Post on 18-Dec-2015
Facilities Planning Facilities Planning - Unit 10- Unit 10
Material Handling EquipmentMaterial Handling Equipment
Material Handling Equipment - 2
Hierarchy of Facility PlanningHierarchy of Facility Planning
Facility Planning
Structural Design
Facility Location
Facility Design
Handling System Design
Layout Design
Source for Figure: Tompkins and White, Facilities Planning, 2nd edition, Wiley
Material Handling Equipment - 3
Components of Material HandlingComponents of Material Handling The MaterialsThe Materials – products, items, substances and/or people
which are being moved, transported, or physically relocated.
The MoveThe Move – (origin, travel path, destination, frequency) to be made.
The MethodThe Method – (equipment, people, procedures, physical facilities) to be used to make the move
Material Handling EquationMaterial Handling Equation
Material Handling Equipment - 4
Principles of Material HandlingPrinciples of Material Handling
The Principles of material HandlingPrinciples of material Handling serve as a starting point to identifying potential problems and assessing need. They are:
1. Planning2. Standardization3. Work4. Ergonomic5. Unit Load6. Space Utilization7. System8. Automation9. Environment10. Life Cycle Cost
Material Handling Equipment - 5
Cost Reduction FormulaCost Reduction Formula
Ask For Every So We Can
Why? Operation Eliminate
Who? Transportation Combine
What? Inspection Change Sequence
Where? Storage Simplify
When? Delay
How?
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Material Handling TaxonomyMaterial Handling TaxonomySource: College-Industry Council on Material Handling Education (CICMHE)Source: College-Industry Council on Material Handling Education (CICMHE)
Material Handling Equipment - 7
Material Handling EquipmentMaterial Handling Equipment
Material handling equipment (MHE) is used for the movement and storage of material within a facility or at a site. MHE can be classified into the following five major categories:
Transport Equipment:Transport Equipment: Equipment used to move material from one location to another (e.g., between workplaces, between a loading dock and a storage area, etc.). The major subcategories of transport equipment are conveyorsconveyors , cranescranes, and industrial trucksindustrial trucks. Material can also be transported manually using no equipmentequipment.
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Material Handling EquipmentMaterial Handling Equipment
Positioning Equipment.Positioning Equipment. Equipment used to handle material at a single location so that it is in the correct position for subsequent handling, machining, transport, or storage. Unlike transport equipment, positioning equipment is usually used for handling at a single workplace. Material can also be positioned manually using no equipment.
Unit Load Formation Equipment.Unit Load Formation Equipment. Equipment used to restrict materials so that they maintain their integrity when handled as a single load during transport and for storage. If materials are self-restraining (e.g., a single part or interlocking parts), then they can be formed into a unit load with no equipment.
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Material Handling EquipmentMaterial Handling Equipment
Storage Equipment.Storage Equipment. Equipment used for holding or buffering materials over a period of time. Some storage equipment may include the transport of materials (e.g., the S/R machines of an AS/RS, or storage carousels). If materials are block stacked directly on the floor, then no storage equipment is required.
Identification and Control EquipmentIdentification and Control Equipment.. Equipment used to collect and communicate the information that is used to coordinate the flow of materials within a facility and between a facility and its suppliers and customers. The identification of materials and associated control can be performed manually with no specialized equipment.
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Material Handling EquipmentMaterial Handling EquipmentTransport EquipmentTransport Equipment
The major subcategories of transport equipment are:The major subcategories of transport equipment are:
Conveyors.Conveyors. Equipment used to move materials over a fixed path between specific points.
Cranes.Cranes. Equipment used to move materials over variable paths within a restricted area.
Industrial Trucks.Industrial Trucks. Equipment used to move materials over variable paths, with no restrictions on the area covered by the movement (i.e., unrestricted area).
No Equipment.No Equipment. Material can also be transported manually using no equipment.
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Material Handling EquipmentMaterial Handling EquipmentTransport EquipmentTransport Equipment
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - ConveyorsTransport Equipment - Conveyors
Conveyors are used:Conveyors are used:1. When material is to be moved frequently between specific
points 2. To move materials over a fixed path 3. When there is a sufficient flow volume to justify the fixed
conveyor investment
Conveyors can be classified in different ways:Conveyors can be classified in different ways:1. Type of product being handled: unit load or bulk load 2. Location of the conveyor: overhead, on-floor, or in-floor 3. Whether or not loads can accumulate on the conveyor
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - ConveyorsTransport Equipment - Conveyors
Chute conveyor
Wheel conveyor
Roller conveyor
Gravity roller conveyor
Live (powered) roller conveyor
Chain conveyor
Slat conveyor
Flat belt conveyor
Magnetic belt conveyor
Troughed belt conveyor
Bucket conveyor
Vibrating conveyor
Screw conveyor
Pneumatic conveyor
Dilute-phase pneumatic conveyor
Carrier-system pneumatic conveyor
Vertical conveyor
Vertical lift conveyor
Reciprocating vertical conveyor
Cart-on-track conveyor
Tow conveyor
Trolley conveyor
Power-and-free conveyor
Monorail
Sortation conveyor
Diverter
Pop-up device
Sliding shoe device
Tilting device
Cross-belt transfer device
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - ConveyorsTransport Equipment - Conveyors
Chute Conveyor
Wheel Conveyor
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - ConveyorsTransport Equipment - Conveyors
Gravity Roller Conveyor
Live (Powered) Roller Conveyor
Chain Conveyor
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - ConveyorsTransport Equipment - Conveyors
Flat Belt Conveyor Slat Conveyor
Magnetic Belt Conveyor
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - ConveyorsTransport Equipment - Conveyors
Troughed Belt Conveyor
Bucket Conveyor
Vibrating Conveyor
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - ConveyorsTransport Equipment - Conveyors
Screw Conveyor
Dilute-Phase Pneumatic Conveyor
Carrier-System Pneumatic Conveyor
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - ConveyorsTransport Equipment - Conveyors
Reciprocating Vertical Conveyor
Vertical Lift Conveyor
Cart-On-Track Conveyor
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - ConveyorsTransport Equipment - Conveyors
Tow Conveyor
Trolley Conveyor
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - ConveyorsTransport Equipment - Conveyors
Power-and-Free Conveyor
Monorail
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - ConveyorsTransport Equipment - Conveyors
Sortation Conveyor
Sortation Conveyor: Diverter
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - ConveyorsTransport Equipment - Conveyors
Sortation Conveyor: Pop-Up Device
Sortation Conveyor: Sliding Shoe Sorter
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - ConveyorsTransport Equipment - Conveyors
Sortation Conveyor: Tilting Device
Sortation Conveyor: Cross-Belt Transfer Device
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - CranesTransport Equipment - Cranes
General characteristics of cranes:General characteristics of cranes:1. Used to move loads over variable (horizontal and vertical)
paths within a restricted area 2. Used when there is insufficient (or intermittent) flow volume
such that the use of a conveyor cannot be justified 3. Provide more flexibility in movement than conveyors 4. Provide less flexibility in movement than industrial trucks 5. Loads handled are more varied with respect to their shape and
weight than those handled by a conveyor 6. Most cranes utilize hoists for vertical movement, although
manipulators can be used if precise positioning of the load is required
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - CranesTransport Equipment - Cranes
Cranes are used to move materials over variable paths within a restricted area. The major types of cranes are:
Jib crane Bridge crane Gantry crane Stacker crane
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - CranesTransport Equipment - Cranes
Jib Crane
Bridge Crane
Stacker Crane
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment - CranesTransport Equipment - Cranes
Gantry Crane
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment – Industrial TrucksTransport Equipment – Industrial Trucks
Industrial trucks:• Used to move materials over variable (horizontal) paths with no
restrictions on the area covered (i.e., unrestricted area) • Provide vertical movement if the truck has lifting capabilities • Used when there is insufficient (or intermittent) flow volume
such that the use of a conveyor cannot be justified • Provide more flexibility in movement than conveyors and
cranes • Not licensed to travel on public roads—"commercial trucks"
are licensed to travel on public roads
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment – Industrial TrucksTransport Equipment – Industrial Trucks
Hand truck
Two-wheeled hand truck
Dolly
Floor hand truck
Pallet jack
Manual pallet jack
Powered pallet jack
Walkie stacker
Manual walkie stacker
Powered walkie stacker
Pallet truck
Platform truck
Walkie platform truck
Rider platform truck
Counterbalanced lift truck
Sit-down counterbalanced lift truck
Stand-up counterbalanced lift truck
Narrow-aisle straddle truck
Narrow-aisle reach truck
Turret truck
Operator-down turret truck
Operator-up turret truck
Order picker
Sideloader
Tractor-trailer
Personnel and burden carrier
Automatic guided vehicle (AGV)
Tow AGV
Unit load AGV
Assembly AGV
Light load AGV
Fork AGV
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment – Industrial TrucksTransport Equipment – Industrial Trucks
Floor Hand Truck
Two-Wheeled Hand Truck
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment – Industrial TrucksTransport Equipment – Industrial Trucks
Manual Pallet Jack
Powered Pallet Jack
Manual Walkie Stacker
Powered Walkie Stacker
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment – Industrial TrucksTransport Equipment – Industrial Trucks
Sit-Down Counterbalanced Lift Truck
Narrow-Aisle (NA) Straddle Truck
Narrow-Aisle (NA) Reach Truck
Operator-Down Turret Truck
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Material Handling EquipmentMaterial Handling EquipmentTransport Equipment – Industrial TrucksTransport Equipment – Industrial Trucks
Assembly AGV
Unit Load AGV
Tow AGV
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The powered industrial trucks are used for moving either mixed or uniform loads intermittently over various paths. While these paths can be somewhat random at the discretion of the driver, the paths are restricted to suitable indoor or outdoor surfaces.
These trucks are used for moving either mixed or uniform loads intermittently over various paths. While these paths can be somewhat random at the discretion of the driver, the paths are restricted to suitable indoor or outdoor surfaces.
Material Handling EquipmentMaterial Handling EquipmentPowered Industrial TrucksPowered Industrial Trucks
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Industrial trucks provide not only a means of transporting materials, but also provide a means of accurate lifting and stacking.
Appropriate tooling for the truck permits users to lift not only pallets, but a wide array of specialized loads. For example, rolls of carpet are easily moved via industrial truck by replacing standard forks with a single tube.
Material Handling EquipmentMaterial Handling EquipmentPowered Industrial TrucksPowered Industrial Trucks
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Powered industrial trucks can be found in almost any manufacturing plant, loading dock, or warehouses. Powered industrial trucks are made by a variety of manufacturers for diverse purposes, including some highly specialized applications.
Internal combustion trucks add the advantage of outdoor use. They can lift 2,000 to 15,000 pounds with some specialty trucks lifting up to 50 tons. They can lift up to 20 feet in height and can operate on gasoline, LP-gas, or diesel fuel.
Material Handling EquipmentMaterial Handling EquipmentPowered Industrial Trucks Powered Industrial Trucks
Slides 37-50 are supplemental to already published CICMHE Material Handling Taxonomy. These slides are created using literature from the Industrial Truck Association and the document, “An Introduction to Material Handling Equipment Selection1” edited by Brett A. Peters.
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The Industrial Truck Association (ITA) has classified the powered trucks into seven classes which are:
Class 1Class 1 – Electric Motor Rider TrucksClass 2Class 2 – Electric Motor Narrow Aisle TrucksClass 3Class 3 – Electric Motor Hand TruckClass 4Class 4 – Internal Combustion Engine Trucks – Cushion Tires OnlyClass 5Class 5 –Internal Combustion Engine Trucks – Pneumatic Tires OnlyClass 6Class 6 –Electric and Internal Combustion Engine Tow TractorsClass 7Class 7 – Rough Terrain Fork Lift Trucks
Each of the classes are divided into “lift codes.” See the ITA Pictorial Model Listing.
Material Handling EquipmentMaterial Handling EquipmentPowered Industrial TrucksPowered Industrial Trucks
Material Handling Equipment - 39
The first five classes are the most common. Detailed information is available through the ITA.
Electric Motor Rider TrucksElectric Motor Rider Trucks are general purpose trucks and are used primarily indoors. These trucks can lift up to 6 tons and up to 18 feet in height. Electric Motor Narrow Aisle TrucksElectric Motor Narrow Aisle Trucks are used in narrow aisle applications. These trucks are used primarily for storage/retrieval in applications similar to AS/RS functions. They can easily lift loads from 2,000 to 4,500 pounds to heights of 40 feet.
Material Handling EquipmentMaterial Handling EquipmentPowered Industrial TrucksPowered Industrial Trucks
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Electric Motor Hand TrucksElectric Motor Hand Trucks are generally used for indoor applications and can handle loads up to 4 tons.
These trucks are perfect for situations in which material is to be moved from one location to another without the need for lifting more than a few inches. For example, this type of truck is commonly used in grocery stores to move pallet loads of cans or boxes to a display location within the store.
An added convenience is that the operator can move among customers in the store safely and without obstructed views.
Material Handling EquipmentMaterial Handling EquipmentPowered Industrial TrucksPowered Industrial Trucks
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Internal Combustion TrucksInternal Combustion Trucks add the advantage of outdoor use. They can lift 2,000 to 15,000 pounds with some specialty trucks lifting up to 50 tons. They can lift up to 20 feet in height and can operate on gasoline, LP-gas, or diesel fuel.
Internal combustion trucks add the advantage of outdoor use. They can lift 2,000 to 15,000 pounds with some specialty trucks lifting up to 50 tons. They can lift up to 20 feet in height and can operate on gasoline, LP-gas, or diesel fuel.
Material Handling EquipmentMaterial Handling EquipmentPowered Industrial TrucksPowered Industrial Trucks
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Material Handling EquipmentMaterial Handling EquipmentPowered Industrial Trucks - ITA ClassificationPowered Industrial Trucks - ITA Classification
Class 1 – Electric Motor Rider TrucksClass 1 – Electric Motor Rider Trucks
Lift Code 1Lift Code 1 Counterbalanced Rider Type, Stand Up
Lift Code 4Lift Code 4 Three Wheel Electric Trucks, Sit-Down
Lift Code 5Lift Code 5 Counterbalanced Rider Type, Cushion Tires, Sit-Down (Includes High & Low Platform)
Lift Code 6Lift Code 6 Counterbalanced Rider, Pneumatic Type Tire, Sit-Down (Includes High & Low Platform)
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Material Handling EquipmentMaterial Handling EquipmentPowered Industrial Trucks - ITA ClassificationPowered Industrial Trucks - ITA Classification
Class 2 – Electric Motor Narrow Aisle TrucksClass 2 – Electric Motor Narrow Aisle Trucks
Lift Code 1Lift Code 1 High Lift Straddle
Lift Code 2Lift Code 2 Order Picker
Lift Code 3Lift Code 3 Reach Type Outrigger
Lift Code 4Lift Code 4 Side Loaders, Turret Trucks, Swing Mast and Convertible Turret/Stock Pickers
Lift Code 6Lift Code 6 Low Lift Pallet and Platform (Rider)
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Material Handling EquipmentMaterial Handling EquipmentPowered Industrial Trucks - ITA ClassificationPowered Industrial Trucks - ITA Classification
Class 3 – Electric Motor Hand TruckClass 3 – Electric Motor Hand Truck
Lift Code 1Lift Code 1 Low Lift Platform
Lift Code 2Lift Code 2 Low Lift Walkie Pallet
Lift Code 3Lift Code 3 Tractors (Draw Bar Pull Under 999 Lbs.)
Lift Code 4Lift Code 4 Low Lift Walkie/Center Control
Lift Code 5Lift Code 5 Reach Type Outrigger
Lift Code 6Lift Code 6 High Lift Straddle
Lift Code 7Lift Code 7 High Lift Counterbalanced
Lift Code 8Lift Code 8 Low Lift Walkie/Rider Pallet
Material Handling Equipment - 45
Material Handling EquipmentMaterial Handling EquipmentPowered Industrial Trucks - ITA ClassificationPowered Industrial Trucks - ITA Classification
Class 4 – Internal Combustion Engine Trucks – Cushion Tires OnlyClass 4 – Internal Combustion Engine Trucks – Cushion Tires Only
Lift Code 3Lift Code 3 Fork, Counterbalanced (Cushion Tire)
Class 5 –Internal Combustion Engine Trucks – Pneumatic Tires OnlyClass 5 –Internal Combustion Engine Trucks – Pneumatic Tires Only
Lift Code 4Lift Code 4 Fork, Counterbalanced (Pneumatic Tire)
Class 6 –Electric and Internal Combustion Engine Tow TractorsClass 6 –Electric and Internal Combustion Engine Tow Tractors
Lift Code 1Lift Code 1 Sit-Down Rider (Draw Bar Pull Over 999 Lbs.)
Class 7 – Rough Terrain Fork Lift TrucksClass 7 – Rough Terrain Fork Lift Trucks
Lift Code 1Lift Code 1 All Rough Terrain Lift Trucks
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Material Handling EquipmentMaterial Handling EquipmentPowered Industrial Trucks - ITA Pictorial Model ListingPowered Industrial Trucks - ITA Pictorial Model Listing
Class I - Electric Motor Rider Trucks (Lift Code 1)
Class I - Electric Motor Rider Trucks (Lift Code 4)
Class I - Electric Motor Rider Trucks (Lift Code 5)
Class I - Electric Motor Rider Trucks (Lift Code 6)
Class II - Electric Motor Narrow Aisle Trucks (Lift Code 1)
Class II - Electric Motor Narrow Aisle Trucks (Lift Code 2)
Material Handling Equipment - 47
Material Handling EquipmentMaterial Handling EquipmentPowered Industrial Trucks - ITA Pictorial Model ListingPowered Industrial Trucks - ITA Pictorial Model Listing
Class II - Electric Motor Narrow Aisle Trucks (Lift Code 4)
Class II - Electric Motor Narrow Aisle Trucks (Lift Code 4)
Class II - Electric Motor Narrow Aisle Trucks (Lift Code 3)
Class II - Electric Motor Narrow Aisle Trucks (Lift Code 4)
Class II - Electric Motor Narrow Aisle Trucks (Lift Code 6)
Class II - Electric Motor Narrow Aisle Trucks (Lift Code 6)
Material Handling Equipment - 48
Material Handling EquipmentMaterial Handling EquipmentPowered Industrial Trucks - ITA Pictorial Model ListingPowered Industrial Trucks - ITA Pictorial Model Listing
Class III - Electric Motor Hand Trucks (Lift Code 1)
Class III - Electric Motor Hand Trucks (Lift Code 4)
Class III - Electric Motor Hand Trucks (Lift Code 2)
Class III - Electric Motor Hand Trucks (Lift Code 5)
Class III - Electric Motor Hand Trucks (Lift Code 3)
Class III - Electric Motor Hand Trucks (Lift Code 6)
Material Handling Equipment - 49
Material Handling EquipmentMaterial Handling EquipmentPowered Industrial Trucks - ITA Pictorial Model ListingPowered Industrial Trucks - ITA Pictorial Model Listing
Class III - Electric Motor Hand Trucks (Lift Code 6)
Class III - Electric Motor Hand Trucks (Lift Code 8)
Class IV – Internal Combustion Engine Trucks (Lift Code 3)
Class III - Electric Motor Hand Trucks (Lift Code 6)
Class III - Electric Motor Hand Trucks (Lift Code 7)
Class V – Internal Combustion Engine Trucks-Pneumatic Tires Only (Lift Code 4)
Material Handling Equipment - 50
Material Handling EquipmentMaterial Handling EquipmentPowered Industrial Trucks - ITA Pictorial Model ListingPowered Industrial Trucks - ITA Pictorial Model Listing
Class VII – Rough Terrain Forklift Trucks (Lift Code 1)
Class VI – Electric and Internal Combustion Engine Tractors (Lift Code 1)
Class VII – Rough Terrain Forklift Trucks (Lift Code 1)
For additional information on industrial truck classification,visit the Industrial Truck Association web site at:
http://www.indtrk.org
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Material Handling EquipmentMaterial Handling EquipmentPositioning EquipmentPositioning Equipment
Positioning equipment is used to handle material at a single location so that the material is in the correct position for subsequent handling, machining, transport, or storage. Unlike transport equipment, positioning equipment is usually used for handling at a single workplace. Material can also be positioned manually using no equipment.
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Material Handling EquipmentMaterial Handling EquipmentPositioning EquipmentPositioning Equipment
As compared to manual handling, the use of positioning equipment can provide the following benefits [Modern Materials Handling, Sept. 1993]:
• raise the productivity of each worker when the frequency of handling is high,
• improve product quality and limit damage to materials and equipment when the item handled is heavy or awkward to hold and damage is likely through human error or inattention, and
• reduce fatigue and injuries when the environment is hazardous or inaccessible.
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Material Handling EquipmentMaterial Handling EquipmentPositioning EquipmentPositioning Equipment
Manual (no equipment)
Lift/tilt/turn table
Dock leveler
Ball transfer table
Rotary index table
Parts feeder
Air film device
Hoist
Balancer
Manipulator
Rigid-link manipulator
Articulated jib crane manipulator
Vacuum manipulator
Industrial robot
Material Handling Equipment - 54
Material Handling EquipmentMaterial Handling EquipmentPositioning EquipmentPositioning Equipment
Lift/Tilt/Turn Table
Dock Leveler
Rotary Index Table
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Material Handling EquipmentMaterial Handling EquipmentPositioning EquipmentPositioning Equipment
Parts Feeder
Rigid-Link Manipulator
Air Film Device
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Material Handling EquipmentMaterial Handling EquipmentPositioning EquipmentPositioning Equipment
Articulated Jib Crane Manipulator
Vacuum Manipulator
Industrial Robot
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Material Handling EquipmentMaterial Handling EquipmentUnit Load Formation EquipmentUnit Load Formation Equipment
Unit load formation equipmentUnit load formation equipment used to restrict materials so that they maintain their integrity when handled a single load during transport and for storage.
Advantages of unit loads:Advantages of unit loads:• More items can be handled at the same time, thereby reducing the
number of trips required and, potentially, reducing handling costs, loading and unloading times, and product damage.
• Enables the use of standardized material handling equipment.
Disadvantages of unit loads:Disadvantages of unit loads:• Time spent forming and breaking down the unit load. • Cost of containers/pallets and other load restraining materials used
in the unit load • Empty containers/pallets may need to be returned to their point of
origin.
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Material Handling EquipmentMaterial Handling EquipmentUnit Load Formation EquipmentUnit Load Formation Equipment
Self-restraining (no equipment)
Pallets
Skids
Slipsheets
Tote pans
Pallet boxes/skid boxes
Bins/baskets/racks
Cartons
Bags
Bulk load containers
Crates
Intermodal containers
Strapping/tape/glue
Shrink-wrap/stretch-wrap
Palletizers
Manual palletizing
Robotic pick and place palletizers
Conventional stripper plate palletizers
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Material Handling EquipmentMaterial Handling EquipmentUnit Load Formation EquipmentUnit Load Formation Equipment
Pallets
Slip Sheets
Tote Pans
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Material Handling EquipmentMaterial Handling EquipmentUnit Load Formation EquipmentUnit Load Formation Equipment
Intermodal Containers
Pallet Boxes/Skid Boxes
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Material Handling EquipmentMaterial Handling EquipmentUnit Load Formation EquipmentUnit Load Formation Equipment
Robotic Pick and Place Palletizers
Manual Palletizing
Shrink-Wrap/Stretch-Wrap
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Material Handling EquipmentMaterial Handling EquipmentStorage EquipmentStorage Equipment
Storage equipment used for holding or buffering materials over a period of time.
The most common reason for storing a product allows the other elements of production to operate more efficiently on a per-unit basis because the fixed costs associated with utilizing the element can be spread over more products; e.g., storing up to a truckload of product in a facility reduces the per-unit costs of shipping; and buffering or storage of WIP enables batch production which reduces the per-unit setup costs.
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Material Handling EquipmentMaterial Handling EquipmentStorage EquipmentStorage Equipment
Other potential reasons for storage include: time bridging—allows product to be available when it is needed (e.g., storing spare machine parts at the facility); processing—for some products (e.g., wine), storage can be considered as a processing operation because the product undergoes a required change during storage; and securing—e.g., nuclear waste storage.
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Material Handling EquipmentMaterial Handling EquipmentStorage EquipmentStorage Equipment
Block stacking (no equipment)
Selective pallet rack
Drive-through rack
Drive-in rack
Flow-through rack
Push-back rack
Sliding rack
Cantilever rack
Stacking frame
Shelves/bins/drawers
Storage carouselAutomatic storage/retrieval systems (AS/RS)
Unit load AS/RS
Mini load AS/RS
Man-on-board AS/RS
Deep-lane AS/RS
Split case order picking system
Mezzanine
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Material Handling EquipmentMaterial Handling EquipmentStorage EquipmentStorage Equipment
Selective Pallet Rack
Drive-Through Rack
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Material Handling EquipmentMaterial Handling EquipmentStorage EquipmentStorage Equipment
Drive-In Rack
Flow-Through Rack
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Material Handling EquipmentMaterial Handling EquipmentStorage EquipmentStorage Equipment
Push-Back Rack
Sliding Rack
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Material Handling EquipmentMaterial Handling EquipmentStorage EquipmentStorage Equipment
Shelves / Bins / Drawers
Storage Carousel
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Material Handling EquipmentMaterial Handling EquipmentStorage EquipmentStorage Equipment
Mini-load AS/RS
Unit Load AS/RS
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Material Handling EquipmentMaterial Handling EquipmentStorage EquipmentStorage Equipment
Man-On-Board AS/RS
Split-Case Order Picking System
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Material Handling EquipmentMaterial Handling EquipmentIdentification and Control EquipmentIdentification and Control Equipment
Manual (no equipment)
Bar codes
Radio frequency (RF) tag
Magnetic stripe
Machine vision
Portable data terminal
Electronic data interchange (EDI)/Internet
Identification and control equipment is used to collect and communicate the information that is used to coordinate the flow of materials within a facility and between a facility and its suppliers and customers.
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Material Handling EquipmentMaterial Handling EquipmentIdentification and Control EquipmentIdentification and Control Equipment
Manual (No Equipment)Manual (No Equipment)
The identification of materials and associated communication can be performed manually with no specialized equipment
Although it is sometimes possible to manually coordinate the operation of a material handling system, it becomes more difficult to do so as the speed, size, and complexity of the system increases
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Material Handling EquipmentMaterial Handling EquipmentIdentification and Control EquipmentIdentification and Control Equipment
Bar CodesBar Codes
Unique bar/space patterns represent various alphanumeric characters
Bar code system consists of bar code label, bar code scanner, and bar code printer
Contact bar code scanners use pen or wand to read labels Non-contact bar code scanners include fixed beam, moving
beam, and omni-directional
1-D codes are most common; 2-D codes enable much greater data storage capability
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Material Handling EquipmentMaterial Handling EquipmentIdentification and Control EquipmentIdentification and Control Equipment
Radio Frequency (RF) TagRadio Frequency (RF) Tag
Data encoded on chip encased in a tag
Non-contact: can be read when the tag is within 30 ft. of an antenna
Tags can either be attached to a container, or permanently or temporarily to an item
RF tags have greater data storage capability than bar codes
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Material Handling EquipmentMaterial Handling EquipmentIdentification and Control EquipmentIdentification and Control Equipment
Magnetic StripeMagnetic Stripe
Data encoded on a magnetic stripe that is readable in almost any environment
Requires contact with a reader
Greater storage capability and more expensive than bar codes
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Material Handling EquipmentMaterial Handling EquipmentIdentification and Control EquipmentIdentification and Control Equipment
Machine VisionMachine Vision
Does not require explicit encoding of data since objects can be identified by their physical appearance
Non-contact, but typically requires structured lighting
More flexible than other identification equipment, but less robust
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Material Handling EquipmentMaterial Handling EquipmentIdentification and Control EquipmentIdentification and Control Equipment
Portable Data TerminalPortable Data Terminal
Handheld, arm-mounted, or vehicle-mounted data storage and communication device
Communicates with a host computer via a radio frequency or infrared link
Variety of input devices available: keyboard, bar code scanner, voice headset
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Material Handling EquipmentMaterial Handling EquipmentIdentification and Control EquipmentIdentification and Control Equipment
Electronic Data Interchange (EDI)/InternetElectronic Data Interchange (EDI)/Internet
Electronic data interchange (EDI) provides standards for inter-corporate transfer of purchase orders, invoices, shipping notices, and other frequently used business documents
Prior to the Internet, EDI required expensive dedicated value added networks (VANs)
EDI is critical for implementing JIT manufacturing
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Material Handling EquipmentMaterial Handling EquipmentIdentification and Control EquipmentIdentification and Control Equipment
Deciding on a Picking Medium in Picking OperationsDeciding on a Picking Medium in Picking Operations
As part of warehousing operations and specifically in picking As part of warehousing operations and specifically in picking operations, identification of the parts and their locations can operations, identification of the parts and their locations can have an impact on the picking speed.have an impact on the picking speed.
The following are the most commonly used mechanisms for The following are the most commonly used mechanisms for communicating picks to order pickers:communicating picks to order pickers: Label Picking Pick to Light Radio Frequency Barcode Picking Voice Picking
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Material Handling EquipmentMaterial Handling Equipment
For complete information and more details about the Material Handling Equipment visit: http://www.ie.ncsu.edu/kay/mhetax/index.htm
This web site is made available through support of TheCollege-Industry Council on Material Handling Education (CICMHE)
The College-Industry Council on Material Handling Education (CICMHE) is an independent organization which prepares and provides information, teaching
materials and various events in support of material handling education and research.
Founded in 1952, the Council is composed of college and university educators, material handling equipment manufacturers, distributors, users and consultants,
representatives of the business press, and professional staff members of organizations concerned with material handling education.
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Material Handling EquipmentMaterial Handling EquipmentEquipment Selection CriteriaEquipment Selection Criteria
Material CharacteristicsMaterial Characteristics
Category Measures
Physical stateSizeWeightShapeConditionSafety risk and risk
of damage
Solid, liquid, or gasVolume; length, width, heightWeight per piece, weight per unit volumeLong and flat, round, square, etc.Hot, cold, wet, etc.Explosive, flammable, toxic; fragile, etc.
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Material Handling EquipmentMaterial Handling EquipmentEquipment Selection CriteriaEquipment Selection Criteria
Flow RateFlow Rate
Manual handlingHand trucks
Powered trucksUnit load AGV
Conveyors ConveyorsAGV train
High
Low
LongShort
Move Distance
Quantity of
Material moved
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Material Handling EquipmentMaterial Handling EquipmentEquipment Selection CriteriaEquipment Selection Criteria
Flow RateFlow Rate
Quantity Distance Method
Low Short Manual, Hand Truck
Low Long Power Trucks, Unit AGV
High Long Conveyor
High Short Conveyor, Vehicle Train
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Material Handling EquipmentMaterial Handling EquipmentEquipment Selection CriteriaEquipment Selection Criteria
Layout TypeLayout Type
Conveyors for product flow, trucks to deliver components to stations.
Limited product variety, high production rate
Product
Hand trucks, forklift trucks, AGVs
Variation in product and processing, low and medium production rates
Process
Cranes, hoists, industrial trucks
Large product size, low production rateFixed Position
Typical Material Handling EquipmentCharacteristicsLayout Type
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Material Handling EquipmentMaterial Handling EquipmentSafety and ErgonomicsSafety and Ergonomics
Scientific research shows an increase in injuries at certain levels of exposure to heavy, frequent and awkward lifting (Washington State Department of Labor and Industries, http://www.lni.wa.gov).
Job design is very important in creating a safe and healthy work environment and the selection of proper material handling devices can help with reducing some of the material handling related injuries.
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Paying special attention to:
Frequent lifting Awkward lifting
Material Handling EquipmentMaterial Handling EquipmentSafety and Ergonomics – Job Design Safety and Ergonomics – Job Design
Heavy lifting
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Material Handling EquipmentMaterial Handling EquipmentSafety and Ergonomics – Job Design Safety and Ergonomics – Job Design
WISHA Lifting Calculator Other tools:
ACGIH Lifting TLV NIOSH Lifting Equation Department of
Energy’s “ErgoEaser”
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Principles for reducing heavy liftingPrinciples for reducing heavy lifting
Reduce the weight Increase the weight Use mechanical assistance Slide instead of lift Team lifting
Material Handling EquipmentMaterial Handling EquipmentSafety and Ergonomics – Job Design Safety and Ergonomics – Job Design
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Principles for reducing frequent liftingPrinciples for reducing frequent lifting
Use mechanical assistance Avoid unnecessary lifting Use mobile storage
Material Handling EquipmentMaterial Handling EquipmentSafety and Ergonomics – Job Design Safety and Ergonomics – Job Design
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Principles for reducing awkward lifting - reachingPrinciples for reducing awkward lifting - reaching
Remove obstacles Slide closer Reduce shelf depth Reduce package size Use mechanical assistance Team lifting
Material Handling EquipmentMaterial Handling EquipmentSafety and Ergonomics – Job Design Safety and Ergonomics – Job Design
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Principles for reducing awkward lifting - bendingPrinciples for reducing awkward lifting - bending
Use mechanical assistance to raise the load Add handles Arrange storage Avoid unnecessary lifting
Material Handling EquipmentMaterial Handling EquipmentSafety and Ergonomics – Job Design Safety and Ergonomics – Job Design
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Principles for reducing awkward lifting – reaching above Principles for reducing awkward lifting – reaching above shouldersshoulders
Arrange storage Use mechanical assistance Use a rolling stair or “safety ladder”
Material Handling EquipmentMaterial Handling EquipmentSafety and Ergonomics – Job Design Safety and Ergonomics – Job Design
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Principles for reducing awkward lifting – twistingPrinciples for reducing awkward lifting – twisting Use conveyors Provide more space Arrange storage
Material Handling EquipmentMaterial Handling EquipmentSafety and Ergonomics – Job Design Safety and Ergonomics – Job Design
Principles for reducing duration of liftingPrinciples for reducing duration of lifting
Rotate to other jobs Use mechanical assistance
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Visit the Occupational Safety & Health Administration web site at http://osha.gov. Specifically, visit the Specifically, visit the OSHA Directorate of Training and Education (DTE) section.
DTE’s “Training Resources” section of the site offers references and resources for many safety related topics including material handling safety.
Material Handling EquipmentMaterial Handling EquipmentSafety and ErgonomicsSafety and Ergonomics
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Material Handling EquipmentMaterial Handling EquipmentSafety – ??Safety – ??