Chapter 5 Material Handling

1
Chapter 5 Material Handling

• EIN 3365
• Dr. C Chen

2
Introduction

• Role and importance of material handling
• Scope and definition of material handling
• Principles of material handling
• Unit load design
• One of the most important element of a material
  handling system
• Various MH equipment and alternatives

3
Importance of Material Handling

• Layout design and material handling are
  inseparable
• It is the backbone of overall production
  operations
• It accounts for
• 25 employees,
• 55 factory space,
• 87 of production time, and
• 15-70 of manufacturing cost

4
Materials Handling Definition

• It is an art and science of
• moving,
• storing,
• protecting, and
• controlling material
• It provides the right amount of the right
  material in the right condition, at the right
  place, in the right position, in the right
  sequence, and for the right cost, by the right
  method(s).

5
The rights

• Right amount
• With focus on JIT (not excessive inventory)
• Right material
• Accurate material ID, to avoid picking wrong
  material
• Right condition
• In the state the customer desires to receive
  (packing)
• Right sequence
• To promote work simplification and operation
  efficiency
• Right orientation
• Positioning the material for ease of handling
• Right place
• To the point of use rather than storing the
  material at some intermediate location
• Right time
• On-time delivery, neither early nor tardy (also
  reduction in delivery time variance)
• Right cost
• Support companys overall greater profitability,
  but not necessarily the lowest cost)
• Right method
• Selection of technology and equipment that
  focuses on requirements.

6
MH Scope

• Conventional view
• Focus solely on the movement of material from one
  location to another within a facility
• Contemporary view
• Expand the focus to the overall movement of
  materials in a factor or warehouse toward an
  integrated material handling plan
• Including moving material from receiving docks to
  the storage areas.
• Progressive view
• A total system including all activities in
  handling material from all suppliers to
  customers.
• SCM view

7
Ten MH principles

• Planning principle
• Need a prescribed course of action
• Standardization principle
• Less variety and customization in the methods and
  equipment
• Work principle
• Work measured by material flow (volume, weight,
  count per unit time) multiplied by travel
  distance
• Ergonomic
• Adapt work conditions to suit the workers
  ability
• Unit load
• To stored and moved as a single entity at one
  time such as a pallet, container, or tote,
  regardless of the number of individual items that
  make up the load.
• Space utilization
• Consider 3D cubic space
• System
• A collection of interacting elements that form a
  whole
• Automation
• System that is controlled by programmed
  instructions
• Environmental
• Not to waste natural resources and not to cause
  negative effects on the environment
• Life cycle cost

8
MHS Design process

• Define the objectives and scope for the MHS
• Analyze the requirements for moving, storing,
  protecting, and controlling material
• Generate alternative designs for meeting MHS
  requirements
• Evaluate alternative MHS designs
• Select the preferred design for moving, storing,
  protecting, and controlling material
• Implement the preferred design including the
  selection of suppliers, training of personnel,
  installation, debug and startup of equipment and
  periodic audits of system performance.

9
The Ideal systems approach to developing
alternative MHS designs

• Aim for the theoretical ideal system
• A perfect system is the one with zero cost,
  perfect quality, no safety hazards, no wasted
  space, and no managerial inefficiencies.
• Conceptualize the ultimate idea system
• The one achievable in the future
• Design the technologically workable ideal system
• The one for which the technology is available
• Install the recommended system
• A cost effective one that will work now without
  obstacle to implement.

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The MHS Equation I

• Why
• What
• materials
• Where
• moves
• When
• moves
• How
• methods
• Who
• methods
• Which
• Preferred system

11
The MHS Equation (II)

• Material
• Moves
• Methods
• Preferred system

12
Material Handling Chart

• Process plan plus material handling
• Including
• Operation (O)
• Transport (T)
• Storage (S)
• Inspection (I)
• Including
• Location, container type, size, weight, quantity,
  frequency, distance, and method of handling.

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Unit load principle

• Definition
• A number of items, or bulk material, so arranged
  or restrained that the mass can be picked up and
  moved as a single object too large for manual
  handlings and which upon being released will
  retain its initial arrangement for subsequent
  movement.

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Ways to maintain the integrity of the unit load

• Tote boxes
• Cartons
• Pallets
• Strapping
• Shrink wrapping
• Stretch wrapping

15
Methods for moving unit loads

• Lifting under the mass
• Inserting the lifting element into the body of
  the unit load
• Squeezing the load between two lifting surfaces
• Suspending the load

16
The effects of unit load size on job completion
times

• When material handling time is significant
  comparing to machining (OP) times, batching can
  significantly affect the completion time for the
  batch of job.
• See the example in Figure 5.3 on page 176.
• A large unit load size (a large batch size)
• A smaller number of material transfers, and thus
  reduction in MH time.
• Prolong in its completion time
• A smaller unit load size (a smaller batch size)
• A higher number of material transfers, and
  increase in MH time
• Also causing delays to its completion time

17
Dimensional relationships among various elements
in a distribution system

• Carton, 12L x 8W x 10H
• Wood pallet,32W x 48L x 5.5H
• Pallet load, 32W x 48L x 45.5H
• Multiple patterns
• 16 cartons per layer,
• 4 layers per pallet
• Trailer,
• patterns of 32x48
• One layer of pallet
• Block stack storage,
• patterns of 32W (x5 pallets) x (482 for
  clearance)(x5 pallets)
• One layer of pallet

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Returnable containers

• Design principles
• Stackability a full container can be stacked on
  the top of another in the same spatial
  orientation (using integrated lids or tabs
  design)
• Nestability the shape of the containers permits
  an empty container to be inserted into another
  empty container.
• See Figure 5.5 on page 177.

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Efficiency measures of using returnable containers

• Container space utilization
• Usable cube/external envelop
• Storage space efficiency
• Usable cube/storage cube
• Container nesting ration
• Container height/nested height
• Trailer space utilization ()
• Trailer return ratio
• Total number of empty containers/total number of
  full containers per trailer

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Pallets and Pallet Sizes

• Common sizes
• 32x40,36x48,40x48,42x42,48x40,48x48
• Fork entry
• Two ways vs. four ways
• Support
• Stringer vs. block
• Container/pallet system
• With progressive dimensions
• Typically, a containers dimension is a half of
  the size of the pallet.
• Here, it may be 1/1, ½, ¼, 1/8, 1/16, etc.
• Material types
• Wood, pressed wood fiber, fiberboard, plastic,
  and metal

21
Pallet Stacking patterns

• Depending on pallet and carton sizes
• See Figure 5.9 on page 183 for various types
• Block pattern
• Row pattern
• Pinwheel pattern
• Honeycomb pattern
• Spit row pattern
• Split pinwheel pattern
• Brick pattern

22
A Mfg. subsystem of packaging, palletization,
storage, and shipping

• A system design example in figure 5.10 on page
  184
• System elements
• Cartons
• Packaging stations
• Conveyers
• Palletizers
• Lift truck (for warehouse operations)
• Lift truck (for shipping dock operations)
• Highway trailer-truck
• System design objectives and concerns
• Investment cost, total unit handling cost,
  payback period, return on investment, space
  utilization.
• System flexibility, reliability, maintainability,
  ease of expansion.

23
MH types

• Containers and utilizing equipment
• Material transport equipment
• Storage and retrieval equipment
• Automatic data collection and communication
  equipment

24
Containers and utilizing equipment

• Containers
• Pallets
• Skids and skid boxes
• Tote pans
• Unitizers
• Stretch-wrap
• palletizers

25
Material transport equipment

• Conveyers
• Chute conveyer
• Belt conveyer
• Roller conveyer
• Wheel conveyer
• Sorting conveyer
• Industrial vehicles
• Walking (hand truck and hand cart)
• Riding (pallet truck, platform truck, tractor
  trailer, etc.)
• Automated (AGV, automated electrified monorail,
  etc)
• Monorails, hoists, and cranes
• Monorail
• Hoists
• Cranes (bridge crane, gantry crane, stacker
  crane, etc.)

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Storage and retrieval equipment

• Unit load SR equipment
• Unit load storage equipment
• Unit load retrieval equipment
• Unit load ASRS
• Small load SR equipment
• Operator-to-stock storage equipment
• Modular storage drawers in cabinets, mezzanine,
  carton flow rack, mobile storage.
• Operator-to-stock retrieval equipment
• Picking cart, order picker truck, person-aboard
  ASR machine
• Stock-to-operator equipment
• Carousels, miniload ASR machines, automatic
  dispenser

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Automatic data collection and communication
equipment

• Automatic identification and recognition
• Bar coding (bar codes and readers)
• Optical character recognition
• Radio frequency tag
• Magnetic stripe
• Machine vision
• Automatic paperless communication
• Radio frequency data terminal
• Voice headset
• Light and computer aids
• Smart card

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Chapter 5 HW

• None

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Concluding remarks

• Read Appendix 5B MH Equipment
• to familiarize your self with various MH devices
• Apply Appendix 5A MH audit checklist
• to your team project