What is Logistics ? The movement of goods through the supply chain “the art and science of obtaining, producing, and distributing material and product in the proper place and in proper quantities” VSM / PED / MSE / MHSE Slide 6TVS Perspective of Logistics Industry aa > Global logistics industry is estimated to be worth USD 300 billion > The annual logistics in any country varies between 9% to 20% of their GDP. we Ref: Logistics industry analysis by market research.com > The annual logistics cost in India is estimated to be 14% of GDP whereas automotive sector contributes to 7 to 8% of GDP. > Out of the total cost 99% is accounted by the unorganized sector VSM / PED / MSE / MHSE Slide 7TVs ; a TVSM/ PED / MSE / MHSE Slide 8Evolution of Logistics Industry Yaa VSM / PED / MSE / MHSE Slide 9TVS Evolution of Logistics Industry VSM / PED / MSE / MHSE Slide 10TVs Evolution of Logistics Industry and Reengineering of organi- Increased competition ational cost structures and globalization Distribution mgmt. Integrated logistics Supply chain mgmt. in the 1970s mgmt. in the 1980s in the 1990s + Nocoordination among * Coordination among functions * Coordination among functions internal to an organization several firms to reduce + Focus on reducing inventory * Achieve a system-wide cost and redundancies and distribution costs objective + Create customer value Focus of the organization Share of the Share of the Market customer Evolution of Logistics and Supply Chain Management Ref: Logistics industry analysis by market research.com ‘TVSM/ PED / MSE / MHSE Slide 11TVS Supply Chain Management Yan Area warehouse SUPPLIERS ---~ fad eaeahl ~——— — " Material flow Information flow Cash flow AaLAUAe! PSQIZAC8— Supplier Slide 12TVS Inbound Logistics ae Weekly ----- mie. soneouiss ||. Frequenc \_¥:80% of value ly | OME “ sus 7 mLKRUN rag Cor ‘Assembly line, Kanban 2BinKanban ' ' ' ' ' 1 ' 7 ' ' ' a <-----4 Information flow ~~ ———— Material tlow Vo Barcoded invoice AaLAUAe! PSQIZAC8— Supplier Slide 13TVS Outbound Logistics aw a Lo - 1 1 Mfg. Plant Area warehouse ‘Secondary Dealership Primary distribution + distribution = weeee information flow torts tow PD Rollout /PED /Apr-13 Slide 14TVs In-house Logistics ax Manufacturing Plant Layout Testing & Booking Venicte | assem) < Maining | Pains I) stores ‘TVSM/ PED / MSE / MHSE Slide 15,TVS In-house Logistics Yad Schematic of vehicle assembly with supporting units ae ee VSM / PED / MSE / MHSE Slide 16TVS Material Handling System Engineering ow. In-house Logistics is also Referred as “Material handling System Engineering” Material Handling System Engineering Consists of + Handling — Material Handling Facilities + Transfer — Material Handling Equipment + Storage — Material Storage Systems VSM / PED / MSE / MHSE Slide 17Video VSM / PED / MSE / MHSE Slide 18What is Material Handling ? VSM / PED / MSE / MHSE Slide 19Material Handling System in Home ow Kitchen equipment stand Cell phone stand ‘TVSM/ PED / MSE / MHSE. Slide 20TVS Material Handling System an Material Handling System - De’ n Material handling system is the art and science of moving, storing, protecting and controlling the materials. + Materials handling system is the movement and storage of materials at the lowest possible cost through the use of proper methods and equipment. + Material handling system 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 movement of raw material, semi-finished goods and finished articles through various stages of production and warehousing ‘TVSM/ PED / MSE / MHSE. Slide 21TVs Material Handling System aw Material handling - Moving: Transfer of the material at the right time and the right place. AL. We ME - Storing: Provides a buffer between operations, facilitates the efficient use of people and machines. ‘TVSM/ PED / MSE / MHSE. Slide 22TVs Material Handling System aw Material handling - Protecting: Includes the packaging, packing against damage and theft. Ratio counter ‘Scanner ‘TVSM/ PED / MSE / MHSE. Slide 23TVS Material Handling Facilities Saw 3W material handling facilities — with modular concept and flexibility to accommodate future models Chassis . Wind sheld trolley in il PD Rollout /PED /Apr-13 Slide 24TVS Material Storage Facilities a Storage Bins Heavy Duty Racking System Lean Lifts Over head Conveyor ‘TVSM/ PED / MSE / MHSE. Slide 25,Hand pallet truck Loading/Unloading Conveyor Stacker Reach Truck Fork Lift VSM / PED / MSE / MHSE Slide 26TVS Importance of Material Handling System an Importance of Material Handling System + 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 + 3.5% of all material handled becomes damaged = ‘Totally eliminate” — However, handling less is not the answer. VSM / PED / MSE / MHSE Slide 27TVS Importance of Material Handling System an > Importance of material handling The primary objective of a material handling system is to reduce the unit cost of production. + Reduce manufacturing cycle time + Reduce delays, and damage + Promote safety and improve working conditions Maintain or improve product quality + Improve productivity + Improve the utilization of facilities + Reduce tare weight Control inventory VSM / PED / MSE / MHSE Slide 28TVS Requirements of Material Handling System ae. > The essential requirements of a good materials handling system: (i) Efficient and safe movement of materials to the desired place. (ii) Timely movement of the materials when needed. (ii) Supply of materials at the desired rate. (iv) Storing of materials utilizing minimum space. (v) Lowest cost solution to the materials handling activities. VSM / PED / MSE / MHSE Slide 29TVS Scope of Material Handling System aw > Scope of material handling * Bulk materials as well as unit materials handing. Bulk handling is particularly relevant in the processing, mining and construction industries. ‘TVSM/ PED / MSE / MHSE. Slide 30TVS Scope of Material Handling System Yaw > Scope of material handlin: + Industrial packaging of in-process materials, semi finished or finished goods, primarily from the point of view of ease and safety of handling, storage and transportation, + Handling of materials for storage or warehousing from raw materials to finished product stage. ‘TVSM/ PED / MSE / MHSE. Slide 31TVS Material handling system equation ‘Why? What? | | Where?| | When? | | How? | | who? | | Which? Material | + Moves + Methods | + | Prefered system Material handling systems alternatives VSM / PED / MSE / MHSE Slide 32v The What Question + What are the types of material to be moved? + What are their characteristics? + What are the amounts moved and stored? VSM / PED / MSE / MHSE Slide 33TVS Material Hani > The Where Question + Where is the material coming from? Where should it come from? + Where is the material delivered? Where should it be delivered? + Where is the material stored? Where should it be stored? + Where can material handling tasks be eliminated, combined or simplified? + Where can you apply mechanization or automation? VSM / PED / MSE / MHSE Slide 34TVS Material Hani > The When Question When is material needed? When should it be moved? When is it time to mechanize or automate? + When should we conduct a material handling performance audit? VSM / PED / MSE / MHSE Slide 35TVS Material Hani > The How Question + How is the material moved or stored? How should material be moved or stored? What are the alternative ways of moving or storing the material? + How much inventory should be maintained? + How is the material tracked? How should the material be tracked? + How should the problem be analyzed? VSM / PED / MSE / MHSE Slide 36TVs Material Handling System Equation Yaw > The Who Question + Who should be handling material? What are the required skills to perform the material handling tasks? + Who should be trained to service and maintain the material handling system? + Who should be involved in designing the system? VSM / PED / MSE / MHSE Slide 37» The Which Question + Which material handling operations are necessary? + Which type of material handling equipment, if any, should be considered? + Which material handling system is cost effective? + Which alternative is preferred? VSM / PED / MSE / MHSE Slide 38TVS Character Characteristic and Classification of materials ic and Classification of Materials ae + Method to be adopted and choice of equipment for a materials handling system primarily depends on the type of materials to be handled. + Basic classification of material is made on the basis of forms, which are () Gases, (ii) Liquids, (il) Semi liquids, (iv) Solids. VSM / PED / MSE / MHSE Slide 39TVS Characteristic and Classification of Materials Saws Gases Handling + Gases are generally handled in tight and where required, pressure resisting containers, However, most common method of handling of large volume of gas is through pipes by the help of compressor, blower etc. This process is known as pneumatic conveying Natural gas pipelines ‘TVSM/ PED / MSE / MHSE. Slide 40TVS Characteristic and Classification of Materials Saws Liquid Handling + Liquids and semi-liquids can be handled in tight or open containers which may be fitted with facilities like insulation, heating, cooling, agitating ete. + Large quantity of stable liquids/semi-liquids are generally conveyed through pipes using suitable pumps, which is commonly known as hydraulic conveying. il pipelines ‘TVSM/ PED / MSE / MHSE. Slide 41TVS Characteristic and Classification of Materials Saws. Solids Handling + Solids form the majority of materials which are handled in industrial situation. Solids are classified into two main groups: - Bulk load - Unit load. Unit ‘TVSM/ PED / MSE / MHSE. Slide 42TVS Characteristic and Classification of Materials ans Bulk load Bulk material handling is an engineering field that is centered around the design of equipment used for the handling of dry materials such as ores, coal, cereals, wood chips, sand. The purpose of a bulk material handling facility may be to transport material from one to several locations ‘TVSM/ PED / MSE / MHSE. Slide 43,TVs Characteristic and Classification of Materials aw. Unit load ~ ‘Picked up and moved between two locations as a single mass”. - These materials are counted by number of pieces like machine parts, packed boxes, fabricated items. . i-j- Example: 1- w-9 Asingle item picked up and moved manually between two locations 2. Two tote pans with identical components picked up moved by a dolly from one machine to another ° ‘One pallet load of nonuniform-size cartons with different products picked up and moved by a lift truck from the packaging area to the shipping dock 4, One full load of products delivered by a truck trailer from a warehouse to a customer store Ifthe trailer is halt full, itis still one unit load. ‘TVSM/ PED / MSE / MHSE Slide 44TVS Character ic and Classification of Materials ae Unit load - Advantages & Disadvantages ‘Advantages: + Standardized handling equipment + Standardized storage equipment + Reduced information and control burden + Efficient space utilization Disadvantages: + Cost of assembly and disassembly + Cost of container and wrappings + Cost of empty container handling and disposal VSM / PED / MSE / MHSE Slide 45ic and Classification of Materials ae TVS Classification of unit load a) Shape of unit loads - Basic geometric forms like rectangular, cylindrical, pyramidal/conical b) Position of C.G. (stability) of load. ¢) Mass of unit load in 10 steps from 0-2.5 kg to more than 5000 kg. ) Volume per unit in 10 steps from 0-10 cm3 to more than 10 m3. e) Type of material in contact with conveying system like metal, wood, paper/cardboard, textile, rubber / plastics, glass and other materials. f) Geometrical shape (flat, concave, convex, irregular/uneven, ribbed etc.) and physical properties (smooth, slippery, rough, hard, elastic etc.) of base surface of unit load. VSM / PED / MSE / MHSE Slide 46TVS Classi ic and Classification of Materials ae n of unit load 9) Specific physical and chemical properties of unit loads like abrasive, corrosive, dust emitting, damp, greasy/oily, hot, cold, fragile, having sharp edges, inflammable, explosive, hygroscopic, sticky, toxic, obnoxious, radioactive etc. h) Loads sen: ive to pressure, shock, vibration, turning/titing, acceleration/deceleration, cold, heat, light, radiation, damp etc. VSM / PED / MSE / MHSE Slide 47ples Soe 1, Planning TVS Material Handling System Pri MH Principles: 19. Performance 18. Capacity 2. Systems 17. Control i 3. Material flow 16. Obsolescence 4. Simplification 15. Maintenance 14, Utilization 5. Gravity 6. Space utilization it 9. Automation 8. Mechanization TVSM / PED / MSE / MHSE Slide 48 13. Dead weight \ + 10. Equipment 12. Adaptability 11. Standardiiples Sa TVS Material Handling System Pri 1. Planning Plan all material handling and storage activities to obtain maximum overall operating efficiency, 2. System Integrate as many handling activities as is practical into a coordinated system of operations, covering vendor, receiving, storage, production, inspection, packaging, warehousing, shipping, transportation and customer. 3, Material flow Provide an operation sequence and equipment layout optimizing material flow. VSM / PED / MSE / MHSE Slide 49TVS Material Handling System Principles aw 4, Simplification : ‘Simplify handling by reducing, eliminating or combining unnecessary movements and/or equipment. 5. Gravity : Utilize gravity to move material wherever practical. 6. Space utilization : ‘TVSM/ PED / MSE / MHSE. Slide 50TVS Material Handling System Principles aw 7. Unit size : Increase the quantity, size or weight of unit loads or flow rate 8. Mechanization : Mechanize handling operations. 9. Automation Provide automation to include both production, handling and storage functions. ‘TVSM/ PED / MSE / MHSE. Slide 51iples Sod TVS Material Handling System Pri 10. Equipment selection In selecting handling equipment consider all aspects of the material handled , the movement and the method to be used. a. ? oi 11. Standardization Standardize handling methods, as well as types and sizes of handling equipment. Eg 12. Adaptability Use methods and equipment that can best perform a variety of tasks and applications where special purpose equipment is not justified VSM / PED / MSE / MHSE Slide 52TVS Material Handling System Principles aw 13. Dead weight Reduce ratio of dead weight of mobile handling equipment to load carried. i's ° 14. Utilization Plan for optimum utilization of handling equipment and manpower. 15. Maintenance Plan for preventive maintenance and scheduled repairs of all handling equipment's. VSM / PED / MSE / MHSE Slide 53TVS 16. 17, 18. 19. 20. iples Sa Material Handling System Pri Obsolescence Replace obsolete handling methods and equipment with more efficient methods or equipment will improve operations. Control : Use material handling activities to improve control of production, inventory and order handling. Capacity Use handling equipment to help achieve desired production capacity. Performance Determine effectiveness of handling performance in terms of expense per unit handled. Safety Provide suitable methods and equipment for safe handling, VSM / PED / MSE / MHSE Slide 54TVS Conditions for improvements Yaw Con ns 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 In-plant containers Backtracking of not standardized material Operators travel excessively for materials and supplies Misdirected material | Excessive demurrage VSM / PED / MSE / MHSE Slide 55TVS Organization for MHFS Yaw Organization for MHFS + Good organization of the materials handling system operation is essential for good results. + Roles of Material handling operations organization: > To move the right material to the right destination on time. > To minimize production downtime due to materials handling breakdowns. > To minimize costs. > To minimize damage and accidents > To supervise personnel and training effectively. > To report production, movement and inventory data. > To advise management. > To plan VSM / PED / MSE / MHSE Slide 56TVS Roles of MHS Organization aw@ Roles of the Material handling organization To move the material v v To staff the materials handling system. > To train materials handling personnel. v To supervise the system y To report on the system's functioning, > To report production, movement and inventory data. y To advise management v To plan, VSM / PED / MSE / MHSE Slide 57TVS Roles of MHS Organization Yan Roles of the Material handling organization: > These functions closely follow the objectives listed in the previous section. > These functions may differ from company to company owing to the nature of the industry, union contracts, industry custom or other causes. > However, these functions are necessary in every company, the organizational location may vary. VSM / PED / MSE / MHSE Slide 58TVS Roles of MHS Organization Saw Tomovemateria === S~CS—sSSCSC‘“‘“SCS The major function and objective of the materials handling organization is to deliver the right material to the right destination at the right time. This is the reason for material handling. Other objectives and functions are secondary ww 2 To minimize downtime In today's highly automated mass production, downtime in any part of the system will shut the whole system down, The resulting loss of production will be very costly to the company. ‘TVSM/ PED / MSE / MHSE. Slide 59TVS Roles of MHS Organization Yaw To minimize damage and accidents Not only are accidents to material and personnel expensive, they interrupt operations and may cause a shutdown. Since materials handling accounts for a substantial proportion of all industrial accidents, the materials handling supervisor should strive to keep these to a minimum a To minimize costs Materials handling operations should be carried out at minimum cost. ‘TVSM/ PED / MSE / MHSE. Slide 60TVS Roles of MHS Organization Yaw To supervise personnel and training effectively ‘A major part of the materials handling manager's time will be spent supervising and training workers. Achieving this objective leads to achieving the major objective of moving the material. VSM / PED / MSE / MHSE Slide 61TVS Roles of MHS Organization Yaw To submit prompt and accurate reports Prompt and accurate reports are essential to management control and to efficient operation of the whole production system. ‘TVSM/ PED / MSE / MHSE. Slide 62TVs Roles of MHS Organization Yaw To advise management The head of the materials handling department should be the person to advise management on the materials handling function. He should keep track of new technology that could improve the system. VSM / PED / MSE / MHSE Slide 63TVS Roles of MHS Organization Yaw To plan Planning requires coordination with the plans and prospects of other divisions of the company regarding future product lines, product changes, volume changes, and relocations. VSM / PED / MSE / MHSE Slide 64TVS Roles of MHS Organization Yaw ‘To report on the system's functioning The system manager reports on the system's functioning in which only deviations from the planned norms are reported, These include breakdowns, personnel problems beyond the authority of the system manager, and recommended replacements and improvements. VSM / PED / MSE / MHSE Slide 65Material Handling Equipment VSM / PED / MSE / MHSE Slide 66TVS Material handling equipment's Saw Material Handling Equipments + Material handling equipment is used to increase output, control costs, and maximize productivity. WHY 272 - To reduce manual efforts gd v gh VSM / PED / MSE / MHSE Slide 67TVs Types of Material handling equipment’s Sam. Types of material equipment's 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 VSM / PED / MSE / MHSE Slide 68TVS ‘Types of Material handling equipment’s aes. ‘ypes of material equipment's 1. Containers and Unitizing Equipment + Containers + Unitizers: 2, Material Transport Equipment + Conveyors + Industrial Vehicles + Monorails, Hoists, and Cranes ‘TVSM/ PED / MSE / MHSE. Slide 69TVs Selection of Material handling equipmen’s Sand. > Factors Affecting the selection of Materials Handling Equipment The selection of materials handling equipment requires the attaining of proper balance between the production problem, the capabilities of the equipment available, and the human element involved. The ultimate aim is to arrive at the lowest cost per unit of material handled, VSM / PED / MSE / MHSE Slide 70TVS Selection of Material handling equipment's ans Factors affecting the selection of Material Handling Equipment VSM / PED / MSE / MHSE Slide 71TVs Selection of Material handling equipment's Sand Equipment factors to be taken into consideration may well include the following: 1. Adaptability: the load carrying and movement characteristics of the equipment should fit the materials handling problem. 2. Flexibility: Where possible the equipment should have flexibility to handle more than one material, referring either to class or size. 3, Load capacity: Equipment selected should have great enough load-carrying characteristics to do the job effectively, yet should not be too large and result in excessive operating costs. 4, Power: Enough power should be available to do the job 5. Speed: Rapidity of movement of material, within the limits of the production process or plant safety, should be considered, ‘TVSM/ PED / MSE / MHSE. Slide 72TVs Selection of Material handling equipment's Sand Equipment factors to be taken into consideration may well include the following: 6. Space requirements: The space required to install or operate materials handling equipment is an important factor in its selection 7. Supervision required: As applied to equipment selection, this refers to the degree of automaticity designed into the equipment. 8. Ease of maintenance: Equipment selected should be easily maintained at reasonable cost. 9. Environment: Equipment selected must conform to any environment regulations. 10. Cost: The consideration of the cost of the equipment is an obvious factor in its selection VSM / PED / MSE / MHSE Slide 73TVs Selection of Material handling equipment's Sand > Selection method of equipment for Material movements ‘Quantity of material moved Conveyors, High Conveyors conveyors bow Manual handin Powered trucks, Mand tucks Unit oad AGV ‘Short Long Move Distance VSM / PED / MSE / MHSE Slide 74TVs Material handling equipment's ~Palletizer Sand. Unitizer: Palletizer * Palletization is the task of taking cases and stacking them in layers on pallets for storage and/or transportation «Manual Palletizing is the most basic and also the most widely used method. Typically, workers remove cases from a conveyor line or an existing pallet load and stack them onto a pallet. * Semi-Automatic Palletizing is used when case weight is a factor and workers are subject to back strain injuries, often resulting from manual palletizing. With a semi-automatic system, a conveyor delivers product to an operator who arranges the cases in layers on a variable height lift table. + Automatic Palletizing provides the fastest, most efficient and most ergonomical method of palletizing, ‘Manual palletizing ‘Semiautomatic palletizer ‘Automatic palletizer VSM / PED / MSE / MHSE Slide 75TVs Material handling equipment’s - Stretch wrapper aw Unitizers: Stretchwrapper * Stretch wrapping is the most cost-effective way to keep loads secured on a pallet. * Manual stretch wrapping. = Semi-Automatic stretch wrapping. = Automatic stretch wrapping. Manual stretch wrapping ‘Semiautomatic ‘Automatic stretch wrapper stretch wrapper VSM / PED / MSE / MHSE Slide 76TVs Material handling equipment’s - Conveyors Sand. Conveyors * Aconveyor system is a common piece of mechanical handling equipment that moves materials from one location to another. * Conveyors are especially useful in applications involving the transportation of heavy or bulky materials. * Conveyor systems allow quick and efficient transportation for a wide variety of materials, which make them very popular in the material handling and packaging industries. * Various conveyor systems, * Chain conveyors * Belt conveyors + Slot conveyors * Roller conveyors Bett conveyor Chain conveyor Roller conveyor ‘Slot conveyor VSM / PED / MSE / MHSE Slide 77TVs Material handling equipment’s - AGV a Automated guided vehicles + An automated guided vehicle or automatic guided vehicle (AGV) is a mobile robot that follows markers or wires in the floor, or uses vision or lasers. They are most often used in industrial applications to move materials around a manufacturing facility or a warehouse. ‘AGY with floor marking acy AGV with toad unit ‘TVSM/ PED / MSE / MHSE. Slide 78TVs Material handling equipment’s Industrial vehicies aw Industrial Vehicles "Industrial trucks refer to the different kinds of transportation items and vehicles used to move materials and products in materials handling. These transportation devices can include small hand-operated trucks, pallet-jacks, and various kinds of forklifts. "These trucks have a variety of characteristics to make them suitable for different operations. Some trucks have forks, as in a forklift, or a flat surface with which to lift items, while some trucks require a separate piece of equipment for loading. = Trucks can also be manual or powered lift and operation can be walk or ride, requiring ‘a.user to manually push them or to ride along on the truck. Tractor truck Fork lift Stacker Hand pallet truck (Towing truck) VSM / PED / MSE / MHSE Slide 79TVs Material handling equipment’s - Monorails and, Monorails + Amonorailis a rail-based transportation system based on a single rail, which acts as its sole support and its guide way. The term is also used variously to describe the beam of the system, or the vehicles traveling on such a beam or track. Types of monorail systems are, 1. Pipe rail system 2. Flat-bar monorail system 3, Structural rail system Monorail system Monorail system ‘Monorail system ‘TVSM/ PED / MSE / MHSE. Slide 80TVs Materiat handing equipment’s— Hoists Sand, Hoists * Ahoist is a device used for lifting or lowering a load by means of a drum or liftwheel around which rope or chain wraps. It may be manually operated, electrically or pneumatically driven and may use chain, fiber or wire rope as its lifting medium. The load is attached to the hoist by means of a liting hook. gy * Its various types are, 1. Chain hand hoists. - Lever operated hoists - Portable hand chain hoists - Differential hoists ¥ = Screw or Worm geared hoists - Spur geared hoists 2. Powered hoists + Electric hoists - Pneumatic hoists Electric heist Pneumatic holst Chain hand hoists VSM / PED / MSE / MHSE Slide 81TVs Material handling equipment’s - Cranes and, Cranes Cranes are a combination of separate hoisting mechanisms with a frame for lifting or a combination of lifting and moving loads which can be truly suspended on or secured to them. Generally it will be used in a factory, for repair and maintenance work and for intermittent lifting jobs. ‘An important advantage of a crane equipped with a rotating boom is the high degree of flexibility provided in picking up and placing loads. The cranes are classified as, - Revolving or rotary cranes - Trackless cranes - Mobile cranes - Bridge cranes - Floating cranes + Helicoptercranes Rotary crane Mobile crane ‘TVSM/ PED / MSE / MHSE. Slide 82TVs Material handling equipment’s - Storage San Storage and Retrieval "Storage and retrieval system provide the combined function of handling and storage the material. Function can be done by automated or semi-automated. + Examples are unit load automated storage and retrieval systems (AS/RS) which store and retrieve whole pallets, mini load systems with storage drawers, micro load systems with storages totes and carousels with extractors. + In hi-rack system, storage and retrieval will be done by manual with the help of handling equipment’. VSM / PED / MSE / MHSE Slide 83TVS Material Storage Systems Saw Containers: Tote pans Atote pan or crate is a large shipping container, often made of plastic, steel and wood, typically used to transport large, heavy or awkward items. PD go ® Qa... & wep VSM / PED / MSE / MHSE Slide 84TVS Containers: Pallets ial Storage Systems Saw + Apallet is a flat transport structure that supports goods in a stable fashion while being lifted by a forklift, pallet jack, front loader, work saver or other jacking device, + Apalletis the structural foundation of a unit load which allows handling and storage efficiencies. Its also called as a skid. Plastic pallets Wooden pallets oS ‘Stool pallets ‘TVSM/ PED / MSE / MHSE. Slide 85TVS Material Storage Systems Saw Storage and Retrieval he J Unit load ASIRS Person-aboard system ASIRS system Hi-rack systems (Using hand stacker) Drive-in-rack systems. ‘TVSM/ PED / MSE / MHSE. Slide 86TVS New generation material handling system ae New generation material handling system The new-generation material handling system are highly automated system based on latest technologies, provided with flexibility capable of changing its own structure or function in response to changes from manufacturing systems, and autonomous functions to enhance system reliability. Such system is defined as “MMHS - Metamorphic Material Handling System”. VSM / PED / MSE / MHSE Slide 87TVS New generation material handling system aa New generation material handling system MMS project perform research and development activities focusing on the following four Points, 1. Life cycle optimization Environmentally conscious manufacturing User-friendliness ROR Contribution to global industry productivity. VSM / PED / MSE / MHSE Slide 88TVS ‘Subjects and objectives of MMHS ant Production Manufacturing System Schedule > Ability of Modulation and 4 CHANGE Autonomy — — — Machining Assembly Inspection Laon SS Se aa Production Line — -——| CHANGE] | System Layout ne : CHANGE Environmental & CHANGE Social Condition CHANGE f Modulation faterial Handling System’ ‘TVSM/ PED / MSE / MHSE. Slide 89TVS Subjects and objectives of MMHS ae New generation material handling system Subjects and objectives of MMHS project conceived from this viewpoint were as follows., 1, Responsive: Responsive to changes that may take place in manufacturing technology and environment, type of product or material to be handled, work schedule and load. 2. Flexible: Capable of transforming itself and altering its function to meet any change in handling requirements. 3. Autonomous: Able to make decisions on its own (to enhance system availability) 4, Highly automatic: Incorporated with next-generation automation technology. 5. Multifunctional: Having such functions as assembling, packaging and disassembling, besides transporting, ‘TVSM/ PED / MSE / MHSE. Slide 90TVS Subjects and objectives of MMHS an 6. Modularized: Composed of various modules, each with a distinct function; e.g planning module, basic module, tool-setting module, communication module, capable of associating or dissociating one another to organize themselves into a configuration as required. 7. Multi-level: Designed into multi-level sub-systems so as to be capable of cooperating other independent material-handling equipment including AGVs and mobile robots. 8. Compatible: Capable of adapting itself to other existing material-handling systems. VSM / PED / MSE / MHSE Slide 91Material Flow Analysis VSM / PED / MSE / MHSE Slide 92TVS Material flow aw Material flow - Material flow is defined as an organized movement of materials (raw materials, basic and auxiliary materials, semi products, tools, and finished products, packages and waste) in the production process or circulation - Material flow draws the routes, outputs, travel distances, times and costs. Simp process fow anaiysisof material ow toughthe company Pani and Wachouse Proaution Pastas ‘ee Material flow diagram Packing Dispatch VSM / PED / MSE / MHSE Slide 93TVS Material flow ax Weekly Ts release Frequene \_¥:90% of Syalue ee : Assembly line MILKRUN == | ee. contrat oe E — Kanban 2BinKanban xy QZ ween Invoration tow ~ >>I ——— Material flow navel ee Barcoded Invoice VSM / PED / MSE / MHSE Slide 94TVS Material flow Yaw Material flow in one module hess ee oe vevwones — fe = dm. * Material flow in warehouse VSM / PED / MSE / MHSE Slide 95TVS Material flow parameters Sans Material flow This movement is expressed by following parameters > Frequency - number of transportations per time unit, > Intensity - the amount transported per time unit, > Length - the distance the material pass from the starting point to the end point, v Performance - the product of the intensity and length of material flow, > Direction - from - to, v Manipulation factor - the number of manipulation operations carried out. VSM / PED / MSE / MHSE Slide 96TVS Material flow parameters Sans The quantifiable parameters are, > Quantity of material [Q] - which can be expressed in units of mass or volume in case of the bulk materials or in manipulation units in case of materials in pieces. > Path [s] - which is expressed in length of track or route of material movement in the area between the source (supplier) and consumer (customer). > Time [t] - is expressed by the duration of any work activity (operation process) or term when to start an activity or finish (time of submission the vehicle for loading, delivery time inventory). > Retention Points - VSM / PED / MSE / MHSE Slide 97TVS Material retention an Retention: The point which is holding the inventory before/after process and re-handling in the material flow, it is called as retention point. sea }@)- Storage L(@)- Painting é Vehicle Vehicle ‘Sub testing assembly assembly VSM / PED / MSE / MHSE Slide 98TVS Material flow Benefits Saw Material flow benefits, Acontrolled material flow would result the following, v Lower overhead costs Minimization of machinery usage vv Increased accuracy in monitoring materials flow v Smoother processing of materials v Increased profits y Reduced waste > Aculture of continuous improvement VSM / PED / MSE / MHSE Slide 99TVS Material flow analysis Saw Material flow analysis “Material flow analysis (MFA) is a systematic assessment of the flows and stocks of materials within a system defined in space and time.” Objectives + Define system of material flows and stocks * Reduce no. of retention + Reduce system complexity while maintaining basis for decision-making * Assess relevant flows and stocks quantitatively, checking mass balance, sensitivities, and uncertainties + Present system results in reproducible, understandable, transparent fashion + Use results as a basis for managing resources, the environment, and wastes VSM / PED / MSE / MHSE Slide 100TVS 7 Steps of Material flow analysis Yaw Material flow analysis techniques Acomplete material flow analysis comprises seven steps. 1. Define the objective of the material flow analysis and the parameters to be monitored . Define the balance scope . Define the balance period Identify and define process steps . Draw the flowchart: material flows — qualitative approach Draw up balances: material flows — quantitative approach NOORON . Interpret the results and draw conclusions. VSM / PED / MSE / MHSE Slide 101TVS Factors affecting Material flow analysis an Nature of materials | Storage concept No, of nodes Track or path Human work factor Level of flow contro! Output Material flow Time analysis »<—————__ Handling units Types of Transportation warehouses machines Technical solution of ‘Space and size of the warehouses area No, of components and No. of operations on Fynea’ot maonals Parameters of material components of materials flows biw eee ‘TVSM/ PED / MSE / MHSE. Slide 102TVS Material flow analysis Yaw The following types of charts can be used for the graphical representation of a material flow analysis: 1. Flow charts: - Aflowchart is a graphic representation of how a process works, showing the sequence of steps. - Itincludes multiple steps, how the process “flows” through from start to finish. - Itis used to describe process that are to be improved. een ones mentees —e (64 VSM / PED / MSE / MHSE Slide 103TVS Material Flow Analysis - Case study Saw@ Case study - Flow analysis for crank case VEne Sr ptendaalam| ‘TVSM/ PED / MSE / MHSE. Slide 104TVS Material flow analysis Yaw 2. Ple charts & Histograms: - Abar graph of a frequency distribution in which the widths of the bars are proportional to the classes into which the variable has been divided and the heights of the bars are proportional to the class frequencies. : Ay ow YY AV LL Bins Plo chart Histogram chart ‘TVSM/ PED / MSE / MHSE. Slide 105TVS Time travel diagram aw 3, Time-travel diagrams: ———— _ Marty, Back to the Future | ————_ Marty and Doc, Back to the Future I Doe, Back to the Future Ill Marty, Back to the Future Ill Biff, Back to the Future Il Alternate timeline @®_ Undetermined time post-1985 ‘TVSM/ PED / MSE / MHSE. Slide 106TVS Sankey diagram Sa 4, Sankey diagram: - Sankey diagrams are a specific type of flow diagram, in which the width of the arrows is shown proportionally to the flow quantity. - They are typically used to visualize energy or material or cost transfers between processes. (tom =e vr a eet = SE monet = fm rec (esr VSM / PED / MSE / MHSE Slide 107Material Handling Safety ‘TVSM/ PED / MSE / MHSE. Slide 108Safety Sod TVS Safety - Safety is the state of being "safe" , the condition of being protected against physical, emotional, occupational, or other types or consequences of failure, damage, accidents, or any other event which could be considered non- desirable. - Safety can also be defined to be the control of recognized hazards to achieve an acceptable level of risk Slide 109 VSM / PED / MSE / MHSETVS Industrial safety Yaw Industrial Safety - Ina factory, handling and storing of materials provide a continuous flow of parts and assemblies through the workplace and ensure that materials are available when needed. - Unfortunately, the improper handling and storing of materials often result in costly injuries. ‘TVSM/ PED / MSE / MHSE. Slide 110Mechanical Hazards aw Mechanical Hazards Hazard Risk [Rotating shafts, pulies, sprockets and gears __[Entanglement Hard surfaces moving together [Crushing [Scissor or shear action [Severing [Sharp edge —-moving or stationary [Cutting or puncturing [Cable or hose connections Slips, trips and falls (e.g. oil leaks) VSM / PED / MSE / MHSE Slide 111TVS Non-Mechanical Hazards aw Non-Mechanical Hazards Hazard Risk Dust Mist (vapours or fumes) lExplosive or flammable atmospheres Noise Heat (radiated or conducted) Ignition sources (flame or spark) High intensity ight (laser, ultra-violet) Molten materials [Heavy metals (lead, cadmium, mercury) Chemicals [Steam Pressurised fluids and gases lonising radiation (x-rays, microwaves) Electrical VSM / PED / MSE / MHSE Slide 112TVS Health and Safety Hazards Yaw Health and Safety Hazards: Physical hazards; lighting, + Ergonomic hazards; force (lifting and pushing/pulling) and posture (bending, reaching and twisting). + Energy hazards; gravity (falling objects). + Materials handling hazards; lifting, pushing/pulling and hazardous substances + Work practice hazards; following established safe work VSM / PED / MSE / MHSE Slide 113TVS Safe work procedures aa Safe Work Procedure: 1. Wear appropriate personal protective equipment. 2. Warm up your muscles (do some light stretching) for a few minutes before you start lifting et porecron tStappoved matt ‘ioe nce ea paorecrOn Sharon are prewon Ganson pons ssaris ae Foor rrorecnon es rn oftatste ‘en eer bse Fibrous ew ‘strane nt ora bons oy aes (rent ah ‘TVSM/ PED / MSE / MHSE. Slide 114TVS Safe work procedures aw 3. Know the approximate weight of the item before you attempt to lift it Use a mechanical lifting device (e.g. dolly, hand truck, cart, etc.) to move a heavy or bulky load wherever possible. 4. Do not attempt to lift a load that is too heavy of too bulky for you. Ask Keep itslow, Wsnotarace! for assistance. Do nat travel or turn ‘witha raised oad, the fork could tp ove. Face your load VSM / PED / MSE / MHSE Slide 115Safe work procedures ae ines: i. Look and plan ahead. Make sure your path is free of obstructions, debris and slip and fall hazards such as grease, oil, water, ete. ii. Ensure that you can lift the load without over-exertion. ili, Ensure that the load is “free” to move. iv. Check that you can get a good grip of the load. v. Stand over the object. vi, Place your feet so you are balanced. vii, Bend your knees (not beyond 90 degrees) and keep your back comfortably upright. viii, Grip the object with your two whole hands (not just the fingers) so you can hold it securely. Avoid grasping the ends of long items. ix, Tighten your abdominal muscles. x. Tuck your chin into your chest. VSM / PED / MSE / MHSE Slide 116Safe work procedures ae ines: xi. Lift by straightening your legs. Use your legs to lift. xii, Lift smoothly without jerking. xili, Hold the load close to your body. xiv, Move your feet if you must turn while lifting. Do not twist your body. xv. When walking with a load, short steps are best. Keep the load at a reasonable height. Watch where you are going. Watch for tripping hazards. ‘TVSM/ PED / MSE / MHSE. Slide 117TVS Safe work procedures Yaw 6. Lowering guidelines (putting a load down) i. Take a wide stance with one foot in front of the other. ii, Keep the load close to your body. il, Keep your back straight. Do not bend over when setting a load down iv, Bend your hips and knees. v. Set the load down. Keep the load tilted so you do not squat your fingers. Avoid a jerky release. vi, Stand up smoothly, easing your muscles. VSM / PED / MSE / MHSE Slide 118