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Material+Handling 1
Material+Handling 1
Material Handling
Material handling is the function of moving the right material to the right place in the right time, in the right amount, in sequence, and in the right condition to minimize production cost. The cost of MH estimates 20-25 of total manufacturing labor cost in the United States [The Material Handling Industry of America (MHIA)]
Considerations cont.
2. Flow rate
Quantity of material moved
High
Conveyors
Manual handling Hand trucks Short
Conveyors AGV train Powered trucks Unit load AGV Long Move Distance
Low
Considerations cont.
3. Plant Layout
Layout Type Fixed position Characteristics Typical MH Equipment
Large product size, low Cranes, hoists, production rate industrial trucks Variation in product and processing, low and medium production rates Hand trucks, forklift trucks, AGVs
Process
Product
2.
MH and storage activities should be fully integrated to form a coordinated, operational system that spans receiving, inspection, storage, production, assembly, , shipping, and the handling of returns. Information flow and physical material flow should be integrated and treated as concurrent activities. Methods should be provided for easily identifying materials and products, for determining their location and status within facilities and within the supply chain.
3. Simplification principle
simplify handling by reducing, eliminating, or combining unnecessary movement and/or equipment. Four questions to ask to simplify any job: Can this job be eliminated? If we cant eliminate, can we combine movements to reduce cost? (unit load concept) If we cant eliminate or combine, can we rearrange the operations to reduce the travel distance? If we cant do any of the above, can we simplify?
4. Gravity principle
Utilize gravity to move material whenever practical.
5.
7. Automation principle
MH operations should be mechanized and/or automated where feasible to improve operational efficiency, increase responsiveness, improve consistency and predictability, decrease operating costs. ASRS is a perfect example.
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10. The dead weight principle Try to reduce the ratio of equipment weight to product weight. Dont buy equipment that is bigger than necessary. Reduce tare weight and save money. 11. The maintenance principle Plan for preventive maintenance and scheduled repairs of all handling equipment. Pallets and storage facilities need repair too. 12. The capacity principle use handling equipment to help achieve desired production capacity i.e. material handling equipment can help to maximize production equipment utilization.
Example
A punch press can cycle every 0.03 minute, but our time standard for manually loading and unloading this press is only 300 pieces per hour. Press capacity = 60 min / 0.03 = 2000 pieces/hr Utilization = 300 / 2000 = 15% Should we buy a new press? If we can purchase a coil-feeding material handling system, we could approach 100% press utilization.