Chapter # 05 Material Handling - PowerPoint Presentation

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2. Chapter # 05 Material HandlingPresented toDr. HarisGroup Members Muhammad Hassan Sarfraz 11-IE-47Muhammad Zameer 11-IE-49Faisal Hafeez 11-IE-5401/10/2014

3. 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”

4. Right amount How much inventory needed?Smaller load size are preferredRight materialManual material handling results in picking wrong materialAutomatic identification is key to accurate identification and picking right material e.g. using Bar-code-based or RFID-based systemRight conditionIt is the state which customer desires to receive the materialThe goods must also be received without damageRight orientationIt means positioning of material for ease of handlingThe orientation should be in such a way that it reduces the handling timeMaterial handling Definition

5. 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 systemRight 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 costMaterial handling Definition

6. The development of MH equipment today is much more complex task than it was in the pastMH solution are no longer a simple case of moving material through conveyorsNew MH technologies have dramatically changed the amount of labor required for MH tasksBefore installation Simulation techniques are used to estimate the cost of different systems, to find an optimal MH systemFrom the time of installation of a MH system, one can reduce cost by continuous improvement in the system.Estimating MH cost

7. 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 costMaterial 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

8. 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

9. Planning principle (what, when, where, how, who)Standardization Principle (Less variety, Customization)Work Principle (volume/weight * distance)Ergonomic Principle (working conditions according to abilities of workers)Unit Load Principle (Single entity)Space Utilization (cubic space)System Principle (Collection of entities)Automation Principle (Electro-mechanical devices)Environmental Principle (not to waste natural resources)Life-Cycle Cost Principle (All cash flows)Material handling Principles

10. 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

11. For development of Alternatives “Ideal System Approach” is used, which consist of four phases;alternative MH system

12. MH system equation=

13. What Question What are the types of material to be moved?What are their characteristicsWhat are amounts moved and storedWhere 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 QuestionWhen should material be moved?When is time to mechanize or automate?MH system equationMATERIALSMOVES

14. How Question How is material moved or stored?How much inventory should be maintained?How should the material be tracked?Who QuestionWhat 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 necessaryWhich types of MH equipment?Which MH system is cost effective?MH system equationMETHODS

15. Material handling planning chart can be used to;Gather information pertaining to a specific MH problemTo provide Preliminary examination of the alternative solutionsThe 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 recordedMH Planning chart

16. This planning chart usually contains 15 columnsFirst eight columns provide information on the Where QuestionThe 9th to 12th column answer the What QuestionThe 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 designThe 15th column tells about the method of material handling with appropriate material handling equipmentMH Planning chart

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18. 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

19. 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 UnderstandingPalletTote pan

20. 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 needSize of Unit load

21. Large Unit LoadsRequire bigger & heavier equipment with higher load capacitiesIncrease WIP inventoryCompletion time increasesMajor advantage is fewer movesSmall unit loads:Increased transportation needsReduce WIP InventoryRequire simple material handling (push carts and similar devices)Decrease job completion timeEFFECTS OF Size of Unit load

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

24. Lifting under the massInserting the lifting elements into the body of unit loadSqueezing the load between two lifting surfacesSuspending the loadBasic manners to move Unit load

25. Containers with good Stacking and Nesting features can provide significant reduction in material handlingReturnable containers

26. This figure shows why we need stackability and nestability

27. 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;Stringer designBlock designPallets and Pallet sizes

28. 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 systemContainer & Pallet Pooling

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30. Example (on efficiency of returnable containers)

31. 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

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

33. 5. Retailer Return Ratio:One stack of empty containers contain 55 containers.The total number of empty containers per trailer; Trailer Return Ratio.

34. Mh equipment classificationContainers and unitizing equipmentContainers (pallets, skids, tote pans)Unitizers (Stretchwrap, Palletizers)Material Transport EquipmentConveyors (chute, belt, roller, wheel, slat, chain, trolley, sorting)Industrial vehicles (walking, Riding, Automated)Monorails, hoists &cranesStorage and retrieval equipmentUnit Load storage and retrieval (Block stacking, Mobile rack)Small load storage and retrieval equipmentAutomatic identification and communication equipmentAutomatic identification and recognition (Bar codes, radio frequency tag)Automatic paperless communication (voice headset, smart card)

35. The development of MH equipment today is much more complex task than it was in the pastMH solution are no longer a simple case of moving material through conveyorsNew MH technologies have dramatically changed the amount of labor required for MH tasksBefore installation Simulation techniques are used to estimate the cost of different systems, to find an optimal MH systemFrom the time of installation of a MH system, one can reduce cost by continuous improvement in the system.Estimating MH cost

36. ?Any Question