Material Handling Systems 4

Logistics Systems Design: Material Handling Systems 21-Jul-03

Copyright © 1994-2003, Marc Goetschalckx, All rights reserved. 13·1

21-Jul-03 Logistics Systems Design Marc Goetschalckx

Logistics Systems Design: Material Handling Systems

13. Material Handling Systems14. Material Handling Models15. Warehousing Systems16. Storage Models17. Order Picking Models


Material Handling Systems Overview

Definition

Classifications


Material Handling Definition

Material handling is concerned with theMovementStorage, andControl

Of materials in a process


Material Handling Is Expensive

10 % to 80 % of product costPhysical distribution costs 25 % of product costMore than 90 % of flow time in job shop production systems




Material Handling in Early Automotive Assembly


Traditional Versus Modern View

TraditionalNot value adding, only cost addingMinimize as much as possibleSupport automation

ModernProvides space and time utilityMaximize flexibilitySupport integration


Stages in M.H.S. Design

Why ?What ?When and where ?How ?By whom ?


Nine Rights of Material Handling

Uses the right METHODTo provide the right AMOUNTOf the right MATERIALTo the right PLACE

At the right TIMEIn the right SEQUENCEIn the right POSITIONIn the right CONDITIONAt the right COST




Material Handling Systems Overview

Definition

Classifications


Classification of Material Handling

by Materialby Methodby Equipment


Categories of Materials

GassesLiquidsBulk materialsDiscrete (unit) loadsDocuments & moneyLivestockPeople


Unit Load Definition

A collection of materials so arranged and restrained that it can be handled, stored, and controlled as a single entity




Unit Load Advantages

Standardized handling equipmentStandardized storage equipmentReduced information & control burdenEfficient macro space utilization


Unit Load Disadvantages

Cost of assembly and disassemblyCost of container and wrappingsCost of empty container handling & disposalInefficient micro space utilization


Unit Load ExamplesPalletDrumTruckOcean going intermodal container


Unit Load Example: Ocean Going Intermodal Container







Categories of Methods

ManualMechanizedAutomated


Labor And Control Providers

CapabilityLabor Control

TypeManual Human HumanMechanized Machine HumanAutomated Machine Machine


Method Characteristics

Flexibility

CapacityProject Job Shop Flow Shop

Manual

HardAutomation

Mechanized &Soft Automated




Characteristics of Material Handling Methods

Characteristic TypeManual Mechanized Automated

Weight Low High HighVolume Low High HighSpeed Low Medium HighFrequency Low Medium HighCapacity Low Medium HighFlexibility High Medium LowAcquisition cost Low Medium HighOperating cost High Medium Low


Manual Handling Illustration:Postman and Farmer


Manual Handling Equipment:Wheelbarrow


Mechanized Handling Illustration: Forklift Truck




Automated Illustration:Deep Lane Storage Detail





CICMHE-MHIA Taxonomy of Material Handling Equipment

www.mhia.org/et/mhe_tax.htm21-Jul-03 Logistics Systems Design Marc Goetschalckx

Equipment Categories

ConveyorsCranes and hoistsIndustrial trucksContainers and supportsStorage equipment

Auxiliary equipmentStorage/retrieval systemsRobotsPipelines




Pipeline Systems

Liquids, gasses, slurries, documentsHigh fixed cost, very low operational cost, high volumeSlow transportation speed but continuous movementDependable and low time varianceLarger diameters are more efficientWater, waste, documents


Pipeline Characteristics

Continuous movementFixed paths - ceiling suspendedVery limited access areaVery high hardware costVery high volumeSynchronous or asynchronous with containers


Conveyors Characteristics

Continuous movementFixed pathsVery limited access areaVery high hardware costVery high volumeAsynchronous versus synchronous


Conveyor Examples

SynchronousBeltRollerPower and free

AsynchronousAutomated electrified monorail (AEM)




Bulk Belt Conveyor in Gold Mining Leach Removal


Bulk Belt Conveyor in Wood Chip Removal


Belt Conveyor in Electronics Assembly


Belt Conveyor With Diverter Bar in Electronics Assembly




Belt Conveyor in A-Frame Order Picking System


Conveyor Network in Electronics Manufacturing


Roller Conveyor With Diverterin Electronics Manufacturing


Roller Conveyor in Order Picking




Power and Free Buffer in Automotive Assembly


Power and Free in Automotive Engine Assembly


Power and Free in Automotive Final Assembly


Automated Electrified Conveyor in Typewriter Manufacturing




Cranes and Hoists Characteristics

Overhead devices with vertical movementIntermittent movementLimited access areaMedium hardware costsMedium volume


Bridge Crane Illustration


Bridge Crane for Aircraft Engine Transport


Moveable Bulk Crane Illustration




Mobile Harbor Crane


Gantry Cranes Unloading a Container Ship


Gantry Crane Example


Cranes and Hoists Access AreasCircular jib access area

Rectangular bridge crane access area




Industrial Trucks Characteristics

Moving vehicles on wheelsIntermitted movementVariable pathsVery wide access areaLow hardware costLow volume


Industrial Trucks Illustration:Counterbalanced Lift Truck


Pallet Jack and Tractor


Tractor Trailer Example




Straddle and CounterbalancedForklift Trucks


Block Stacking Operation With Counterbalanced Truck


Order Picking Truck


Stacker Cranes Example




AGV With Collision Bumpers


AGVS With Load Station


AGV Load Station


AGVS to ASRS Interface




Multiload AGV in Semiconductor Manufacturing


Multiload AGV Interfacing With Clean Room


AGVS and Gantry Cranes for Intermodal Containers


Stacker Cranes for Intermodal Containers




Containers Characteristics

To maintain a unit load


Container Examples

PalletTote boxIntermodal container


Storage Equipment Characteristics

To hold materials


Storage Equipment Examples

Person-to-partBlock stackingPallet rackGravity flow rackBin shelving

Part-to-personCarouselsMiniload




Block Stacking Storage of Household Appliances


Bin Shelving


Order Picking From Bin Shelving


Pallet Rack




Shelves With Quantity Displays (Pick-to-light)


Small Parts Carousel Example


Auxiliary Equipment Types

Bar code readersStretch wrappersPalletizersLift tablesMeasuring framesAir film handling equipmentRadio frequency terminals..


Pallet Positioners




Voice Communications for Hands-free Order Picking


Radio Frequency Communications Terminals


Storage & Retrieval Characteristics

Combined handling and storage


Unit Load AS/RS Illustration




Storage & Retrieval TypesPart-to-person

Unit load AS/RSMiniload (storage drawer)Microload (tote stacker)Carousel with extractorV and A frame order pickingDeep lane storage

Person-to-partPerson-aboard


Unit Load Storage System With Multiple Aisles


Unit Load System Example


Unit Load ASRS for Paper Rolls




Unit Load ASRS for Thread Coils


Miniload Example


Deep Lane Storage System Detail


Deep Lane Storage System




Deep Lane Storage Example


Unit Load, Deep Lane, Storage Retrieval System Detail

Activ System Detail (Retrotech)


Unit Load, Deep Lane, Automated Staging Warehouse

Activ System(Retrotech)


A-Frame Automatic Order Picking Example Detail




Person-aboard Example


Person-aboard Example:Inside the Aisle View


Robot Characteristics

ProgrammableAnthropomorphic (gripper)General purpose (multifunctional)


Robot Degrees of Freedom




Six Degree of Freedom Robot Example

Fanuc 710i


Japanese Robot Classification

Manual manipulatorFixed sequence robotVariable sequence robotPlay back robotNumerically controlled robotIntelligent robot


Robot Application Areas

3 D areasDullDirtyDangerous

70 % automotive industry


Robotic Processes

Spot and arc weldingPick and placePaint spraying




Welding Robot Example


Pick and Place Robot Example


Robotic Assembly


Robotic Machine Part Loading




Pick and Place Palletizing Robot Example

Motoman21-Jul-03 Logistics Systems Design Marc Goetschalckx

Pick and Place Clean Room Robot

MotomanK3crpic


Robotic Part Unloading With Vacuum


Robotic Spray Painting in Automotive Assembly