8/16/2019 mams13.ppt

1/41

MODELING AND ANALYSIS OF

MANUFACTURING SYSTEMS 

Session 13

MATERIAL HANDLING

SYSTEMS

 E. Gutierrez-MiraveteSpring !!"

 

8/16/2019 mams13.ppt

2/41

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

8/16/2019 mams13.ppt

3/41

MHS DESIGN GOALS

• TO CONTRI$UTE TO THE

EFFECTI%ENESS AND

EFFICIENCY OF THE &LANT

• USUALLY) LESS IS $ETTER 

8/16/2019 mams13.ppt

4/41

MHS FEATURES

• CORRECT &RODUCT *(HAT+

• LOCATION *(HERE+

• TIMING *(HEN+

• METHOD *(HO , HO(+

•CONDITION *HO(+

• ORIENTATION *HO(+

• UANTITY *HO( MUCH+

8/16/2019 mams13.ppt

5/41

UESTIONS

• (HAT IS &OINT OF USE STORAGE

• (HAT IS A UNIT LOAD

• (HY IS NOT AL(AYS TRUE THAT

LESS IS $ETTER

8/16/2019 mams13.ppt

6/41

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%+

8/16/2019 mams13.ppt

7/41

MHS OTHER COM&ONENTS

• CONTAINERS

• RO$OTS

• $AR CODES

• RADIO FREUENCY SYSTEMS

8/16/2019 mams13.ppt

8/41

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(

8/16/2019 mams13.ppt

9/41

MHS &RINCI&LES

"6.- LAYOUT

"7.- COST

"/.- MAINTENANCE!.- O$SOLESCENCE

 

8/16/2019 mams13.ppt

10/41

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

8/16/2019 mams13.ppt

11/41

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

8/16/2019 mams13.ppt

12/41

DECISION MODEL

• MINIMI5E *:

8/16/2019 mams13.ppt

13/41

T(O #EY FEATURES OF

MODERNS MHS

• FLE8I$ILITY• MODULARITY

8/16/2019 mams13.ppt

14/41

$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 +

8/16/2019 mams13.ppt

15/41

$UL# LOAD RECEI%AL

• (ITH A SINGLE SER%ER AND

&OISSON ARRI%ALS) SYSTEM

$EHA%ES AS AN M1M1"1inBUEUE

• En. /.0• E;. /.3

8/16/2019 mams13.ppt

16/41

CON%EYOR ANALYSIS 

8/16/2019 mams13.ppt

17/41

CON%EYOR DESIGN GOAL

• TO &RO%IDE THE DESIRED

LE%ELS OF &ERFORMANCE IN

THE INTENDED EN%IRONMENT

8/16/2019 mams13.ppt

18/41

DECISION %ARIA$LES

• S&EED

•

LENGTH• CARRIER S&ACING

• CARRIER CA&ACITY

• NUM$ER OF LOAD AND

UNLOAD STATIONS

8/16/2019 mams13.ppt

19/41

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

8/16/2019 mams13.ppt

20/41

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 *:+

8/16/2019 mams13.ppt

21/41

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

8/16/2019 mams13.ppt

22/41

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

8/16/2019 mams13.ppt

23/41

CRITERIA

• FOR $LOC#ING

J λ >1v K "

• FOR SUCCESSFUL HANDLING OF

CON%EYOR TRAFFIC THROUGH

UNLOADING

Mu µ K λ1J 

8/16/2019 mams13.ppt

24/41

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+

8/16/2019 mams13.ppt

25/41

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

8/16/2019 mams13.ppt

26/41

&ATH FLE8I$ILITY

• CON%EYORS FI8ED &ATH

• MANNED TRUC#S FLE8I$LE &ATH

• AG%'S SEMI-FLE8I$LE &ATH

8/16/2019 mams13.ppt

27/41

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

8/16/2019 mams13.ppt

28/41

UESTIONS

• HO( ARE AG%S CONTROLLED

 – CENTRAL COM&UTER , LOCAL

CONTROLLERS

• HO( DO AG%'S NA%IGATE

 – INDUCTI%E GUIDE&ATHS

 – OTHER SYSTEMS

8/16/2019 mams13.ppt

29/41

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

8/16/2019 mams13.ppt

30/41

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

8/16/2019 mams13.ppt

31/41

&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+

8/16/2019 mams13.ppt

32/41

&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+

8/16/2019 mams13.ppt

33/41

&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

8/16/2019 mams13.ppt

34/41

&ATH DESIGN

• MATERIAL HANDLING &ATHS *See

E; /.7+

• TANDEM A&&ROACH *See Fig /.7+

8/16/2019 mams13.ppt

35/41

%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

8/16/2019 mams13.ppt

36/41

%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+

8/16/2019 mams13.ppt

37/41

%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+

8/16/2019 mams13.ppt

38/41

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

8/16/2019 mams13.ppt

39/41

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

8/16/2019 mams13.ppt

40/41

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+

8/16/2019 mams13.ppt

41/41

&ALLET SI5E AND

LOADING