CHAPTER 6
MATERIAL HANDLING
Material Handling
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.
The cost of MH estimates 20-25 of total manufacturing labor cost in the United States [The Material Handling Industry of America
(MHIA)]
Goals of Material Handling
The primary goal is to reduce unit costs of production
Maintain or improve product quality, reduce damage of materials Promote safety and improve working conditions 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
Goals of Material Handling
Promote increased use of facilities Reduce tare weight (dead weight) Control inventory
Overview of Material Handling Equipment
Material handling equipment includes:
Transport Equipment: industrial trucks, Automated Guided vehicles (AGVs), monorails, conveyors, cranes and hoists. Storage Systems: bulk storage, rack systems, shelving and bins, drawer storage, automated storage systems. Unitizing Equipment: palletizers Identification and Tracking systems
Considerations in Material Handling System Design
1. Material Characteristics
Category Physical state Size Weight Shape Condition Safety risk and risk of damage Measures Solid, liquid, or gas Volume; length, width, height Weight per piece, weight per unit volume Long and flat, round, square, etc. Hot, cold, wet, etc. Explosive, flammable, toxic; fragile, etc.
Considerations cont.
2. Flow rate
Quantity of material moved
High Low
Conveyors
Conveyors AGV train Powered trucks Unit load AGV
Manual handling Hand trucks
Short
Long
Move Distance
Considerations cont.
3. Plant Layout
Layout Type Fixed position Characteristics Typical MH Equipment Large product size, low productionCranes, hoists, industrial trucks rate Variation in product and processing, low and medium production rates Hand trucks, forklift trucks, AGVs
Process
Product
Limited product variety, high production rate
Conveyors for product flow, trucks to deliver components to stations.
20 Principles of Material Handling
1. The Planning Principle
Large-scale material handling projects usually require a team approach. Material handling planning considers every move, every storage need, and any delay in order to minimize production costs. The plan should reflect the strategic objectives of the organization as well as the more immediate needs.
2. The systems principle: MH and storage activities should
be fully integrated to form a coordinated, operational system that spans receiving, inspection, storage, production, assembly, , shipping, and the handling of returns. 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.
3.
Simplification principle
simplify handling by reducing, eliminating, or combining unnecessary movement and/or equipment. Four questions to ask to simplify any job:
Can this job be eliminated? If we cant eliminate, can we combine movements to reduce cost? (unit load concept) If we cant eliminate or combine, can we rearrange the operations to reduce the travel distance? If we cant do any of the above, can we simplify?
4. Gravity principle
Utilize gravity to move material whenever practical.
5. Space utilization principle
The better we use our building cube, the less space we need to buy or rent. Racks, mezzanines, and overhead conveyors are a few examples that promote this goal.
6. Unit load principle
Unit loads should be appropriately sized and configured at each stage of the supply chain. The most common unit load is the pallet
cardboard pallets plastic pallets wooden pallets steel skids
pp 164 - 169
8. Automation principle
MH operations should be mechanized and/or automated where feasible to improve operational efficiency, increase responsiveness, improve consistency and predictability, decrease operating costs. ASRS is a perfect example.
10. Equipment selection principle
Why? What? Where? When? How? Who? If we answer these questions about each move, the solution will become evident. Look at pp 160-161.
11.
The standardization principle
standardize handling methods as well as types and sizes of handling equipment too many sizes and brands of equipment results in higher operational cost. A fewer sizes of carton will simplify the storage.
13.
12. The dead weight principle
Try to reduce the ratio of equipment weight to product weight. Dont buy equipment that is bigger than necessary. Reduce tare weight and save money. Plan for preventive maintenance and scheduled repairs of all handling equipment. Pallets and storage facilities need repair too. use handling equipment to help achieve desired production capacity i.e. material handling equipment can help to maximize production equipment utilization.
13. The maintenance principle
14. The capacity principle
Example
A punch press can cycle every 0.03 minute, but our time standard for manually loading and unloading this press is only 300 pieces per hour.
Press capacity = 60 min / 0.03 = 2000 pieces/hr Utilization = 300 / 2000 = 15%
Should we buy a new press? If we can purchase a coil-feeding material handling system, we could approach 100% press utilization.
