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8/8/2019 6. Material Handling Storage Facilities & Layout (2)
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MATERIAL HANDLING, STORAGEFACILITIES & LAYOUT
GROUP 6
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Material Handling-DefinitionMaterial handling is the art and science of moving,storing, protecting, and controlling material Right amount
Right material Right condition
Right place
Right time
Right position
Right sequence
Right cost
Right method(s)
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Need for Improvement
Time spend in material handling
Costly handling and no value addition
Excessive loading and unloading
Repeated manual handling
Long distance material movement
Congestion and damages
Ideal scenario is ¶No Handling·
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How to Improve?
Eliminating or reducing handling
Improving the efficiency of handling
Making the correct choice of material handling
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Elimination & Reduction Method study approach
Outline
flow process
flow diagrams
Questioning
When? Where? How? Who? Why?
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Improving Efficiency Increase no of units handled
Increase the speed of handling
Ensure easy transportation
Use gravity for advantage
Ensure straight line movement
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Types of MaterialsTypes of Materials
Gases
Liquids
Solids
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Gases and Liquids
Pipelines
SolidsConveyors
Industrial Trucks
Cranes
HoistsContainers
AGVs
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FACTORS CONSIDERED WHEN CHOOSING MATERIAL HANDLINGFACTORS CONSIDERED WHEN CHOOSING MATERIAL HANDLINGEQUIPMENTEQUIPMENT
Material properties
Layout and characteristics of the
building Production flow
Cost consideration
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PipelinesPipelines
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ConveyorsConveyors
Gravity or powered devices commonlyused for moving uniform loads
continuously from point to point overfixed paths, where the primaryfunction is conveying.
Types:
Belt
Roller
Overhead
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Belt ConveyorsBelt Conveyors
An endless fabric, rubber, plastic,leather or metal belt operating over
suitable drive, tail end, and bendterminals and over bend idlers orslider bed for handling material,packages or objects placed directly
upon the belt
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Belt conveyorBelt conveyor
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Belt conveyorBelt conveyor
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Belt conveyor in airportsBelt conveyor in airports
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Roller ConveyorsRoller Conveyors
A conveyor which supports the loadon a series of rollers, turning on fixed
bearings and mounted between siderails at fixed intervals determined bythe size of object to be carried, whichis usually moved manually or by
gravity.
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Roller conveyorRoller conveyor
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Roller conveyorRoller conveyor
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Overhead ConveyorsOverhead Conveyors
An endless chain supported by trolleysfrom an overhead track.
At a height of 8-9 ft from floor.
It frees the floor and eliminatesinterference with other traffic. Tracks
may dip to lower level for moreconvenient access to carts
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Overhead ConveyorsOverhead Conveyors
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Industrial TrucksIndustrial Trucks
Hand or powered vehicles used for themovement of mixed or uniform loads
intermittently over various pathshaving suitable running surfaces andclearances, where the primaryfunction is maneuvering.
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Industrial TrucksIndustrial Trucks
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ForkliftsForklifts
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CRANES
DIFFERENT TYPES:
OVERHEAD CRANES
GANTRY CRANES
JIB CRANES
LOADER CRANES
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OVERHEAD CRANES
Also known as a ³suspended crane´.
Can lift very heavy, bulky, lengthy loads. It consists of a bridge constructed from one or
several girders supporting a mobile hoist.
The floor area remains completely free for other
activities.
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OVERHEAD CRANE
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GANTRY CRANES
Gantry Cranes provide an economical way to lift
materials anywhere in a facility.
They are supported on legs with wheels, that run on
rails on the ground.
Used for very heavy loads (over 20 tones)
Cheaper but slower than overhead cranes.
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GANTRY CRANES
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JIB CRANES
Pillar and wall-mounted jibs are typically needed to
service specific work areas.
Jib cranes help to cut setting up and idle times and
reduce unnecessary waiting for an overhead crane.
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J
IB CRANES Wall traveling jibs cranes with under hung or top
running hoist trolleys are also available.
The main characteristic of all designs is the low jib
deadweight and correspondingly large outreach
and high load capacity.
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JIB CRANES
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LOADER CRANES
Hydraulically-powered articulated arm fitted to a trailer,
used to move goods onto or off of the trailer.
Unlike most cranes the operator must move around to be
able to view his load; hence he has a portable cabled or
radio linked control system.
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LOADER CRANE
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HOISTS
Hand Chain Wheel Driven Trolley
Wire Hoists Chain Hoists
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HAND CHAINWHEEL
DRIVEN TROLLEY
High quality chain hoists
are easy to use, the large
spur gears make raising andlowering the loads easy.
They are compact and
lightweight, which allows
them to be used be usedanywhere.
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WIRE HOIST
Heavy-duty,
frequent lifting
calls for an electric
hoist. An electrichoist utilizes the
same components
as a manual hoist
but utilizes a motor for speed and ease
of operation.
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ELECTRIC CHAIN HOIST
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AGVs (Automated Guided Vehicles)
To bring work to operator
Increases productivity and flexibility
of scheduling Advantages over conveyors
Bigger load sizes than conveyors
Frequency of service is different
Changing Path
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Parts of AGVs Transmitter ± Sends out Signals (Optical
or Audio)
Receiver ± Receives Reflected Signal,Conditions the Signal, Sends it to theLogical Unit
Logical Unit ± Heart of the AGV, Decodes
the Received Signal and Acts accordingto a Pre-Stored Programme.
AGVs (Automated Guided Vehicles)
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Important Considerations
Sensitive to extreme temperatures andfumes
Floor consideration
AGVs (Automated Guided Vehicles)
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AGVs (Automated Guided Vehicles)
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AGVs (Automated Guided Vehicles)
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Advantages
Reduce Manpower
Increase Productivity Efficient long-distance movements
Reduce Product Damage
Maintain Better Control of Material
Management Creates an ergonomic, safe environment
AGVs (Automated Guided Vehicles)
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Disadvantages
High Initial Cost
Maintenance Cost
AGVs (Automated Guided Vehicles)
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STORAGE
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Why storage is needed?
Floor space savings
Increased picking speeds
Health & safety
Improved stock accuracy
Stock security
Flexibility
large impact on the company'sbottom line
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Types of Storage
Raw Material Storage
Work-in-process Storage
Finished goods storage
Storage for supplies, packing materials,maintenance, scrap materials and the like
Storage for special tools- jigs, fixtures,
inactive equipment Office Storage- Active and inactive records
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Liquid Storage Raw Material Storage
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Silo Raw Material Storage
Silos arestructures for
storing bulkmaterials. itused inagriculture to
store grain,coal, cement,carbon black.
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Coil Storage Raw Material Storage
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Shelf
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Rack Storage
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Vertical carousel
an automated computer
controlled vertical carousel
which can operate both as
a central inventory store or
as an on-line materials
handling system, providing
accurate, real-time data
from the shop floor to high
level planning systems
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Vertical carousel
The vertical
carousel
concept makesmaximum use of
ceiling heights.
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Horizontal carousel
This storage runs
directly on the floor,
eliminating expensivesupport structures
and allowing
headroom to beused effectively
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Movable Rack
Racks mounted
on movable
carriages
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Arrangement of Cars inVolkswagen Golf
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Stacking
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Stacking
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Cold Storage
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Types of boxes to store files
Group records by series and by
disposition date; clearly labeled
within boxes.
Boxes should not be overfilled.
Place archival records in a separate
box from non-archival
Each record has:
Contains unique numbersidentifying contents (accession
number, location, disposition date,
record status).
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Fixed Shelf File:
Requires no assembly.
Solid steel reinforced construction
throughout for added unit rigidity.
Storage Cabinets
Very customisable
For personal use
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Open Shelf Filing System
Ideal for Open Shelf Filing,
Library Book Stacks, Heavy
Duty Industrial Storage,
Clean appearance with
remarkable strength.
Lateral Filing systems
Attached to the wall, savingvaluable floor space
Allows easier, more efficient
access to your most used
files.
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Stocking & Retrieving Files
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PLANT LAYOUT
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PLANT LAYOUT
A proper arrangement of machinery, equipment andmaterials.
Initially developed at the start of any office or firm.
Saves a lot of space and helps in free flow of operations.
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Recosideration Introduction of new plant
Redesigning existing facilities
Inefficient operation
Product change
Accidents or safety hazards
Excessive transfer times and buffers
Plant Layout
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Major types of layout
Product layout
Process layout
Fixed product layout Group layout
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Product layout
Also known as line layout or mass production.
The arrangement of machinery and equipment at oneplace for production of particular product.
e.g. Bottling plant, car assembly etc.
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Advantages
A high rate of output
Low unit cost due to highvolume
Low material handlingcost/unit as the units
follow the same sequenceof operations
High utilization of laborand equipment.
Disadvantages
Intensive division of laborusually creates dull,
repetitive jobs thatprovide little opportunityfor advancement & maylead to stress and moraledown
The system is inflexible tochanges in volume of o/por changes in product orprocess design
Preventive maintenanceand quick repairs areexpensive
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Process layout
Layouts that are designed to process items or provideservices that involve the variety of processingrequirements. It features departments or otherfunctional group in which similar kind of activities are
performed.
e.g. machine shop, textile spinning etc.
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Advantages System can handle
variety of processingrequirements
General purposeequipments are lesscostly than thespecialized equipmentand is easier and lesscostly to maintain
It is possible to useindividual incentiveplan
Disadvantages In process inventory
cost is high
Material handling isslow and inefficient
Equipment utilizationrates are low
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Fixed product layout
Layout in which the product or project remainsstationary and workers materials and equipmentsare moved as required
e.g. shipbuilding, aircraft construction etc
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Advantages
Material movement is
reduced
Provide job enrichmentopportunities
Promotes pride andquality because anindividual can complete
the whole job
Disadvantages
Personal and equipmentmovement is increased
May result in duplicateequipment
Require greater skill for
personnel
Require generalsupervision
May result in increasedspace and greater work inprogress
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Group layout
Layout in which workstations are grouped into a cell
that can process items that have similar processingrequirements
e.g. Product with similar design (shape, size, function)cs
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Advantages
Smoother flow lines and
shorter travel distancesare expected than forprocess layouts
Team atmosphere and jobenlargement benefitsoften results
Has some of the benefitsof the product layouts & process layouts; it is a
compromise between thetwo
Disadvantages
General supervisionrequired
If flow is not balanced ineach cell, buffers andwork in progress storageare required in the cell toeliminate the need for
added material handlingto and from the cell
Has some of thedisadvantages of theproduct & processlayouts; it is thecompromise between thetwo
Decreases the opportunityto use special purposetools
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Production volume and product varietydetermines type of layout
combination
layout
process layout
product variety
production
volume
product
layout
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