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Part III MATERIAL HANDLING AND IDENTIFICATION TECHNOLOGIES

Chapters:10. Material Transport Systems11. Storage Systems12. Automatic Identification and Data Capture

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Material Handling Technologies in the Production System

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Ch 10 Material Transport Systems

Sections:1. Introduction to Material Handling Equipment2. Material Transport Equipment3. Analysis of Material Transport Systems

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Material Handling Defined

“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)Estimated to represent 20-25% of total manufacturing labor cost in US

The proportion varies depending on type of production and degree of automation

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Material Handling

Handling of materials must be performed SafelyEfficientlyAt low costIn a timely mannerAccurately (the right materials in the right quantities to the right locations)And without damage to the materials

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Logistics

“Concerned with the acquisition, movement, storage, and distribution of materials and products as well as theplanning and control of these operations 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

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External Logistics

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Internal Logistics

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Categories of Material Handling Equipment

1. Material transport equipment - to move materials inside a factory, warehouse, or other facility

2. Storage - to store materials and provide access to those materials when required

3. Unitizing equipment - refers to (1) containers to hold materials, and (2) equipment used to load and package the containers

4. Identification and tracking systems - to identify and keep track of the materials being moved and stored

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Design Considerations in Material Handling

Material characteristicsFlow rate, routing, and schedulingPlant layoutUnit load principle

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Material Characteristics

Material characteristics affect type of transport and storage equipment required

Solid, liquid or gasSize WeightShape - long, flat, bulkyCondition - hot, cold, wet, dirtyRisk of damage - fragile, brittle, sturdySafety risk - explosive, flammable, toxic, corrosive

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Flow Rate, Routing, and Scheduling

Flow rate - amount of material moved per unit timeExamples: pieces/hr, pallet loads/hr, tons/hrWhether 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 delivery

Prompt delivery when requiredUse of buffer stocks to mitigate against late deliveries

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Plant Layout

Material handling equipment considerations must be included in the plant layout design problemCorrelation between layout type and material handling equipment:Plant layout type Material handling equipmentFixed-position Cranes, hoists, industrial trucksProcess Hand trucks, forklift trucks, AGVsProduct Conveyors for product flow

Trucks to deliver parts to stations

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Unit Load Principle (unitizing)

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 simultaneouslyRequired number of trips is reducedLoading/unloading times are reducedProduct damage is decreased

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Unit Load Containers

(a) Wooden pallet, (b) pallet box, (c) tote box

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Material Transport Equipment

Five categories:1. Industrial trucks2. Automated guided vehicles (AGV)3. Monorails and other rail guided vehicles4. Conveyors5. Cranes and hoists

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Industrial Trucks

Two basic categories:1. Non-powered (low cost/low rate of delivery)

Human workers push or pull loads

2. Powered (medium cost)Self-propelled, guided or driven by humanCommon example: forklift truck

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Nonpowered Industrial Trucks (Hand Trucks)

(a) Two-wheel hand truck, (b) four-wheel dolly, (c) hand-operated low-lift pallet truck

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Powered Trucks:Walkie Truck

Wheeled forks insert into pallet openingsNo provision for riding; truck is steered by worker using control handle at front of vehicle

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Powered Trucks:Forklift Truck

Widely used in factories and warehouses because pallet loads are so commonCapacities from 450 kg (1000 lb) up to 4500 kg (10,000 lb)Power sources include on-board batteries and internal combustion motors

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Powered Trucks:Towing Tractor

Designed to pull one or more trailing carts in factories and warehouses, as well as for airport baggage handlingPowered by on-board batteries or IC engines

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Automated Guided Vehicles

An Automated Guided Vehicle System (AGVs) is a material handling system that uses independently operated, self-propelled vehicles guided along defined pathways in the facility floorTypes of AGV:

Driverless trainsPallet trucksUnit load AGVs

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Automated Guided Vehicles:Driverless Automated Guided Train

First type of AGVs to be introduced around 1954Common application is moving heavy payloads over long distances in warehouses and factories without intermediate stops along the route

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Automated Guided Vehicles:AGV Pallet Truck

Used to move palletized loads along predetermined routesVehicle is backed into loaded pallet by worker; pallet is then elevated from floorWorker drives pallet truck to AGV guide path and programs destination

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Automated Guided Vehicles:Unit Load Carrier

Used to move unit loads from station to stationOften equipped for automatic loading/unloading of pallets and tote pans using roller conveyors, moving belts, or mechanized lift platforms

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AGVs Applications

1. Driverless train operations - movement of large quantities of material over long distances

2. Storage and distribution - movement of pallet loads between shipping/receiving docks and storage racks

3. Assembly line operations - movement of car bodies and major subassemblies (motors) through the assembly stations

4. Flexible manufacturing systems - movement of workparts between machine tools

5. Miscellaneous - mail delivery and hospital supplies

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Vehicle Guidance Technology

Method by which AGVs pathways are defined and vehicles are controlled to follow the pathways Three main technologies:

Imbedded guide wires - guide wires in the floor emit electromagnetic signal that the vehicles followPaint strips - optical sensors on-board vehicles track the white paint stripsSelf-guided vehicles - vehicles use a combination of

Dead reckoning - vehicle counts wheel turns in given direction to move without guidanceBeacons located throughout facility - vehicle uses triangulation to compute locations

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Vehicle Guidance Using Guide Wire

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Vehicle Management

Two aspects of vehicle management:Traffic control - to minimize interference between vehicles and prevent collisions1. Forward (on-board vehicle) sensing2. Zone controlVehicle dispatching1. On-board control panel2. Remote call stations3. Central computer control

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Zone Control

Zone control to implement blocking system. Zones A, B, and D areblocked. Zone C is free. Vehicle 2 is blocked from entering Zone A by vehicle 1. Vehicle 3 is free to enter Zone C.

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Vehicle Safety

Travel velocity of AGV is slower than typical walking speed of human workerAutomatic stopping of vehicle if it strays from guide path

Acquisition distanceObstacle detection system in forward direction

Use of ultrasonic sensors commonEmergency bumper - brakes vehicle when contact is made with forward objectWarning lights (blinking or rotating red lights)Warning sounds of approaching vehicles

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Rail-Guided Vehicles

Self-propelled vehicles that ride on a fixed-rail systemVehicles operate independently and are driven by electric motors that pick up power from an electrified railFixed rail system

Overhead monorail - suspended overhead from the ceilingOn-floor - parallel fixed rails, tracks generally protrude up from the floor

Routing variations are possible: switches, turntables, and other special track sections

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Overhead Monorail

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Conveyor Systems

“Large family of material transport equipment designed to move materials over fixed paths, usually in large quantities or volumes”

1. Non-powered Materials moved by human workers or by gravity

2. PoweredPower mechanism for transporting materials is contained in the fixed path, using chains, belts, rollers or other mechanical devices

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Conveyor Types

RollerSkate-wheel BeltIn-floor towlineOverhead trolley conveyor Cart-on-track conveyor

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Roller Conveyor

Pathway consists of a series of rollers that are perpendicular to direction of travelLoads must possess a flat bottom to span several rollersPowered rollers rotate to drive the loads forwardUn-powered roller conveyors also available

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Skate-Wheel Conveyor

Similar in operation to roller conveyor but use skate wheels instead of rollersLighter weight and unpoweredSometimes built as portable units that can be used for loading and unloading truck trailers in shipping and receiving

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Belt Conveyor

Continuous loop with forward path to move loadsBelt is made of reinforced elastomerSupport slider or rollers used to support forward loopTwo common forms:

Flat belt (shown)V-shaped for bulk materials

(Support frame not shown)

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In-Floor Tow-Line Conveyor

Four-wheel carts powered by moving chains or cables in trenches in the floorCarts use steel pins (or grippers) to project below floor level and engage the chain (or pulley) for towingThis allows the carts to be disengaged from towline for loading and unloading

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Overhead Trolley Conveyor

A trolley is a wheeled carriage running on an overhead track from which loads can be suspendedTrolleys are connected and moved by a chain or cable that forms a complete loopOften used to move parts and assemblies between major production areas

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Cart-On-Track Conveyor

Carts ride on a track above floor levelCarts are driven by a spinning tubeForward motion of cart is controlled by a drive wheel whose angle can be changed from zero (idle) to 45 degrees (forward)

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Powered Conveyor Operations and Features

Types of motions1. Continuous - conveyor moves at constant velocity2. Asynchronous - conveyor moves with stop-and-go

motionThey stop at stations, move between stations

Another classification of conveyors:1. Single direction2. Continuous loop3. Recirculating

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(a) Single-Direction Conveyor and (b) Continuous Loop Conveyor

(a) Single direction conveyor

(b) Continuous loop conveyor

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Cranes and Hoists

Handling devices for lifting, lowering and transporting materials, often as heavy loadsCranes

Used for horizontal movement of materialsHoists

Used for vertical lifting of materialsCranes usually include hoists so that the crane-and-hoist combination provides

Horizontal transport Vertical lifting and lowering

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Hoist

Hoist with mechanical advantage of four:

(a) sketch of the hoist

(b) diagram to illustrate mechanical advantage

(a) (b)

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Bridge Crane

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Gantry Crane

A half-gantry crane

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Jib Crane

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Analysis of Material Transport Systems

Analysis of vehicle-based systemsFrom-to charts and network diagramsTypes of systems: industrial trucks, AGVS, rail-guided vehicles, and asynchronous conveyor operations

Conveyor analysisSingle-direction conveyorsClosed loop conveyorsRecirculating conveyor systems

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Network Diagram Showing Deliveries between Load/Unload Stations