Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 MATERIAL HANDLING (Textbook Chapter 5)

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

MATERIAL HANDLING(Textbook Chapter 5)


Toward a definiton

• Material Handling accounts for: – 25% of all employees,– 55% of all factory space,– 87% of production time– 15-70% of the total cost of a manufactured product

• 3-5% of all material handled becomes damaged– “Totally eliminate”– However, handling less is not the answer.


Motivations:

• Material handling is a means by which:– Total manufacturing costs are reduced through

• Reduced inventory

• Improved safety

• Reduced pilferage

• Improved material control.

– Manufacturing quality is improved by:• Reducing inventory

• Reducing damage

– Any production strategy is executed.


Definitions:

•Material handling is the art and science of moving, storing, protecting, and controlling material

–Moving: Required to create time and place utility. The value of having the material at the right time and the right place.

–Storing: Provides a buffer between operations, facilitates the efficient use of people and machines.

–Protecting: Includes the packaging, packing against damage and theft.

–Controlling: Physical: Orientation, sequence and space between material.Status: Real-time awareness of the location, amount, destination, origin,

ownership, and schedule of material.


MH-PrinciplesMH-Principles

MH

1. Planning

2. Standardization

3. Work principle

4. Ergonomic

5. Unit load

6. Space Utilization

7. System

8. Automation

9. Environmental 10. Life Cycle Cost


Conditions for improvementConditions for improvement

MH

Idle production equipment due to material shortage

Material piled directly on floor

In-plant containers not standardized

Operators travel excessively for materials and

suppliesExcessive demurrage

Misdirected material

Backtracking of material

Automatic data collection system

not used

No pre-kitting of work

System not capable of change or expansion


Six-step engineering desing process

1. Define the objectives and scope for the material handling system.

2. Analyze the requirements for moving, storing, protecting, and controlling material.

3- Generate alternative designs for meeting material handling system requirements.

4. Evaluate alternative material handling system designs.

5. Select the preferred design for moving, storing, protecting, and controlling material.

6. Implement the preferred design, including the selection of suppliers, training of personnel, installation, debug and startup of equipment, and periodic audits of system performance.


Developing Alternative MHS Designs

NADLER’s IDEALS approach:

1. Aim for the theoretical ideal system.

2. Conceptualize the ultimate ideal system.

3. Design the technologically workable ideal system.

4. Install the recommended system.



The What Question1. What are the types of material to be moved?2. What are their characteristics?3. What are the amounts moved and stored?

The Where Question• Where is the material coming from? Where

should it come from?• Where is the material delivered? Where

should it be delivered?• Where is the material stored? Where should it

be stored?• Where can material handling tasks be

eliminated, combined or simplified?• Where can you apply mechanization or

automation?The When Question1. When is material needed? When should it be

moved?2. When is it time to mechanize or automate?3. When should we conduct a material handling

performance audit?

The How Question1. How is the material moved or stored? How should material be moved or stored? What are the alternative ways of moving or storing the material?2. How much inventory should be maintained?3- How is the material tracked? How should the material be tracked?4. How should the problem be analyzed?The Who Question1. Who should be handling material? What are the required skills to perform the material handling tasks?2. Who should be trained to service and maintain the material handling system?3. Who should be involved in designing the system?The Which Question1. Which material handling operations are necessary?2. Which type of material handling equipment, if any, should be considered?3. Which material handling system is cost effective?4. Which alternative is preferred?


UNIT LOAD

“picked up and moved between two locations as a single mass”

Example:1. a single item picked up and moved manually

between two locations

2. Two tote pans with identical components picked up moved by a dolly from one machine to another

3. One pallet load of nonuniform-size cartons with different products picked up and moved by a lift truck from the packaging area to the shipping dock

4. One full load of products delivered by a trucktrailer from a warehouse to a customer store If the trailer is half full, it is still one unit load.

Larger unit load:

+ fewer moves

- bigger and heavier equipment

-wider aisles

-higher floor load capacities

-increased work-in-process inventory

Smaller unit load:

+ reduced work-in-process inventory

+simple material handling methods (i.e., push carts)

+reduced completion time (How??)

-more moves

-increased material handling time

“Achieving single unit production requires the materail handling time to be shorter than the unit processing time.”








Categories of Material Handling Equipment

1. Containers and Unitizing Equipment

• Containers

• Unitizers

2. Material Transport Equipment

• Conveyors

• Industrial Vehicles

• Monorails, Hoists, and Cranes

3. Storage and Retrieval Equipment

• Unit Load Storage and Retrieval

• Unit Load Storage Equipment

• Unit Load Retrieval Equipment

• Small Load Storage and Retrieval

4. Automatic Data Collection and Communication Equipment

• Automatic Identification and Recognition

• Automatic Paperless Communication


Containers: Tote pans


Containers: Pallets


Unitizers: Palletizer


Unitizers: Stretchwrapper


Conveyors


Conveyors


Industrial Vehicles


Industrial Vehicles


Storage and Retrieval


Storage and Retrieval


Monorails, Hoists and Cranes


Stock to operator: Carousels


Stock to operator: Carousels


MH-PrinciplesMH-Principles

MH

1. Orientation

2. Planning

3. Systems

4. Unit load principle

5. Space utilization

6. Standardization

7. Ergonomic

8. Energy9. Ecology

10. Mechanization

11. Flexibility

12. Simplification

13. Gravity

14. Safety

15. Computerization

16. System Flow

17. Layout

18. Cost19. Maintenance

20. Obsolescence


MATERIALS HANDLING

TEKS 130.403 (c) 12 d

Shared by Ryan Patton, Irving ISD

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Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 MATERIAL HANDLING (Textbook Chapter 5)