged during handling?
Do shop trucks operate empty more than 20% of the time?
Does the plant have an excessive number of re-handling points?
Is power equipment used on jobs that could be handled by gravity?
Are too many pieces of equipment being used because their scope of activity is
continued?
Are many handling operations unnecessary?
Are single pieces being handled where unit loads could be used?
Are floors and ramps dirty and in need of repair? Is handling equipment being overloaded?
Is there unnecessary transfer of material from one container to another?
Are inadequate storage areas hampering efficient scheduling of movement?
Is it difficult to analyze the system because there is no detailed flow chart?
Are indirect labor costs too high?