Material HandlingMaterial Handling

Material Handling System Design

OutlineOutline

Definitions

Unit Load

Material Handling Equipment

Importance of Material HandlingImportance of Material Handling

In a typical factory, material Handling accounts for:

MH

MHMH55%55%

Factory Space

87%Productiontime

15%70%

Product Cost

Material Handling DefinitionsMaterial Handling Definitions

MH is the art and science of moving, storing, protecting, and controlling material.

PROVIDE

Right amount

Right material

Right time

Right condition

Right place

Right position

Right sequence

Right cost

Right methods

New MHI Material Handling DefinitionNew MHI Material Handling Definition

Material Handling is the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal.  The focus is on the methods, mechanical equipment, systems and related controls used to achieve these functions.

Source: MHI website - Glossaryhttp://www.mhia.org/keywords/keyworddescr_template.cfm?keyword_id=762

Aligns with “progressive view” of scope of material handling defined by Apple, that is a total system view (p. 166 text)

Operations

Subjects

Business Processes

Objectives of Material HandlingObjectives of Material Handling

Increase the efficiency of material flow

Reduce MH cost

Improve facilities utilization

Safety and working conditions

Manufacturing process

Increase productivity

Source: D.R.Sule, Manufacturing facilities

Highlights of DefinitionsHighlights of Definitions

Art and science

Right stuff in the right way

Efficient Storage and Movement

Movement of “parts” with machines

Methods/Controls of movement to meet facility objectives

Throughout the supply chain

MH ExamplesMH Examples Material Handling is not restricted to the manufacturing or distribution environment

ConstructionMail Delivery

HospitalsMass Transportation

Material Handling PrinciplesMaterial Handling Principles

Defined by the Material Handling Institute and the College-Industry Council on Material Handling Education (CICME) (p.167 text):

6. Space Utilization (3-D)

7. System

8. Automation

9. Environmental

10. Life Cycle Cost

(procurement-removal)

*Most important according to textbook authors

1. Planning

(what,when,where)

2. Standardization

3. Work (cost x flow)

4. Ergonomic

5. *Unit Load

Material Handling Systems DesignMaterial Handling Systems Design

Define the objectives & scope

Analyze the requirements

Generate alternative designs

Evaluate alternative designs

Select the preferred design

Implement the preferred design

Work simplification in MHWork simplification in MH

Framework for identifying MH solutions

Evaluate each movement:1. Can the move be eliminated ?

2. Can the move be combined with another or within an in-transit operation ?

3. Can the move be simplified ?

4. Can the sequence of moves be changed to advantages ?

Why?

MH Planning ChartMH Planning Chart

Analyzing MH solutions

MH Planning Chart: (Figure 5.2, pg 173)

• Information w.r.t. a specific MH solution• Record ALL movements (people + machines)

→ Reveals unnecessary movements and storage

Unit LoadsUnit Loads

• A unit load is the unit to be moved or handled at one time.

• A unit load includes the container, carrier, or support that will

be used to move materials.

Stacking

Forklift

Pallet

Unit Load

Pallet sized byANSI (American National

Standard Institute)

Unit Load Unit Load

• Examples: tote boxes, “cassette”, cartons, skids, pallets, pallet boxes, intermodal container, one unit of product, etc.

• Most popular: plastic containers and pallets• Factors for determining unit load/ container:

– Size of carrier– Size and weight of items– Space for storing loaded/unloaded container– Equipment used for moving– Cost, supply and maintenance– Aisle widths, door sizes, and clear stacking heights– Environmental regulations

Unit Load and Handling SystemUnit Load and Handling System

The unit load is an integral part of the material handling system and a “simultaneous” determination should be made.

Design the Unit Load

Design the Handling/Storage

system

In-class Exercise: Unit Load and Cycle TimeIn-class Exercise: Unit Load and Cycle Time

We have a system with two machines. Every unit of the product has to go through Machine 1 first and then through Machine 2.

Machine 1

1 min/unit

Machine 2

1 min/unit

We move the product using forklift trucks. The company has several of them going around permanently. We can use one whenever we need. The move from Machine 1 to Machine 2 takes two minutes.

The forklift truck moves a batch (or a lot) of units at a time.

How many units should we move at a time using the forklift truck to minimize the time of completion of an order of 16 units?

In other words, how big should the unit load be to minimize completion time?

Unit Load and Unit Load and Cycle TimeCycle Time

MH time > processing time => MH constrained

Large unit loads: longer cycle times, fewer moves

Small unit loads: lower cycle time, lower WIP, more frequent handling

Lot size = 16 unitsMachining = 1 min/unitOperations 1 and 2MH = 2 min/trip

M1MHM2

16 34

UL = 16 units

M1MHM2

18 26

UL = 8 units

M1MHM2

6 20

UL = 2 units

M1MHM2

4 34

UL = 1 unit

Unit Load DisadvantagesUnit Load Disadvantages

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.

Review QuestionsReview Questions

1. The Unit Load remains the same throughout the facility.

True or False?

2. Which statement is the most accurate?a) Material Handling should be reduced as much as possible.

b) The materials, movements, and methods define the MH system.

c) The unit load should be decided before any other MH decisions.

d) The what, where, and when, defines the how and who.

Classification of M.H. EquipmentClassification of M.H. Equipment

I. Containers & unitizers

II. Material Transport Equipment

1. Conveyors

2. Industrial Trucks & Vehicles

3. Monorails, Hoists & Cranes

III. Storage & Retrieval

Equipment

IV. Automatic Identification &

Communication Equipment

MH Equipment ResourcesMH Equipment Resources

• MHE Taxonomy (http://www.ise.ncsu.edu/kay/mhetax/index.htm)

• The Material Handling Multimedia Bank

(http://www.centor.ulaval.ca/MHMultimediaBank)

• Textbook (Appendix 5b)

• Material Handling Industry of America (http://www.mhia.org)

• CICMHE Website (http://www.mhia.org/cicmhe/)

• MaterialHandlingInfo.com (http://208.226.12.140/mhi/)