January 27, 20161 Material handling System design and decision Unit 3 Management January 27, 201 Supply Chain 6 packing and storing of substances in any form. • Most manufacturers today have moved to automated materialshandling systems to minimize the amount of handling. 01/27/16 .Material handling System design and decision 2 Materials handling is the art and science of moving. Material Handling adds value to product cost. To Increase storage capacity and to provide higher productivity at lower manufacturing costs. Concerned with scheduling of production control. Objectives of Materials Handling To Lowers unit materials handling cost. To provide Contribution for better quality by avoiding damages to products. To provide better control of the flow of materials.Importance of Material Handling 3 Function of production control. Material Handling increases effectiveness of in plant layout by reducing the cost. . To provide better working conditions. To reduce manufacturing cycle time. . Materials handling process and technologies impact productivity by influencing personnel. Material handling is a key logistics activity that can’t be overlooked.Materials Handling 4 Advancements in materials handling technology and equipment offer the potential to substantially improve logistics productivity. space. and capital equipment requirements. gravity flow should be incorporated in system design . the system should be designed to provide maximum continuous product flow. Whenever practical.5 Principles of Material Handling Equipment for handling and storage should be as standardized as possible. Handling equipment should be utilized to the maximum extent possible. Investment should be in handling rather than stationary equipment. In handling equipment selection the ratio of dead weight to payload should be minimized. When in motion. Types of Handling Systems 6 . 1. The types of equipment most commonly used in mechanized systems are: Lift Trucks Rider Trucks Towlines Tractor Trailers Conveyors carousels . MECHANIZED SYSTEMS 7 Mechanized Systems employ a wide range of handling equipment. 1. Pallet-less or Clamp trucks 2. Rider truck applications unloading equipment. and shuttling loads. Types of lift trucks are: High-Stacking trucks. . of general materials handling utility. Lift trucks can move loads of master cartons both horizontally and vertically but are limited to handling unit loads. Rider trucks are widely used in consumer package goods warehouses. is operating include of order typical loading and transportation selection and accumulation. Rider Trucks Rider trucks effective provide method a low-cost. Lift Trucks 8 Lift trucks also called forklifts. Towlines Towlines are utilized to provide 4. Tractor Trailers Tractor trailers consist of a driver- continuous power to four-wheel guided power unit towing a number trailers. . The main advantage of a tow tractor with trailers is flexibility. of individual four-wheel trailers. like a towline. The most common application of towlines is for case goods order selection. is used during order selection. The tractor in combination with trailer. The main advantage of a towline is continuous movement.9 3. Carousel operates on a different concept than most other mechanized handling equipment. gravity and roller or belt movement. . In gravity and roller driven applications permit rearrangement Unit 3 Supply Chain Management with minimum difficulty. repack and service parts. Carousels 10 It is used widely in shipping and receiving operations and serve as the basic handling device for a number of order systems. Conveyors are classified according to power. Carousel systems also utilized computergenerated directed pick carousal lists and rotation computerto further increase order selector productivity.5. the conveyors is driven by a chain. In power configuration. Conveyors 6. The typical carousel application is for the selection of packages in such items as pack. . SEMI AUTOMATED SYSTEMS 11 Mechanized handling is often supplemented by semiautomatic equipment. Robotics. Typical equipment utilized in semiautomated handling includes: Automated Guided Vehicles [AGV]. Live Racks. Computerized Sortation.2. Vehicle for movement. The system consists of four components. Computer control system. Guidance system. Pickup and drop off locations.1. Automated Guided Vehicles [AGV] 12 The AGVS is a mechanized material handling equipment without an operator. . The optical sensing reads the bar code on the items. . Computerized Sortation The sorting device will sort the material based on the sorting code.13 2. The automatic sorting device increases system productivity through. Speed Accuracy Elimination of manual labor. Robotics 14 These are human like machines with microprocessor to perform the programmed activity or series of activities. The use of the live rack reduces the need to use lift trucks to transfer unit loads. The advantage of live rack storage is the potential for automatic rotation of product as a result of rear loading. . Robotics can be used in extreme temperature environments like cold storage or deep freezers.3. 4. Robotics can be used for break bulk or consolidation operations. Live Racks Live racks are commonly used to reduce manual labor in warehouses is storage rack design in which product automatically flows to the desired selection position. Automated Systems The concept of automated handling has offered great potential and limited accomplishment.15 3. Potential to automate Order selection Automated storage/retrieval . Order selection The basic objective was to integrate mechanized. Information technology plays an important part in all handling systems. A major disadvantage of automation is its dependency on proprietary information technology networks. Potential to automate 16 An Automated system has the potential to operate faster and more accurately than its mechanized counterpart.1. Automated system have been designed and constructed for specific applications. and automated handling into a system that offers the advantages of high productivity and accuracy while using minimal labor. semiautomated. Unit 3 Supply Chain Management The general process begins with an automated order selection device preloaded with . 2. . The storage machine is positioned to service different aisles by transfer cars.17 3. The initial function of the storage equipment is to reach the desired storage location rapidly. Automated storage/retrieval Automated storage system that use high-rise storage is a popular form of automation. 4. Information directed systems use mechanized handling controlled by information technology. Information-Directed Systems 18 The concept of information-directed handling is relatively new and the subject of a great deal of research and development. RF Wireless (Wi-Fi) Pick-to-Light . There are two common examples of information-directed material handling systems. Pick-to-Light Pick-to-light is a carousel system variation that is becoming increasingly common.1.RF Wireless (Wi-Fi) 19 The basic use of Wi-Fi to instruct movement of lift trucks is expanded in an informationdirected application to become a highly integrated materials handling system. The main advantage of RF is to improve speed and flexibility of lift truck operations. 2. . In these systems order selectors pick designated items directly into cartons or onto conveyors from lighted carousel locations or storage bins. RF technology provides real-time communication to central data processing systems.
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