Measures of Material Handling Systems: TVSM / Ped / Mse / Mhse Slide 1

Measures of Material Handling
Systems
TVSM / PED / MSE / MHSE Slide 1

Performance Measure
Performance Measure
• A performance measure may be defined as a metric for quantifying efficiency
and effectiveness.
• As applied to material handling systems, the effectiveness of a material

handling system describes to what extent the system performs the required
handling tasks.
• Whereas, efficiency describes how economically the required tasks are

performed.
• It is possible for an effective system to be inefficient, and for an efficient

system to be ineffective.
• Performance measures may characterized based on

– Quality, time, cost, resource utilization, operating efficiency and flexible
measures

Measures
Measures
• Reliability
• Friction and noise
• Serviceability
• Maintainability
• TPM for MHF

Reliability
Reliability
• Reliability is the mathematical measure of the dependability of equipment.
• It may be measured in percent downtime or its converse, percent uptime.
• Either way measures the availability of the equipment to do the job it was
purchased to do.

Reliability
• Reliability is also a function of the user’s maintenance and operations

policies. Poor maintenance and continual overloading will decrease
reliability.
• Reliability data are usually an average derived from a sample of a number of

items. An individual item within the sample may deviate substantially from
the mean of the group.

Reliability
• Examples of commonly used reliability measures are :
1. Availability
2. Failure rate
3. Mean time between failure (MTBF)
4. Mean time to repair (MTTR)

Availability and Failure Rates
• Useful life should be High for any MHF
• It is the most common inquiry about a MHFS / MHES lifespan, and is

important in decision making process.

MTBF (Mean Time Between Failures)
MTBF
• When MHFS / MHES must be installed into critical application in Industry,

MTBF becomes very important.
• Failure rate of the each component of the system must be considered in

MTBF of the system.

MTTR (Mean Time To Repair)
MTTR
• It is the time needed to repair a MHFS / MHES.
• In an operational system, repair generally means replacing a failed part. Thus

MTTR can be viewed as mean time to replace a failed part in a system.
• Taking too long to repair a facility or equipment drives up the cost of

installation in the long run, due to down time until the new part arrives and
the possible window of time required to schedule the installation.

• Availability
• MTBF
• MTTR

Noise control
Noise control
• Since noise is an occupational hazard, noise control technology should aim at
reducing noise to acceptable levels by action on the material handling systems
and the work environment.
• Prior to the selection and design of control measures, noise sources must be
identified and the noise produced must be carefully evaluated.
• Sources of noise in Material handling systems:
– Mechanical shock between parts.
– Unbalanced rotating equipment like wheels of trolley.
– Friction between metal parts.
– Vibration of the parts in material handling system.

Noise control
• Methods to control noise :
– Maintenance
• Replacement or adjustment of worn or loose parts like joints, wheels, bearings.
• Balancing of unbalanced equipment.
• Lubrication of moving parts.
– Substitution of materials
• Plastic materials instead of metal parts.
– Specification of quiet material handling systems.
– Substitution of parts in equipment

• Usage of belt conveyors instead of roller conveyors.

Serviceability
Serviceability
• The availability, quality and accessibility of service facilities are important.
• The owner of equipment should be able to secure spare parts and good
maintenance service quickly and cheaply from the manufacturer or his
representative.
• Considering of all standard parts / materials (with standard dimensions) readily

available in market can eliminate the Non availability of system components,
thus MTTR can be reduced.
Maintainability
Maintainability
• Maintainability is the measure of the ease and efficiency with which a materials
handling system can be maintained.
• The increased efficiency and lower unit cost of mass producing original
equipment have led to lower first costs in relation to maintenance costs.
Maintainability
TPM for MHFS :
• An important operational aspect of a material handling system is good

maintenance of the equipment.
• “Maintenance is defined as to keep in an existing state (as of efficiency, repair

and validity) to preserve from failure or decline.”
The major features of maintainability are designed into the system from the
start. They include location of controls, lube points and panels for each
access, avoiding components subject to frequent failure, and redundancy of
vital components.

Maintainability
• Activities covered under Maintenance are :
– Repairing components and assemblies.
– Replacing defective parts.
– Adjusting the system for maximum operating efficiency.
– Routine preventive actions like lubricating, checking and inspection of

MHE.
– Keeping maintenance record for effective work.

Maintainability
• Maintenance objectives:
To keep the system operating at highest possible efficiency.
To minimize production loss and downtime. Minimize system failures

and breakdowns.
To perform the maintenance function as efficiently and economically as

possible.

Reactive maintenance
Reactive maintenance
– No matter how good the maintenance, emergency calling for immediate
maintenance action will arise. Some are due to poor preventive
maintenance, some to accidents, and some to failures that could not be
forecast or predicted.

Preventive Maintenance
Preventive Maintenance
– Preventive maintenance is designed to prevent future serious
maintenance problems and emergencies.
– Small amounts of time and money are spent continuously in order to

avoid large expenditures and losses later.
– Preventive maintenance includes regular lubrication, minor checking,

quick tests, and routine inspections. Some of these will prevent future
troubles.
– Emergency repairs are costly by themselves, but this expense is minor

compared to production interruptions.
Maintenance

Design / Selection Measures
Design / Selection Measures :
• Feasibility Analysis.
• Functional Analysis.
• Flexibility in Material handling systems.
• Traceability in Material handling systems.

Feasibility Analysis
• Feasibility analysis is an investigation into the extent to which a proposed

design can be carried out and to which it will be economically viable.
• Feasibility analysis is essential for effectiveness of Material handling

systems.

Contents of Feasibility Analysis:
1. Description of the material handling system.
2. Technical feasibility.
3. Operational feasibility.
4. Economic feasibility.
5. Other factors.
6. Alternatives.

1. Description of material handling system:
• Introduction of the report should be a narrative description of the project.
• It should identify the project, discuss its background and the reasons for the
project, and present the major features.
• Along with the narrative, the project should present the important conditions
surrounding the project.
• The goals and objectives of the proposed system and the criteria and
constraints should be listed.
2. Technical feasibility:
• Technical feasibility includes the ability of the material handling system to

move the product, maintainability, reliability, and ability to withstand loads
and forces.

3. Operational feasibility:
• This is defined as the ability of the material handling system to meet operational
requirements such as units of product moved per hour.
Technical feasibility is the ability of the system and its components to meet the
required strength and similar specifications. whereas Operational feasibility is
its ability to meet the movement requirements of the production system of
which the material handling system is a part.

4. Economic feasibility:
• It is the ability of the material handling system to earn back the investment plus a
return acceptable to management.
• Unless a system is economically worthwhile, technical and operational feasibility

is immaterial.
• Methods of assessing economic feasibility:
1. Payback period
2. Present worth
3. Equivalent uniform annual amount
4. Rate of return
5. Unit cost

Problems related to economic feasibility :

# 1.
A materials handling system report carries the following estimates:

Installed cost = $ 14,500
Annual savings = $ 18,000
Annual operating costs = $ 3,200
What is payback period?

Hint : Payback period = (Installed cost / Net annual savings).
Activity : Plot the graph for solution. (hint : Dollars v/s Years).

# 2.
A company is investing buying a warehouse. Two locations are under
consideration. The required rate of return is 35 % per year before taxes.
Location.
A B
Land cost $ 600,000 $ 900,000
Building cost $ 3,500,000 $ 2,000,000
Service life 20 years 20 years
Salvage value after 20 yrs. $ 1,000,000 $3,000,000
Operating costs / year
Material handling $ 900,000 $ 600,000
Others $ 300,000 $ 500,000
Which location do you recommend on a present – worth basis?
Hint :
Present worth of a uniform annual amount: ((1 + i)n – 1) / (i (1+ i)n )
Present worth of a future sum : 1 / ( 1 + i)n
i= Rate of return,
n = Service life in years.
Activity : Prepare a chart for solution. (hint : bar diagram)
5. Other factors :
• Characteristics and data like downtime, delivery time, personnel requirements,

training, and information on similar systems if available.
6. Alternatives:
• In this section are listed the alternatives considered but not recommended.
• Each should have a brief description and a statement of reasons why the
selected option was recommended over a rejected one.

Multicriteria evaluation:
• Feasibility analysis for non – economic and qualitative factors.
1. For and against:

a. List down the advantages and disadvantages of each alternative for
each criteria.
b. No attempt is made to weight, rank, scale or otherwise

quantitatively evaluate the factors.
Example :

2. Scaling :
a. One way to combine several criteria into one figure of merit for
evaluation in scaling.
b. The estimated worth of each criterion is expressed as a numerical scale

value usually on the basis of 1 to 100.
c. The scale values can be combined since they are independent of the
units of measurement.
d. Major difficulties with this method are establishing the scale and
assigning values to the individual alternatives.
Example :

3. Ranking :
a. In this method, each alternative is ranked against the others for each
of the chosen criteria.
b. The rankings are added. The lowest alternative is ranked 1.
c. Others are ranked in order up to the highest, which is given a rank

equal to the number of alternatives.
d. The alternative with the highest rank total is recommended.
Example :

4. Weighting :
a. Not every criterion in a multi-criteria evaluation is equally important.
Normally economic factors will predominate.
b. One way to handle this problem is to weight each factor in

accordance with its relative importance.
c. Weighting usually goes with ranking or other similar methods.

5. Factor analysis :
a. Factor analysis is a combination of ranking or scaling with weighting.
b. A weight is assigned to each factor according to its importance.

This weight is then multiplied by the rank assigned to the alternative for
that factor.
c. The weighted ranks are added. Note that in this method, the ranks
are from 3 for the best to 1 for the worst.

Example :

Functional Analysis
Functional Analysis
• Vehicle travel
• Vehicle travel proportions
• Vehicle travel : Response time
• Handling time per job
• Vehicle utilization
• Mean load waiting times
• Mean queue lengths

Functional Analysis
Vehicle travel
• Vehicle travel is generally measured as actual path distances travelled by

the Material handling equipment.
• The total vehicle travel distance consists of loaded and empty vehicle travel.
• Vehicle travel distance is easily calculated when the flow volumes and the
distances between the stations are known.

Functional Analysis
Vehicle Travel Proportions
• A Material handling equipment / facility may be in one of the three states at a

given time:
Travelling loaded
Travelling empty
Idle
• Travel time percentages may be calculated as a fraction of time that a device is

travelling loaded, travelling empty and waiting in an empty state.
• That is, T = TL + TE + TI
TI = total idle time,

T = total time,
TL = as above (total loaded travel time),
TE = as above (total empty travel time).

Functional Analysis
Handling Time Per Job
• The handling time per job is comprised of the time directly

associated with material handling.
• This time includes:

– The time the job spends in queues waiting for the material handling
vehicle.
– The total travel time.
– The total loading and unloading times.
– The total vehicle blocking times.
• The total handling time per job includes the time from when a job
enters the system until it leaves the system.

Functional Analysis
Mean load waiting times :
• The mean load waiting time is defined as the mean time loads wait in queues for
material handling transportation.
• These queues are located either at processing stations or at separate load

transfer stations.
Mean queue lengths :
• The mean queue length is the mean number of loads waiting for a material
handling vehicle over a specific length of time.

Traceability of MHFS
• Tracking keeps track of the location and status of every work piece in the
system.

• Tracking can serve several purposes like,
• Making adjustments to the production schedule to compensate for

breakdowns and to meet changed priorities.
• Aiding scheduling of future production.
• Material handling control, i.e timely movement of material to and from the
workplace is essential to be efficient.
• Recording maintenance activities of MHFS.
• Status tracking and reporting.
• Provide communication between operator and management.

VEHICLE MONITORING SYSTEM (VMS) :
• INTELLIGENT SYSTEM to monitor Battery of the TOW TRUCK.
• Record starting & ending time of moving, idling and charging of the truck.
• Communicate with Server via GPRS.
• Indicates Tow Truck’s movement details on a 2 x 16 LCD as well as set of

LEDs.

OVERALL ARCHITECTURE
Cell-
Phone
Service
provider

Components that make VMS
The TOW TRUCK is fitted with VMS unit. The VMS unit (using
GPS) time stamps and records the position and activities. The
DATA is sent through GPRS to the data server in the factory
TOW TRUCK VMS in near real-time.
Module
The factory Server has a Static IP. Each TOW Truck has a
GPRS Module and sends data over Cell Phone service
provider’s network to Factory Server’s Static IP. The factory
FACTORY
SERVER server is connected to LAN and all PCs in LAN.
The Vehicle Monitoring System (VMS) is an intelligent µC

based unit with an unique ID and monitors truck’s battery
2x16 LCD current and voltage. VMS records its current position and
speed using a GPS module. VMS has an inbuilt memory to
Vehicle Monitoring log the data even in case of a communication fault.
System with GPS &
GPRS Modules

Measures of Material Handling Systems: TVSM / Ped / Mse / Mhse Slide 1

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Measures of Material Handling

TVSM / PED / MSE / MHSE Slide 1

• As applied to material handling systems, the effectiveness of a material

• Whereas, efficiency describes how economically the required tasks are

• It is possible for an effective system to be inefficient, and for an efficient

• Performance measures may characterized based on

TVSM / PED / MSE / MHSE Slide 2

• Friction and noise

• TPM for MHF

TVSM / PED / MSE / MHSE Slide 3

• It may be measured in percent downtime or its converse, percent uptime.

TVSM / PED / MSE / MHSE Slide 4

• Reliability is also a function of the user’s maintenance and operations

• Reliability data are usually an average derived from a sample of a number of

TVSM / PED / MSE / MHSE Slide 5

• Examples of commonly used reliability measures are :

3. Mean time between failure (MTBF)

4. Mean time to repair (MTTR)

TVSM / PED / MSE / MHSE Slide 6

• Useful life should be High for any MHF

• It is the most common inquiry about a MHFS / MHES lifespan, and is

TVSM / PED / MSE / MHSE Slide 7

• When MHFS / MHES must be installed into critical application in Industry,

• Failure rate of the each component of the system must be considered in

TVSM / PED / MSE / MHSE Slide 8

• In an operational system, repair generally means replacing a failed part. Thus

• Taking too long to repair a facility or equipment drives up the cost of

TVSM / PED / MSE / MHSE Slide 9

TVSM / PED / MSE / MHSE Slide 10

• Sources of noise in Material handling systems:

– Mechanical shock between parts.

– Unbalanced rotating equipment like wheels of trolley.

– Friction between metal parts.

– Vibration of the parts in material handling system.

TVSM / PED / MSE / MHSE Slide 11

• Methods to control noise :

• Balancing of unbalanced equipment.

• Lubrication of moving parts.

– Specification of quiet material handling systems.

– Substitution of parts in equipment

TVSM / PED / MSE / MHSE Slide 12

• Considering of all standard parts / materials (with standard dimensions) readily

TPM for MHFS :

• An important operational aspect of a material handling system is good

• “Maintenance is defined as to keep in an existing state (as of efficiency, repair

TVSM / PED / MSE / MHSE Slide 15

• Activities covered under Maintenance are :

– Repairing components and assemblies.

– Replacing defective parts.

– Adjusting the system for maximum operating efficiency.

– Routine preventive actions like lubricating, checking and inspection of

– Keeping maintenance record for effective work.

TVSM / PED / MSE / MHSE Slide 16

To keep the system operating at highest possible efficiency.

To minimize production loss and downtime. Minimize system failures

To perform the maintenance function as efficiently and economically as

TVSM / PED / MSE / MHSE Slide 17

TVSM / PED / MSE / MHSE Slide 18

– Small amounts of time and money are spent continuously in order to

– Preventive maintenance includes regular lubrication, minor checking,

– Emergency repairs are costly by themselves, but this expense is minor

TVSM / PED / MSE / MHSE Slide 20