5.Material Handling System Design and Decision

May 7, 2018 | Author: Saranya Sathiyamoorthy | Category: Automation, Warehouse, Forklift, Transport, Science And Technology


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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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