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Material HandlingMaterial Handling
Material Handling System Design
OutlineOutline
Definitions
Unit Load
Material Handling Equipment
Importance of Material HandlingImportance of Material Handling
In a typical factory, material Handling accounts for:
MH
MHMH55%55%
Factory Space
87%Productiontime
15%70%
Product Cost
Material Handling DefinitionsMaterial Handling Definitions
MH is the art and science of moving, storing, protecting, and controlling material.
PROVIDE
Right amount
Right material
Right time
Right condition
Right place
Right position
Right sequence
Right cost
Right methods
New MHI Material Handling DefinitionNew MHI Material Handling Definition
Material Handling is the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal. The focus is on the methods, mechanical equipment, systems and related controls used to achieve these functions.
Source: MHI website - Glossaryhttp://www.mhia.org/keywords/keyworddescr_template.cfm?keyword_id=762
Aligns with “progressive view” of scope of material handling defined by Apple, that is a total system view (p. 166 text)
Operations
Subjects
Business Processes
Objectives of Material HandlingObjectives of Material Handling
Increase the efficiency of material flow
Reduce MH cost
Improve facilities utilization
Safety and working conditions
Manufacturing process
Increase productivity
Source: D.R.Sule, Manufacturing facilities
Highlights of DefinitionsHighlights of Definitions
Art and science
Right stuff in the right way
Efficient Storage and Movement
Movement of “parts” with machines
Methods/Controls of movement to meet facility objectives
Throughout the supply chain
MH ExamplesMH Examples Material Handling is not restricted to the manufacturing or distribution environment
ConstructionMail Delivery
HospitalsMass Transportation
Material Handling PrinciplesMaterial Handling Principles
Defined by the Material Handling Institute and the College-Industry Council on Material Handling Education (CICME) (p.167 text):
6. Space Utilization (3-D)
7. System
8. Automation
9. Environmental
10. Life Cycle Cost
(procurement-removal)
*Most important according to textbook authors
1. Planning
(what,when,where)
2. Standardization
3. Work (cost x flow)
4. Ergonomic
5. *Unit Load
Material Handling Systems DesignMaterial Handling Systems Design
Define the objectives & scope
Analyze the requirements
Generate alternative designs
Evaluate alternative designs
Select the preferred design
Implement the preferred design
Work simplification in MHWork simplification in MH
Framework for identifying MH solutions
Evaluate each movement:1. Can the move be eliminated ?
2. Can the move be combined with another or within an in-transit operation ?
3. Can the move be simplified ?
4. Can the sequence of moves be changed to advantages ?
Why?
MH Planning ChartMH Planning Chart
Analyzing MH solutions
MH Planning Chart: (Figure 5.2, pg 173)
• Information w.r.t. a specific MH solution• Record ALL movements (people + machines)
→ Reveals unnecessary movements and storage
Unit LoadsUnit Loads
• A unit load is the unit to be moved or handled at one time.
• A unit load includes the container, carrier, or support that will
be used to move materials.
Stacking
Forklift
Pallet
Unit Load
Pallet sized byANSI (American National
Standard Institute)
Unit Load Unit Load
• Examples: tote boxes, “cassette”, cartons, skids, pallets, pallet boxes, intermodal container, one unit of product, etc.
• Most popular: plastic containers and pallets• Factors for determining unit load/ container:
– Size of carrier– Size and weight of items– Space for storing loaded/unloaded container– Equipment used for moving– Cost, supply and maintenance– Aisle widths, door sizes, and clear stacking heights– Environmental regulations
Unit Load and Handling SystemUnit Load and Handling System
The unit load is an integral part of the material handling system and a “simultaneous” determination should be made.
Design the Unit Load
Design the Handling/Storage
system
In-class Exercise: Unit Load and Cycle TimeIn-class Exercise: Unit Load and Cycle Time
We have a system with two machines. Every unit of the product has to go through Machine 1 first and then through Machine 2.
Machine 1
1 min/unit
Machine 2
1 min/unit
We move the product using forklift trucks. The company has several of them going around permanently. We can use one whenever we need. The move from Machine 1 to Machine 2 takes two minutes.
The forklift truck moves a batch (or a lot) of units at a time.
How many units should we move at a time using the forklift truck to minimize the time of completion of an order of 16 units?
In other words, how big should the unit load be to minimize completion time?
Unit Load and Unit Load and Cycle TimeCycle Time
MH time > processing time => MH constrained
Large unit loads: longer cycle times, fewer moves
Small unit loads: lower cycle time, lower WIP, more frequent handling
Lot size = 16 unitsMachining = 1 min/unitOperations 1 and 2MH = 2 min/trip
M1MHM2
16 34
UL = 16 units
M1MHM2
18 26
UL = 8 units
M1MHM2
6 20
UL = 2 units
M1MHM2
4 34
UL = 1 unit
Unit Load DisadvantagesUnit Load Disadvantages
Time spent forming and breaking down the unit load.
Cost of containers/pallets and other load restraining materials used in the unit load
Empty containers/pallets may need to be returned to their point of origin.
Review QuestionsReview Questions
1. The Unit Load remains the same throughout the facility.
True or False?
2. Which statement is the most accurate?a) Material Handling should be reduced as much as possible.
b) The materials, movements, and methods define the MH system.
c) The unit load should be decided before any other MH decisions.
d) The what, where, and when, defines the how and who.
Classification of M.H. EquipmentClassification of M.H. Equipment
I. Containers & unitizers
II. Material Transport Equipment
1. Conveyors
2. Industrial Trucks & Vehicles
3. Monorails, Hoists & Cranes
III. Storage & Retrieval
Equipment
IV. Automatic Identification &
Communication Equipment
MH Equipment ResourcesMH Equipment Resources
• MHE Taxonomy (http://www.ise.ncsu.edu/kay/mhetax/index.htm)
• The Material Handling Multimedia Bank
(http://www.centor.ulaval.ca/MHMultimediaBank)
• Textbook (Appendix 5b)
• Material Handling Industry of America (http://www.mhia.org)
• CICMHE Website (http://www.mhia.org/cicmhe/)
• MaterialHandlingInfo.com (http://208.226.12.140/mhi/)