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Materials Handling Analysis

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Material HandlingMaterial handling is the function of moving the

right material to the right place, at the right time, in the right amount, in sequence, and in

the right position or condition to minimize production costs.

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Five Aspects of Material Handling1. Movement2. Quantity3. Time4. Space5. Control

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Goals of Material Handling Maintain or improve products quality,

reduce damage, and protect materials Promote safety and improve working

conditions Promote productivity

Straight flow Automate as required Use gravity! It’s free power

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Goals of Material Handling Promote increased facility use

Cube utilization Versatile equipment Develop a PM program

Reduce tare weight (dead weight) Control inventory

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Material HandlingProper material handling can: Improper Material Handling

accounts for 50% of all work related injuries

Material Handling accounts for 40% of the organization’s operating costs.

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Material HandlingProper material handling can: Improve ergonomics Minimize total costs Improve worker safety Reduce human exertion Minimize physical labor

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Material Handling Examples

Lift tables are available with complete 360-

degree turntables so that the operator can work from one side.

They can also be made to tilt up to 90

degrees so that master cartons can be accessed more easily without bending over

into the carton

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Material Handling Examples

Filled drums can be moved utilizing one

person will the proper material

handling equipment.

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Material Handling Examples

How about combining four trips into one?

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Material Handling Examples

Sheet goods. . .why use more than one worker when you can achieve the same results with less waste of waiting

and risk of injury?

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Material Handling Examples

Odd shapes? No problem. . .

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Material Handling Examples

Roll stock . . .

Heavy coil . . .

Heavy boxes . . .

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Material Handling Examples

Conveyors . . .

Gravity Conveyor

Powered Roller Conveyor

Ball Transfer Table

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Material Handling Examples

Telescoping Conveyors . . .

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Material Handling Examples

Stretchaveyor Systems. . .

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Material Handling Supporting Pull Manufacturing

Custom built for unique products.

Note: Holding slots designed to aid inventory control.

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Material Handling Supporting Pull Manufacturing Container holds

approximately 200 pieces.

Note: Kanban sign

Note: Tare weight for weigh counting

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Material Handling IdealsMaterial Handling Ideals to live

by. . .1. KISS – “keep it simple and sane”2. “the best material handling

system is no material handling system at all”

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Material Handling Basic Questions

What operation are we doing? Why do we need to move this

material? Where is the material going? When and how often are we doing it? How are we currently doing it? Who is performing this function?

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Cost Justification ExampleAn oil remanufacturing company uses clay in its manufacturing process. The clay comes into the plant in 80# bags (only size available) stacked 40/pallet and 50 pallets/boxcar. Two carloads per year are used. Since there is no railroad spur to the dock, the union and company agreed that two part-time workers would be hired for one week, twice a year at the rate of $7.50/hr to unload these cars. You are asked to investigate the process and provided recommendations for improvement.

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Cost Justification ExampleWhy is this done? We need clay, and the railroad is by far the cheapest way to transport it. Let’s look at it like this:

What? = 80# x 40 bags x 50 pallets = 160,000#/boxcar

Where? = From the boxcar to the warehouse (300 feet)

Who? = Two temporary workers

When? = One week, twice a year

How? = Manually unload the pallets then move these pallets into the storeroom with the fork truck that we own.

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Cost Justification Example

What do we know?

4 weeks x 40 hrs/week x $7.50/hr = $1,200/year

1. Is the current method the cheapest in the long run?

2. How could you justify a $2,400 expenditure (2 year ROI) to improve the task that is performed so infrequently?

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Part of Body Affected by Injury

Number of Nonfatal Occupational Injuries & Illnesses

Upper Extremities27%

Back30%

Neck2% Shoulder

6%

Lower Extremities24%

Body Systems1%

Multiple Parts10%

1999 BLS Data

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Cost Justification ExampleWhat do we know now?

1. Consider the worker.

2. Material handling is not a simple cost benefit analysis.

3. Look at the whole approach when asking the questions.

4. Consider the claim rates of the company.

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SECS Study

Eliminate

Combine

Simplify

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Large Vs. Small Unit LoadOne should always try to maximize / optimizemaximize / optimize the quantity, size, and weight of the load handled.

The intent is to reduce the overall number of movements or trips required to move or transport a given quantity of materials. Don’t increase load at the expense of inventory!

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Materials Handling and Cycle Time

Operation A

Lot Size Container Size Cycle Time1

100

100

1

100

1

30 min

3,000 min

1,020 min

Operation B

Move

Operation C

Move

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Cycle Time ExampleRemember the second ideal?“the best material handling system is no material

handling system at all”

How about SECS?Do we really need to move between the operations?

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Material Handling Utopia The best of both worlds combines

manufacturing and shipping containers Prevalent in the auto industry

Stackable / nestable racks Collapsible containers Inexpensive to acquire and retain

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Material Handling with Pallets

The most common unit load is the pallet. Almost anything can be stacked on a pallet, tied with bonding or plastic wrap, and moved around the plant or world as on unit. Pallets are made of a variety of materials with greatly differing costs.

Cardboard pallets @ $1 ea will make one trip

Plastic pallets @ $4 ea will make 20 trips

Wooden pallets @ $20 ea will make 100 trips

Steel skids @ $150 ea will make 2,000 trips

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Material Handling with Pallets

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Collapsible Containers

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Collapsible and Nestable Containers

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Materials Handling Analysis Tools Operation process chart (OPC) is used to analyze

relations between operations and is useful for analyzing assembly operations and layout

Flow process chart is used to identify detailed problems such as delay in time, storage costs and material handling costs

Flow diagram mainly concerns with floor space, traffic congestion and traveling distance

PERT chart is used as a project scheduling tool and concerns with timing objective and costs for major projects

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The Performance Principle

Material Handling Hours

Total Labor HoursPercentage of M.H. =

Know what your material handling costs are and continuously work to reduce them. The process chart provides the form to calculate the unit cost of every move. Tracking this percentage can show the improvements in performance.

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From-To Charts Can indicate both volume and process

flow Constructed like a mileage chart List the process steps in their “natural”

direction Can be computer generated or simple

hash tabulation marks Note both the required sequence and

intensity of materials flow Note the handling difficulty and cost

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From-To Chart Most exact technique

of the three

Considers the importance of the parts

Establishes a relative importance ranking

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From-To Chart Example Step 1-

Establish the Relative ImportanceRelative Importance factor

Part No. Quantity per Day Weight in Pounds Total Weight (lbs) Relative Importance1 2,000 0.5 1,000 1.02 2,000 9.0 18,000 18.03 3,000 15.0 45,000 45.0

Step 2-– Create the from-to matrix

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From-To Chart ExampleR A B C D S Total

R 1 18 45 64

A 1 45 18 64

B 18 1 19

C 18+45 1 64

D 1 45 46

S

Total: 257

FRO

M

To

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From-To Chart Example Step 3- Assign the penalty points

Double P.P.

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From-To Chart Example Step 4- Determine the efficiency and evaluate

Efficiency = 257 / 699

= 37%

Can we do better?

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5 MsFive basic factors affect all moves: Man Materials Methods of handling Moves – distances and elevations Money – cost of materials

movement and handling equipment

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Questions and Comments