Chapter # 05 Material Handling

Presented toDr. Haris

Group Members Muhammad Hassan Sarfraz 11-IE-47Muhammad Zameer 11-IE-49Faisal Hafeez 11-IE-54

01/10/2014

Material handling Definition

“Material handling means providing the right amount of the right material, in the right condition, at the right place, in the right position, in the right sequence, for the right

cost and by the right method”

• Right amount • How much inventory needed?• Smaller load size are preferred

• Right material• Manual material handling results in picking wrong material• Automatic identification is key to accurate identification and picking right material

e.g. using Bar-code-based or RFID-based system

• Right condition• It is the state which customer desires to receive the material• The goods must also be received without damage

• Right orientation• It means positioning of material for ease of handling• The orientation should be in such a way that it reduces the handling time

Material handling Definition

• Right placeIt is desirable to directly transport material to point of use rather than store the

material at some intermediate location.

• Right timeIt means ON-TIME deliveryThe goal is to achieve a lower cycle time MH system

• Right costIt is not necessarily the lowest costMinimizing cost is wrong objective in material handling system designThe most appropriate goal is to design most efficient material handling system at

the most reasonable cost

Material handling Definition

The development of MH equipment today is much more complex task than it was in the past

MH solution are no longer a simple case of moving material through conveyorsNew MH technologies have dramatically changed the amount of labor required for

MH tasks Before installation Simulation techniques are used to estimate the cost of

different systems, to find an optimal MH system From the time of installation of a MH system, one can reduce cost by

continuous improvement in the system.

ESTIMATING MH COST

• In a typical facility, material handling accounts for;25% of all employees55% of all factory space87% of all production time15 to 70% of total product cost

• Material Handling can be viewed as a mean by which total manufacturing costs are reduced through more efficient material flow control, lower inventories and improved safety.

SCOPE OF MATERIAL HANDLING

Facility designers should be familiar with all the safety requirements for the type of facility they are designing.

Poor ergonomics ,which means setting the workers in the job instead of setting the job for workers, accounts for one-third of all workplace injuries.

A poor layout for the rack area is a common shortfall in the designs of pallet-rack solutions in industries.

OSHA regulations for general industry provide the basis and represent the minimum standards.

SAFETY CONSIDERATIONS

1) Planning principle (what, when, where, how, who)2) Standardization Principle (Less variety, Customization)3) Work Principle (volume/weight * distance)4) Ergonomic Principle (working conditions according to abilities of

workers)5) Unit Load Principle (Single entity)6) Space Utilization (cubic space)7) System Principle (Collection of entities)8) Automation Principle (Electro-mechanical devices)9) Environmental Principle (not to waste natural resources)10)Life-Cycle Cost Principle (All cash flows)

MATERIAL HANDLING PRINCIPLES

6 steps to design Material Handling system;Define objective and scope Analyze the requirements for moving, storing, protecting and controlling materialsGenerate alternative designs for MH system requirementEvaluate alternative material handling system designsSelect the preferred designImplement the preferred design

It is unrealistic to expect that the material handling system will operate perfectly the first time around.Adopting a posture of continuous improvement will result in far more efficient operation of material handling system.

DESIGNING MH SYSTEM

For development of Alternatives “Ideal System Approach” is used, which consist of four phases;

ALTERNATIVE MH SYSTEM

AIM• Aim for theoretical

Ideal System

• Theoretical Ideal System has;• Zero cost• Perfect Quality• No hazards• No wasted space

CONCEPTUALIZE• Conceptualize the

Ultimate ideal system

• Ultimate Ideal System is a system that would be achievable in future

DESIGN• Design the

technologically workable system

• Technologically workable system has;• Not applicable • High cost• Not appropriate

conditions

INSTALL• Install the

recommended system

• Recommended system is;• Cost effective• Match our

requirements

MH SYSTEM EQUATION

=

• What Question • What are the types of material to be moved?• What are their characteristics• What are amounts moved and stored

• Where Question • Where is the material coming from?• Where is the material delivered?• Where is the material stored?• Where can material handling tasks be eliminated, combined or

simplified?

• When Question• When should material be moved?• When is time to mechanize or automate?

MH SYSTEM EQUATION

MATERIALS

MOVES

• How Question • How is material moved or stored?• How much inventory should be maintained?• How should the material be tracked?

• Who Question• What are required skills to perform MH tasks?• Who should be trained to service and maintain the MH system?• Who should be involved in designing the system?

• Which Question • Which MH operations are necessary• Which types of MH equipment?• Which MH system is cost effective?

MH SYSTEM EQUATION

METHODS

• Material handling planning chart can be used to;Gather information pertaining to a specific MH problemTo provide Preliminary examination of the alternative solutions

• The result from analyses using this chart can be used in simulation of alternative solutions

• Following figure shows a planning chart which includes;• Information on operations (O), transportations (T), storages (S) and inspection (I)• All movements, performed by operator or machine should be recorded

MH PLANNING CHART

• This planning chart usually contains 15 columns• First eight columns provide information on the Where Question• The 9th to 12th column answer the What Question• The frequency to move is recorded In 13th column. Frequency is calculated based on

estimated production volume and the capacity of unit load.• The 14th column tells about length of the move. The distance moved can only be

calculated after the completion of facility layout design• The 15th column tells about the method of material handling with appropriate

material handling equipment

MH PLANNING CHART

Definition:“A single item, a number of items, or bulk material, which is arranged or restrained so that the load can be stored and picked up and moved between two locations as a single mass.”• The nature of unit load could change each time an item, or a number of

items, or bulk material is moved. Variability in quantity/size per move is permissible.

UNIT LOAD DESIGN

A single item moved between two locations manually constitutes one unit load.

Two tote pans with identical components moved by a dolly from one machine to the other constitute one unit load.

One pallet load of non uniform-sized cartons moved by a lift truck from packaging area to the shipping dock constitute one unit load.

Further Understanding

Pallet

Tote pan

Size of Unit Load can rangefrom a single part carried by a person to:Each carton moved through conveyorsA number of cartons on a pallet moved by fork lift trucksA number of containers moved by rail across states or by container ships across

continents. Two important elements in determining the size of the unit load are;

Cube (length x with x height)Weight limitCarton boxes, pallets, tote pans can be used according to need

SIZE OF UNIT LOAD

Large Unit Loads• Require bigger & heavier equipment with higher load capacities• Increase WIP inventory• Completion time increases• Major advantage is fewer movesSmall unit loads:• Increased transportation needs• Reduce WIP Inventory• Require simple material handling (push carts and similar devices)• Decrease job completion time

EFFECTS OF SIZE OF UNIT LOAD

Important conclusion: In order to achieve single unit production the material handling time must be shorter than the unit processing time.

1. Lifting under the mass2. Inserting the lifting elements into the body of unit load3. Squeezing the load between two lifting surfaces4. Suspending the load

BASIC MANNERS TO MOVE UNIT LOAD

• Containers with good Stacking and Nesting features can provide significant reduction in material handling

RETURNABLE CONTAINERS

• Full container can be stacked on top of another full container in the same spatial orientationStackability

• The shape of the containers permits an empty container to be inserted into another empty container

Nestability

This figure shows why we need stackability and nestability

A common method of containing the unit load. They come in a variety of designs and are usually dictated by the

application. Common designs are;a) Stringer designb) Block design

PALLETS AND PALLET SIZES

It was widely accepted in Europe first then north American companies adopted it also.

It means, instead of buying, rent containers and pallets for a fee per day per container or pallet.

Whenever you need them, you go to the nearest depot and get as many as you need.

After use, they are returned to the nearest depot or another company in the supply chain.

The figure in next slide shows the container/pallet flow in a).Conventional

b). Pallet pooling system c). Integrated logistics and pallet pooling system

CONTAINER & PALLET POOLING

Example (on efficiency of returnable containers)

1. Container Space utilization:Divide the useable cube by the exterior envelope of the container.

2. Storage space efficiency:Ratio of useable cube and the storage of cube.

3.Container nesting ratio:Overall container height by the nested height.

Solution

4. Trailer Space Utilization:• Along the Length= containers.• Along the width= containers.• Along the height= containers.

Total= containers.

• Utilization

5. Retailer Return Ratio:• One stack of empty containers contain 55 containers.

• The total number of empty containers per trailer;

• Trailer Return Ratio.

MH EQUIPMENT CLASSIFICATION

1. Containers and unitizing equipment1. Containers (pallets, skids, tote pans)2. Unitizers (Stretchwrap, Palletizers)

2. Material Transport Equipment1. Conveyors (chute, belt, roller, wheel, slat, chain, trolley, sorting)2. Industrial vehicles (walking, Riding, Automated)3. Monorails, hoists &cranes

3. Storage and retrieval equipment1. Unit Load storage and retrieval (Block stacking, Mobile rack)2. Small load storage and retrieval equipment

4. Automatic identification and communication equipment1. Automatic identification and recognition (Bar codes, radio frequency tag)2. Automatic paperless communication (voice headset, smart card)

The development of MH equipment today is much more complex task than it was in the past

MH solution are no longer a simple case of moving material through conveyorsNew MH technologies have dramatically changed the amount of labor required for

MH tasks Before installation Simulation techniques are used to estimate the cost of

different systems, to find an optimal MH system From the time of installation of a MH system, one can reduce cost by

continuous improvement in the system.

ESTIMATING MH COST

?Any Question