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Ch06 Facilities MaterialHandling
Ch06 Facilities MaterialHandling
MATERIAL HANDLING
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I. Introduction
• Material Handling accounts for:
– 25% of all employees,
– 55% of all factory space,
– 87% of production time
– 15-70% of the total cost of a manufactured product
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Definitions:
• Material handling (MH) is the art and science of moving, storing,
protecting, and controlling of goods and materials.
– Moving: Required to create time and place utility. The value of
having the material at the right time and the right place.
– Storing: Provides a buffer between operations, facilitates the
efficient use of people and machines.
– Protecting: Includes the packaging, packing against damage
and theft.
– Controlling: Physical: Orientation, sequence and space
between material.
Status: Real-time awareness of the location, amount,
destination, origin, ownership, and schedule of material.
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Definitions:
• MH means providing the right amount of the right material, in
the right condition, at the right place, in the right position, in
the right sequence, and for the right cost, by the right
methods.
- Right amount: how much inventory is needed?
- Right material
- Right condition: state in which customer desires the material
- Right sequence
- Right place: address both transportation and storage
- Right time: on-time delivery
- Right cost: not necessary the lowest cost
- Right method.
II. MH Principles
1. Planning
9. Environmental 10. Life Cycle Cost
2. Standardization
8. Automation
MH
7. System 3. Work principle
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Conditions for improvement
System not capable Idle production
No pre-kitting of of change or equipment due to
work expansion material shortage
Material piled
Automatic data
directly on floor
collection system
not used
MH
Backtracking of In-plant containers
material not standardized
Operators travel
Misdirected material excessively for
materials and
Excessive
supplies
demurrage
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III. Designing material handling systems (MHS)
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2. The MHS equation & questions
The MHS equation:
Materials + Moves +
Methods =
Recommended systems
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Fig 05_04
shows several
stages in the
material flow
process where
dimensional
relationships
play a major
role.
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Fig 05_05
shows why
these two
features
play key
roles in
moving
and storing
containers
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Efficiency of returnable containers
• Given the following dimensions of a plastic reusable containers:
– Inside dimensions: 18” x 11” x 11”
– Outside dimensions: 20” x 12” x 12”
– Each nested container: 20” x 12” x 2”
– The storage opening : 24” x 16” x 14”
A trailer with inside dimensions of 240” x 120” x 120” is used to transport these containers.
Assume no clearance is needed.
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Unit load interactions with warehouse components
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The pallet loading pattern for each carton-pallet pair must be prescribed
as shown in two above figures.
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V. Material handling equipment
Categories of Material Handling Equipment
1. Containers and Unitizing Equipment
• Containers
• Unitizers
2. Material Transport Equipment
• Conveyors
• Industrial Vehicles
• Monorails, Hoists, and Cranes
3. Storage and Retrieval Equipment
• Unit Load Storage and Retrieval
• Unit Load Storage Equipment
• Unit Load Retrieval Equipment
• Small Load Storage and Retrieval
4. Automatic Data Collection and Communication Equipment
• Automatic Identification and Recognition
• Automatic Paperless Communication 20
Containers: Tote pans
Containers: Pallets
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Unitizers: Palletizer Unitizers: Stretchwrapper
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Conveyors Automatic
identification and
recognition
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Industrial Vehicles Storage and Retrieval
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VII. Safety considerations
• The key to a safe facility is concentrating on the
interface between the workforce and the
equipment.
• The following table shows recommended aisle
widths for facility design.
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