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Automated Material HandlingAutomated Material HandlingTrends & PracticesTrends & Practices

Dr. Richard E. WardMaterial Handling Industry of America

Charlotte, North Carolina, USA

Scientia Logistica July 5 6, 2007

Accelerating the Supply Chain: Contact to CashAccelerating the Supply Chain: Contact to Cash

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Accelerating the Supply Chain:Accelerating the Supply Chain:Contact to CashContact to Cash

Continuous flow of material and goodsContinuous flow of material and goodsNo barriers,No barriers, impedencesimpedencesororinefficenciesinefficencies

Speed !Speed !

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Our Definition. . .. . .

Material handling, whether performed at work stationsor as product in transit, represents the safe,

continuous, unimpeded flow of material andgoods throughout the entire supply chain

. . . and in the process meeting strict performance and

economic requirements by way of the methodsemployed to move, store, control andprotect material and goods at all stages in their

journey through manufacturing and distribution

. . . with the end objective being that they arrivewhere and when they are needed, in theright quantity and the right condition.

Material handlingMaterial handling,, whether performed at work stationswhether performed at work stationsor as product in transit, represents the safe,or as product in transit, represents the safe,

continuouscontinuous,, unimpeded flowunimpeded flow of material andof material andgoods throughout the entire supply chain

goods throughout the entire supply chain

. . . and in the process meeting strict performance and. . . and in the process meeting strict performance and

economic requirements by way of theeconomic requirements by way of the methodsmethodsemployed toemployed to move, store, control andmove, store, control andprotectprotect material and goods at all stages in theirmaterial and goods at all stages in their

journey

journey through manufacturing and distributionthrough manufacturing and distribution

. . . with the end objective being that they arrive. . . with the end objective being that they arrivewhere and when they are needed, in thewhere and when they are needed, in theright quantity and the right condition.

right quantity and the right condition.

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The Logistics Industry TodayThe Logistics Industry Today

MHIA began in 1945 as the Material Handling Institute, largelyMHIA began in 1945 as the Material Handling Institute, largely

as a fork truck organization, and has never stopped evolving.as a fork truck organization, and has never stopped evolving.

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FocusFocus

AS/RS

AGVS

Lift Trucks

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AS/RSAS/RS

Automated Storage& Retrieval Systems

F/A = Fixed Aisle Systems

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AS/RS = C/VLMCarouselsVertical Lift Modules

Horizontal Carousel

Vertical Carousel

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AS/RS = C/VLM

Horizontal Carousels . . . Alternative PodConfigurations

Vertical Lift Modules

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AS/RS = C/VLMVertical CarouselsVertical Lift Modules

Carousels

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AS/RS = C/VLM

Vertical Carousels . . .Vertical Lift Modules

Wide Choice ofCarrier Configurations

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AS/RS = C/VLMCarouselsVertical Lift Modules

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AS/RS = C/VLM

CarouselsVertical Lift Modules . . . With Flexible Application

Configurations

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AGVSAGVSAutomatic GuidedVehicles System

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(Much) faster machines . . . 1300 1500 fpm horizontal900 fpm vertical

(More) sophisticated shuttles . . . Particularly twin shuttles

Non conventional unit loads . . . e.g., hanging goods

The definition (top guided floor running) we used touse is becoming obsolete . . .

e.g., a shuttle for every level,

horizontal vs. vertical mastor no cranes and no aisles

Examining F/A AS/RS:Examining F/A AS/RS: Observed TrendsObserved Trends

Bottom line: More functionality / (much) higher throughputs

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One exampleOne exampleof a nonof a non--

conventionalconventional

loadload

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The traditional view . . .The traditional view . . .

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Two newer views . . .Two newer views . . .

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Yet another view . . .Yet another view . . .

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And two more . . .And two more . . .

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Continuing right along . . .Continuing right along . . .

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And not to be missed . . .And not to be missed . . .

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Focusing briefly onFocusing briefly on AGVSAGVS ::observed trendsobserved trends

The technology has matured . . . Stable, highly reliable,designed to be maintained

A possible resurgence in path following guidance New options for power systems

Lead-acid, sealed batteries

No batteries (e.g., IPT)

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Arrangement F-Pickups

Um die Energiebertragung mglichsteffizient zu gestalten, d.h. arm an Um-gebungsverlusten, empfehlen wir deneingezeichneten Raum frei von ferro-

magnetischen Werkstoffen zu halten.

F-Abnehmer

Speiseleiter(Hin- und Rckleitung)

*

*blicher Wert fr Einbaumittellage,bitte spe zifische Toleranzbereicheder Abnehmer beachten !

Pickups

IPTIPT SystemsSystems

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Arrangement T-Pickups

Freiraum fr Kon vektionskhlung

von 20 mm beachten !

Um die Energiebertragung mglichsteffizient zu gestalten, d.h. arm an Um-gebungsverlusten, empfehlen wir deneingezeichneten Raum frei von ferro-magnetischen Werkstoffen zu halten.

T-Abnehmer mit Rollen

Speiseleiter(Hin- und Rckleitung)

Pickup

IPTIPT SystemsSystems

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58 vehicles 1.5 kW per vehicle for drive, lift andswivel motors

Track length ~ 2 x 180m

AUDI, Germany: Floor Conveying SystemEngine Assembly Line

ReferencesReferences

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35 vehicles 1.5 kW per vehicle for drive, lift and

swivel motors Track length ~ 150 m

ReferencesReferences BMW, Germany: Floor ConveyingSystemEngine Assembly Line

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AGVSAGVS Greater choices in steering (more mobile,requiring less space in which to maneuver.)

New design tools for use by the end user +supplier design tools that ease and speed installation

Other countries (e.g., Japan) still lead the way interms of greater numbers of light load, simple (small# of vehicle) systems.

Advances in navigation and guidance

LADARLADAR

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NIST Industrial AutonomousNIST Industrial AutonomousVehicles ProjectVehicles Project

RogerRoger BostelmanBostelman, IAV Project Manager, IAV Project Manager

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What Range Sensors Exist?What Range Sensors Exist?NIST PublicationNIST Publication

Published comprehensive reportPublished comprehensive report

on nexton next--generation LADAR forgeneration LADAR for

manufacturing, construction, andmanufacturing, construction, and

mobilitymobility

Also contains section on NISTAlso contains section on NIST

BAA: Next Generation LADARBAA: Next Generation LADARfor Driving Unmanned Groundfor Driving Unmanned Ground

VehiclesVehicles

Available for download at:Available for download at:

www.isd.mel.nist.gov/whatsnew.htmwww.isd.mel.nist.gov/whatsnew.htm

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The Logistics Industry TodayThe Logistics Industry Today

MHIA began in 1945 as the Material Handling Institute, largelyMHIA began in 1945 as the Material Handling Institute, largely

as a fork truck organization, and has never stopped evolving.as a fork truck organization, and has never stopped evolving.

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Lift Truck Trends . . .

Ergonomics

Energy

Maneuverability

The Driving Forces The Results

Productivity

Space Savings

TCO

Total Cost ofOwnership

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AC Drive MotorsAC Drive Motors

More Uptime

More Performance

Lower Maintenance Cost

Faster, smoother operation

Runs longer on a single charge

More time working

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Annual Maintenance ComparisonAnnual Maintenance Comparison

ServicingServicing CommutatorsCommutators

Replacing Brushes & SpringsReplacing Brushes & Springs

Monthly Brush InspectionsMonthly Brush Inspections

Removing Carbon DustRemoving Carbon Dust

Monthly CleaningMonthly Cleaning

LaborLabor

CommutatorsCommutators

Spring SetsSpring Sets

Brush SetsBrush SetsPartsParts

DC MotorsDC Motors

NONO CommutatorsCommutators

NONO Brushes & SpringsBrushes & Springs

NONO BrushesBrushes

NONO Carbon DustCarbon Dust

NONO Monthly CleaningMonthly Cleaning

LaborLabor

NONO CommutatorsCommutators

NONO Spring SetsSpring Sets

NONO Brush SetsBrush SetsPartsParts

AC MotorsAC Motors

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Fuel Cells Energy stored as hydrogen & converted toelectricity as needed

Higher productivity because they can be rapidlyrefueled in several minutes vs. several hours

(NO NEED TO CHANGE BATTERIES)

Typically one shift to charge & one shift tocool down. Hence,for a 3 shift operation youneed 3 batteries per truck + charger +

charging room

Environmentally safe . . . Only bi-productis water & heat

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Raymonds Fuel CellLiving Lab

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www.mhia.orgwww.asrssolutions.org

www.agvssolutions.org

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Automated Material HandlingAutomated Material Handling

Trends & PracticesTrends & Practices

Dr. Richard E. WardMaterial Handling Industry of America

Charlotte, North Carolina, USA

Scientia Logistica July 5 6, 2007

Accelerating the Supply Chain: Contact to CashAccelerating the Supply Chain: Contact to Cash