6. Material Handling Storage Facilities & Layout (2)

8/8/2019 6. Material Handling Storage Facilities & Layout (2)

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MATERIAL HANDLING, STORAGEFACILITIES & LAYOUT

GROUP 6

Material Handling-DefinitionMaterial handling is the art and science of moving,storing, protecting, and controlling material Right amount

Right material Right condition

Right place

Right time

Right position

Right sequence

Right cost

Right method(s)

Need for Improvement

Time spend in material handling

Costly handling and no value addition

Excessive loading and unloading

Repeated manual handling

Long distance material movement

Congestion and damages

Ideal scenario is ¶No Handling·

How to Improve?

Eliminating or reducing handling

Improving the efficiency of handling

Making the correct choice of material handling

Elimination & Reduction Method study approach

Outline

flow process

flow diagrams

Questioning

When? Where? How? Who? Why?

Improving Efficiency Increase no of units handled

Increase the speed of handling

Ensure easy transportation

Use gravity for advantage

Ensure straight line movement

Types of MaterialsTypes of Materials

Liquids

Solids

Gases and Liquids

Pipelines

SolidsConveyors

Industrial Trucks

Cranes

HoistsContainers

FACTORS CONSIDERED WHEN CHOOSING MATERIAL HANDLINGFACTORS CONSIDERED WHEN CHOOSING MATERIAL HANDLINGEQUIPMENTEQUIPMENT

Material properties

Layout and characteristics of the

building Production flow

Cost consideration

PipelinesPipelines

ConveyorsConveyors

Gravity or powered devices commonlyused for moving uniform loads

continuously from point to point overfixed paths, where the primaryfunction is conveying.

Types:

Roller

Overhead

Belt ConveyorsBelt Conveyors

An endless fabric, rubber, plastic,leather or metal belt operating over

suitable drive, tail end, and bendterminals and over bend idlers orslider bed for handling material,packages or objects placed directly

upon the belt

Belt conveyorBelt conveyor

Belt conveyor in airportsBelt conveyor in airports

Roller ConveyorsRoller Conveyors

A conveyor which supports the loadon a series of rollers, turning on fixed

bearings and mounted between siderails at fixed intervals determined bythe size of object to be carried, whichis usually moved manually or by

gravity.

Roller conveyorRoller conveyor

Overhead ConveyorsOverhead Conveyors

An endless chain supported by trolleysfrom an overhead track.

At a height of 8-9 ft from floor.

It frees the floor and eliminatesinterference with other traffic. Tracks

may dip to lower level for moreconvenient access to carts

Overhead ConveyorsOverhead Conveyors

Industrial TrucksIndustrial Trucks

Hand or powered vehicles used for themovement of mixed or uniform loads

intermittently over various pathshaving suitable running surfaces andclearances, where the primaryfunction is maneuvering.

Industrial TrucksIndustrial Trucks

ForkliftsForklifts

CRANES

DIFFERENT TYPES:

OVERHEAD CRANES

GANTRY CRANES

JIB CRANES

LOADER CRANES

OVERHEAD CRANES

Also known as a ³suspended crane´.

Can lift very heavy, bulky, lengthy loads. It consists of a bridge constructed from one or

several girders supporting a mobile hoist.

The floor area remains completely free for other

activities.

OVERHEAD CRANE

GANTRY CRANES

Gantry Cranes provide an economical way to lift

materials anywhere in a facility.

They are supported on legs with wheels, that run on

rails on the ground.

Used for very heavy loads (over 20 tones)

Cheaper but slower than overhead cranes.

GANTRY CRANES

JIB CRANES

Pillar and wall-mounted jibs are typically needed to

service specific work areas.

Jib cranes help to cut setting up and idle times and

reduce unnecessary waiting for an overhead crane.

IB CRANES Wall traveling jibs cranes with under hung or top

running hoist trolleys are also available.

The main characteristic of all designs is the low jib

deadweight and correspondingly large outreach

and high load capacity.

JIB CRANES

LOADER CRANES

Hydraulically-powered articulated arm fitted to a trailer,

used to move goods onto or off of the trailer.

Unlike most cranes the operator must move around to be

able to view his load; hence he has a portable cabled or

radio linked control system.

LOADER CRANE

HOISTS

Hand Chain Wheel Driven Trolley

Wire Hoists Chain Hoists

HAND CHAINWHEEL

DRIVEN TROLLEY

High quality chain hoists

are easy to use, the large

spur gears make raising andlowering the loads easy.

They are compact and

lightweight, which allows

them to be used be usedanywhere.

WIRE HOIST

Heavy-duty,

frequent lifting

calls for an electric

hoist. An electrichoist utilizes the

same components

as a manual hoist

but utilizes a motor for speed and ease

of operation.

ELECTRIC CHAIN HOIST

AGVs (Automated Guided Vehicles)

To bring work to operator

Increases productivity and flexibility

of scheduling Advantages over conveyors

Bigger load sizes than conveyors

Frequency of service is different

Changing Path

Parts of AGVs Transmitter ± Sends out Signals (Optical

or Audio)

Receiver ± Receives Reflected Signal,Conditions the Signal, Sends it to theLogical Unit

Logical Unit ± Heart of the AGV, Decodes

the Received Signal and Acts accordingto a Pre-Stored Programme.

Important Considerations

Sensitive to extreme temperatures andfumes

Floor consideration

Advantages

Reduce Manpower

Increase Productivity Efficient long-distance movements

Reduce Product Damage

Maintain Better Control of Material

Management Creates an ergonomic, safe environment

Disadvantages

High Initial Cost

Maintenance Cost

STORAGE

Why storage is needed?

Floor space savings

Increased picking speeds

Health & safety

Improved stock accuracy

Stock security

Flexibility

large impact on the company'sbottom line

Types of Storage

Raw Material Storage

Work-in-process Storage

Finished goods storage

Storage for supplies, packing materials,maintenance, scrap materials and the like

Storage for special tools- jigs, fixtures,

inactive equipment Office Storage- Active and inactive records

Liquid Storage Raw Material Storage

Silo Raw Material Storage

Silos arestructures for

storing bulkmaterials. itused inagriculture to

store grain,coal, cement,carbon black.

Coil Storage Raw Material Storage

Rack Storage

Vertical carousel

an automated computer

controlled vertical carousel

which can operate both as

a central inventory store or

as an on-line materials

handling system, providing

accurate, real-time data

from the shop floor to high

level planning systems

Vertical carousel

The vertical

carousel

concept makesmaximum use of

ceiling heights.

Horizontal carousel

This storage runs

directly on the floor,

eliminating expensivesupport structures

and allowing

headroom to beused effectively

Movable Rack

Racks mounted

on movable

carriages

Arrangement of Cars inVolkswagen Golf

Stacking

Cold Storage

Types of boxes to store files

Group records by series and by

disposition date; clearly labeled

within boxes.

Boxes should not be overfilled.

Place archival records in a separate

box from non-archival

Each record has:

Contains unique numbersidentifying contents (accession

number, location, disposition date,

record status).

Fixed Shelf File:

Requires no assembly.

Solid steel reinforced construction

throughout for added unit rigidity.

Storage Cabinets

Very customisable

For personal use

Open Shelf Filing System

Ideal for Open Shelf Filing,

Library Book Stacks, Heavy

Duty Industrial Storage,

Clean appearance with

remarkable strength.

Lateral Filing systems

Attached to the wall, savingvaluable floor space

Allows easier, more efficient

access to your most used

files.

Stocking & Retrieving Files

PLANT LAYOUT

A proper arrangement of machinery, equipment andmaterials.

Initially developed at the start of any office or firm.

Saves a lot of space and helps in free flow of operations.

Recosideration Introduction of new plant

Redesigning existing facilities

Inefficient operation

Product change

Accidents or safety hazards

Excessive transfer times and buffers

Plant Layout

Major types of layout

Product layout

Process layout

Fixed product layout Group layout

Product layout

Also known as line layout or mass production.

The arrangement of machinery and equipment at oneplace for production of particular product.

e.g. Bottling plant, car assembly etc.

Advantages

A high rate of output

Low unit cost due to highvolume

Low material handlingcost/unit as the units

follow the same sequenceof operations

High utilization of laborand equipment.

Disadvantages

Intensive division of laborusually creates dull,

repetitive jobs thatprovide little opportunityfor advancement & maylead to stress and moraledown

The system is inflexible tochanges in volume of o/por changes in product orprocess design

Preventive maintenanceand quick repairs areexpensive

Process layout

Layouts that are designed to process items or provideservices that involve the variety of processingrequirements. It features departments or otherfunctional group in which similar kind of activities are

performed.

e.g. machine shop, textile spinning etc.

Advantages System can handle

variety of processingrequirements

General purposeequipments are lesscostly than thespecialized equipmentand is easier and lesscostly to maintain

It is possible to useindividual incentiveplan

Disadvantages In process inventory

cost is high

Material handling isslow and inefficient

Equipment utilizationrates are low

Fixed product layout

Layout in which the product or project remainsstationary and workers materials and equipmentsare moved as required

e.g. shipbuilding, aircraft construction etc

Advantages

Material movement is

reduced

Provide job enrichmentopportunities

Promotes pride andquality because anindividual can complete

the whole job

Disadvantages

Personal and equipmentmovement is increased

May result in duplicateequipment

Require greater skill for

personnel

Require generalsupervision

May result in increasedspace and greater work inprogress

Group layout

Layout in which workstations are grouped into a cell

that can process items that have similar processingrequirements

e.g. Product with similar design (shape, size, function)cs

Advantages

Smoother flow lines and

shorter travel distancesare expected than forprocess layouts

Team atmosphere and jobenlargement benefitsoften results

Has some of the benefitsof the product layouts & process layouts; it is a

compromise between thetwo

Disadvantages

General supervisionrequired

If flow is not balanced ineach cell, buffers andwork in progress storageare required in the cell toeliminate the need for

added material handlingto and from the cell

Has some of thedisadvantages of theproduct & processlayouts; it is thecompromise between thetwo

Decreases the opportunityto use special purposetools

Production volume and product varietydetermines type of layout

combination

layout

process layout

product variety

production

volume

product

layout

6. Material Handling Storage Facilities & Layout (2)

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