material handling - part1

Arif Rahman – The Production Systems 1

Slide 4Material Handling

Arif Rahman, ST MT

Arif Rahman – The Production Systems

Material handling is the movement, storage, protection and control of materials throughout the manufacturing and distribution process including their consumption and disposal (The Material Handling Industry of America)Material handling is the function of moving the right material to the right place in the right time, in the right amount, in sequence, and in the right condition to minimize production cost.

Material Handling

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The art and science of moving, storing, protecting, and controlling material.

Providing¤ Right amount¤ Right material¤ Right condition¤ Right place¤ Right position¤ Right sequence¤ Right cost¤ Right method

Material Handling

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Material-handling system is an integrated system involving such activities as handling, storing and controlling material.

¤ Handling transportation and movement system

¤ Storage Storage system¤ Controlling material Automation

identification & data capture

Material Handling System

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To move raw material, working process, finish parts, tools and supplies from one location to another (to facilitate the over all operation of manufacturing)

Consists of: Movement of materials from sources of supply, all intra-plant handling & distribution of finished goods customers.

Material Handling Scope of Movement

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Concerned with the acquisition, movement, storage, and distribution of materials and products to satisfy customer demand

Two categories of logistics:External logistics - transportation and related activities

that occur outside of a facility (between different geographical locations). Five traditional modes of transportation: rail truck, air, ship, and pipeline

Internal logistics - material handling and storage within a facility

Material Handling and Logistics

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It consumes more time

It needs extra cost

It triggers some troublesome.

The materials can be damaged since improper movement

The materials can be lost in transit

Material Handling Risks

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Handling of materials must be performed ¤ Safely and smoothly¤ Efficiently and directly¤ At low cost¤ In a timely manner¤ Accurately (the right materials in the right

quantities to the right locations)¤ And without damage to the materials

Material Handling Consideration

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1. Form of material at point of origin, e.g., liquid, granular, sheets, etc.

2. Characteristics of the material, e.g., fragile, radioactive, oily, etc.

3. Original position of the material, e.g., under the earth, in cartons, etc.

4. Flow demands, e.g., amount needed, continuous or intermittent, timing, etc.

5. Final position, where material is needed, e.g., distance, elevation differences, etc.

Material Handling Factors

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6. In-transit conditions, e.g., transocean, jungle, city traffic, inplant, etc., and any hazards, perils, special events or situations that could occur during transit

7. Handling equipment available, e.g., devices, prices, reliability, maintenance needs, etc.

8. Form and position needed at destination

9. Integration with other equipment and systems

10.Degree of control required

Material Handling Factors

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Reduce Unit Material Handling Cost¤ Eliminate Unnecessary Handling¤ Handle Material in Batch Lots¤ Minimize Required Handling Time

¤ Replace Handling Equipment as Appropriate

Reduce Production Time¤ Minimize Delays of Machine Operations¤ Maintain Uniform, Appropriate Movement of Material¤ Use Automatic Processing When Appropriate

Material Handling Objectives

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Reduce Overhead¤ Minimize Non-Productive Labour¤ Prevent and Reduce Damage to Materials¤ Coordinate All Material Handling Systems

¤ Maintain or Improve Product Quality

¤ Control Inventory

Conserve Floor Space¤ Avoid Excessive Stock Storage¤ Move Materials in a Position to Save Space

¤ Use Equipment Requiring No Floor Space


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Prevent Accidents¤ Reduce Physical Load Required¤ Insure Handling Equipment is Safe¤ Promote safety and improve working conditions

Improve Employee Morale¤ Provide Proper Relationship Between Employee &

Work


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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¤ Promote Increased Use Of Facilities


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Increase capacity

Improve working conditions

Improve customer services

Increase equipment and space utility

Reduce Costs

Material Handling Benefits

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Overview of Material Handling Equipment

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Material transport equipment¤ to move materials inside a factory, warehouse, or

other facility¤ industrial trucks, Automated Guided vehicles (AGVs),

monorails (and other rail guided vehicles), conveyors, cranes and hoists

Storage systems¤ to store materials and provide access to those

materials when required

¤ bulk storage, rack systems, shelving and bins, drawer storage, automated storage systems

Material Handling Equipment

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Unitizing equipment¤ refers to (1) containers to hold materials, and (2)

equipment used to load and package the containers¤ Pallets, boxes, baskets, barrels, pails, and drums;

palletizers, depalletizers

Identification and tracking systems¤ to identify and keep track of the materials being

moved and stored

¤ Bar codes, magnetic stripes, radio frequency tags

Material Handling Equipment

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Considerations in Material Handling System Design

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Material characteristics

Flow rate, routing, and scheduling

Plant layout

Unit load principle

Factors that influence the design

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Category MeasuresPhysical stateSizeWeight

ShapeConditionRisk of damageSafety risk

Solid, liquid, or gasVolume; length, width, heightWeight per piece, weight per unit volumeLong and flat, bulky, round, square, etc.Hot, cold, wet, dirty, stickyFragile, brittle, sturdyExplosive, flammable, toxic, corrosive, etc.

Material Characteristics

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Flow rate amount of material moved per unit time¤ Examples: pieces/hr, pallet loads/hr, tons/hr¤ Whether the material must be moved in individual

units, as batches, or continuously (pipe line)

Routing pick-up and drop-off locations, move distances, routing variations, conditions along the route (surface, traffic, elevation)Scheduling timing of each individual delivery¤ Prompt delivery when required¤ Use of buffer stocks to mitigate against late deliveries

Flow Rate, Routing, and Scheduling

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Manual handlingHand trucks

Powered trucksUnit load AGV

Conveyors ConveyorsAGV trainHigh

Low

LongShort Move Distance

Quantity of material moved

Flow Rate, Routing, and Scheduling

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In the case of a new facility, the design of handling system should be considered as part of the layout designThe layout should provide the following information for use in the design of the handling system:¤ Locations where materials must be picked up (load stations)¤ Locations where materials must be delivered (unload stations)¤ Possible routes between these locations¤ Distances that must be travelled to move materials¤ Flow patterns, opportunities to combine deliveries, possible

places where congestion might occur¤ Total area of the facility and areas within specific departments in

the layout¤ Arrangement of equipment in the layout

Plant Layout: Layout Type

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Layout Type

Characteristics Typical MH Equipment

Fixed – position

Process

Product

Large product size, low production rate

Variation in product and processing, low and medium production rates

Limited product variety, high production rate

Cranes, hoists, industrial trucks

Hand trucks, forklift trucks, AGVs

Conveyors for product flow, trucks to deliver components to stations.

Plant Layout: Layout Type

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Fixed Path¤ Equipment: Conveyors, Elevators, Lifts,

Pipes/Tubes¤ Advantages:

• More economical if large volume of material moved to same place

• One power supply to drive entire “belt” – more economical

• Reduction in need for lot identification tags• Can be used to pace the workers

¤ Disadvantages: Less economical if material follows diverse paths

Plant Layout: Path

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Limited Area (Semi-Fixed Path)¤ Equipment: cranes, trucks¤ Advantages: Can cover a wider area¤ Disadvantages: Still limited to area covered

Plant Layout: Path

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Wide Area (Variable Path)¤ Equipment:

• Manual: trucks 2-wheel, trucks 4-wheel, lift truck, dolly

• Powered: power lift truck, forklift truck, multiple trailer, yard truck, over-the-road truck, rail, portable conveyor

¤ Advantages: flexible¤ Disadvantages: must have portable power

supply with each piece of equipment

Plant Layout: Path

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In general, the unit load should be as large as practical for the material handling system that will move and store it¤ A unit load is the mass that is to be moved or

otherwise handled at one time

Reasons for using unit loads in material handling:¤ Multiple items handled simultaneously¤ Required number of trips is reduced¤ Loading/unloading times are reduced¤ Product damage is decreased

Unit Load Principle (unitizing)

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Wooden pallet Pallet box Tote box

Unit Load Containers

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Unit Load Containers : Wooden Pallet

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Single faced pallet Double faced pallet Double faced reversible pallet

Two-way Entry pallet Four-way Entry pallet


Unit Load Containers : Pallet Box

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Pallet Crate Skid Box Pallet Box


Unit Load Containers : Pallet Box

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Unit Load Containers : Box

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Cartoon Box

Tote Pan

Tote Box Crate

Bins


Unit Load Containers : Others

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The 10 Principles of Material Handling

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1. Planning Principle2. Standardization Principle3. Work Principle4. Ergonomic Principle5. Unit Load Principle6. Space Utilization Principle7. System Principle8. Automation Principle9. Environmental Principle10.Life Cycle Cost Principle

The 10 Principles of Material Handling

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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

Definition: A plan is a prescribed course of action that is defined in advance of implementation. In its simplest form a material handing plan defines the material (what) and the moves (when and where); together they define the method (how and who).

1. Planning Principle

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The plan should be developed in consultation between the planner(s) and all who will use and benefit from the equipment to be employed.Success in planning large scale material handling projects generally requires a team approach involving suppliers, consultants when appropriate, and end user specialists from management, engineering, computer and information systems, finance and operations.The plan should promote concurrent engineering of product, process design, process layout, and material handling methods, as opposed to independent and sequential design practices.The material handling plan should reflect the strategic objectives of the organization as well as the more immediate needs.

1. Planning Principle : Key Points

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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

2. Standardization Principle

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Standardization means less variety and customization in the methods and equipment employed

Standardization applies to sizes of containers and other load forming components as well as operating procedures and equipment

The planner should select methods and equipment that can perform a variety of tasks under a variety of operating conditions and in anticipation of changing future requirements

Standardization, flexibility and modularity must not be incompatible

2. Standardization Principle : Key Points

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Material handling work should be minimized without sacrificing productivity or the level of service required of the operation

3. Work Principle

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The measure of material handling work is flow rate (volume, weight or count per unit of time) multiplied by the distance moved

Consider each pickup and set-down, or placing material in and out of storage, as distinct moves and components of the distance moved

Simplifying processes by reducing, combining, shortening or eliminating unnecessary moves will reduce work

3. Work Principle : Key Points

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Where possible, gravity should be used to move materials or to assist in their movement while respecting consideration of safety and the potential for product damageThe work principle applies universally, from mechanized material handling in a factory to over-the-road truckingThe work principle is implemented best by appropriate layout planning: locating the production equipment into a physical arrangement corresponding to the flow of work. This arrangement tends to minimize the distances that must be traveled by the materials being processed

3. Work Principle : Key Points

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Human capabilities and limitations must be recognized and respected in the design of material handling tasks and equipment to ensure safe and effective operations

4. Ergonomic Principle

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Ergonomics is the science that seeks to adapt work or working conditions to suit the abilities of the workerThe material handling workplace and the equipment employed to assist in that work must be designed so they are safe for peopleThe ergonomic principle embraces both physical and mental tasksEquipment should be selected that eliminates repetitive and strenuous manual labour and which effectively interacts with human operators and users

4. Ergonomic Principle : Key Points

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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

5. Unit Load Principle

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A unit load is one that can be stored or 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 loadLess effort and work is required to collect and move many individual items as a single load than to move many items one at a timeLarge unit loads are common both pre and post manufacturing in the form of raw materials and finished goods

5. Unit Load Principle : Key Points

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Load size and composition may change as material and product moves through stages of manufacturing and the resulting distribution channels.Smaller unit loads are consistent with manufacturing strategies that embrace operating objectives such as flexibility, continuous flow and just-in-time delivery. Smaller unit loads (as few as one item) yield less in-process inventory and shorter item throughput times.

5. Unit Load Principle : Key Points

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Effective and efficient use must be made of all available space

6. Space Utilization Principle

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Space in material handling is three dimensional and therefore is counted as cubic spaceIn storage areas, the objective of maximizing storage density must be balanced against accessibility and selectivity.When transporting loads within a facility the use of overhead space should be considered as an option. Use of overhead material handling systems serves valuable floor space for productive purposes.

6. Space Utilization Principle : Key Points

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Material movement and storage activities should be fully integrated to form a coordinated, operational system which spans receiving, inspection, storage, production, assembly, packaging, unitizing, order selection, shipping, transportation and the handling of returnsDefinition: A system is a collection of interacting and/or interdependent entities that form a unified whole

7. System Principle

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Systems integration should encompass the entire supply chain including reverse logistics. It should include suppliers, manufacturers, distributors and customers.Inventory levels should be minimized at all stages of production and distribution while respecting considerations of process variability and customer service.Information flow and physical material flow should be integrated and treated as concurrent activities. Methods should be provided for easily identifying materials and products, for determining their location and status within facilities and within the supply chain and for controlling their movement.

7. System Principle : Key Points

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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 to eliminate repetitive or potentially unsafe manual laborDefinition: Automation is a technology concerned with the application of electro-mechanical devices, electronics and computer-based systems to operate and control production and service activities. It suggests the linking of multiple mechanical operations to create a system that can be controlled by programmed instructions

8. Automation Principle

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In any project in which automation is being considered, pre-existing processes and methods should be simplified and/or re-engineered before any efforts at installing mechanized or automated systems. Such analysis may lead to elimination of unnecessary steps in the method. If the method can be sufficiently simplified, it may not be necessary to automate the process.Items that are expected to be handled automatically must have standard shapes and/or features that permit mechanized and/or automated handling.

8. Automation Principle : Key Points

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Interface issues are critical to successful automation, including equipment to equipment, equipment to load, equipment to operator, and in-control communications.

Computerized material handling systems should be considered where appropriate for effective integration of material flow and information management.

8. Automation Principle : Key Points

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Environmental impact and energy consumption should be considered as criteria when designing or selecting alternative equipment and material handling systems

9. Environmental Principle

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Environmental consciousness stems from a desire not to waste natural resources and to predict and eliminate the possible negative effects of our daily actions on the environmentContainers, pallets and other products used to form and protect unit loads should be designed for reusability when possible and/or biodegradability after disposalMaterials specified as hazardous have special needs with regard to spill protection, combustibility and other risks.

9. Environmental Principle : Key Points

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A thorough economic analysis should account for the entire life cycle of all material handling equipment and resulting systems

10. Life Cycle Cost Principle

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Life cycle costs include all cash flows that will occur between the time the first dollar is spent to plan or procure a new piece of equipment, 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.

10. Life Cycle Cost Principle : Key Points

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A plan for preventive and predictive maintenance should be prepared for the equipment, and the estimated cost of maintenance and spare parts should be included in the economic analysis.A long-range plan for replacement of the equipment when it becomes obsolete should be prepared.Although measurable cost is a primary factor, it is certainly not the only factor in selecting among alternatives. Other factors of a strategic nature to the organization and which form the basis for competition in the market place should be considered and quantified whenever possible.

10. Life Cycle Cost Principle : Key Points

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Safer Operating Conditions

Lower Costs

Better utilization and performance of material handling systems

The Principles Benefits

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One of the most important of the principles is the unit load principleIn general, the unit load should be as large as practical for the material handling system that will move and store it¤ A unit load is the mass that is to be moved or

otherwise handled at one time

Reasons for using unit loads in material handling:¤ Multiple items handled simultaneously¤ Required number of trips is reduced¤ Loading/unloading times are reduced¤ Product damage is decreased

The Principles Most Importances

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Included in the definition of unit load is the container that holds or supports the materials to be movedThese containers are standardized in size and configuration to be compatible with the material handling systemPallets are probably the most widely used, owing to their versatility, low cost, and compatibility with various types of material handling equipment


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Depth =x Dimension

Width =y Dimension

800 mm (32 in) 1000 mm (40 in)

900 mm (36 in) 1200 mm (48 in)

1000 mm (40 in) 1200 mm (48 in)

1060 mm (42 in) 1060 mm (42 in)

1200 mm (48 in) 1200 mm (48 in)


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Standard Pallet Sizes Commonly Used in Factories and Warehouses

Arif Rahman – The Production Systems 66

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material handling - part1

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