Material Handling

Material Handling
Learning Objectives
After studying this topic, you should be able to
explain about:
1. Scope and Definition of Material Handling
2. Material Handling Principles
3. Designing Material Handling Systems
4. Unit Load Design
5. Material Handling Equipment
6. Material Handling Equipment Selection and
Assignment model
7. Safety Considerations
9/13/2015 TLF week 5: Material Handling 2
Definition of Material Handling
• Material handling is the art and science of
moving, storing, protecting and controlling
material.
• Material handling is an activity that uses the right
method to provide the right amount of the right
material at the right condition, at the right place,
at the right time, in the right sequence, in the
right position and at the right cost
• Systems perspective  material handling is an
integral part of the overall facility design process.
• 20-70% of product cost attributed to material
handling
Material Handling Facts
Materials handling and storage accounts for
 25% of all employees
 55% of factory space
 87% of production time
 15-70% of the production cost of a product
 Damage to 3-5% of the products handled

Scope of Material Handling
• The conventional view focuses solely on the
movement of material from one location to another,
usually within the same manufacturing and distribution
facility.
• The contemporary view expands the focus to the
overall movement of material in a factory or
warehouse, and an effort is made to develop an
integrated material handling plan.
• The progressive view is a total system view that looks
at material handling as all activities in handling
material from all suppliers, handling material within
the manufacturing and distribution facility and the
distribution of finished goods to customers.
10 Material Handling Principles by CIC-MHE
1. Planning: defines the material (what) and the moves
(when and where) and the method of handling (how and
who)
2. Standardization : is a way of achieving uniformity in the
material handling methods, equipment, controls and
software without sacrificing needed flexibility, modularity
and throughput.
3. Work measurement: material handling flow (volume,
weight, or count per unit of time) multiplied by the
distance moved.
4. Ergonomic is the science that seeks to adapt work and
working conditions to suit the abilities of the worker.
5. Unit load is one that can be stored or moved as a single
entity at one time, regardless of the number of individual
items that make up the load.

10 Material Handling Principles by CIC-MHE
6. Space utilization. Effective and efficient use must be
made of all available space.
7. System is a collection of interdependent entities that
interact and form a unified whole.
8. Automation is a technology for operating and controlling
production and service activities electro-mechanical
devices, electronics and computer based systems with the
results of linking multiple operations and creating a
system that can be controlled by programmed
instructions.
9. Environmental refer to conserving natural resources and
minimizing the impact of materials handling activities on
the environment.
10. Life cycle cost include all cash flows that occur between
the time the first dollar is spent on the material handling
equipment or method until its disposal or replacement.
Material Handling Checklists

Designing Material Handling Systems
The six-step engineering design process in the context of
material handling:
1. Define the objectives and scope for the material handling
system.
2. Analyze the requirements for moving, storing protecting
and controlling material.
3. Generate alternative designs for meeting material
handling system requirements.
4. Evaluate alternative material handling system designs.
5. Select the preferred design for moving, storing, protecting
6. Implement the preferred design, including the selection of
suppliers, training of personnel, installation, debug and
startup of equipment and periodic audits of system
performance.
Designing Material Handling Systems
The six-step engineering design process in the context of
material handling:
1. Define the objectives and scope for the material handling
system.
2. Analyze the requirements for moving, storing protecting
3. Generate alternative designs for meeting material
handling system requirements.
4. Evaluate alternative material handling system designs.
5. Select the preferred design for moving, storing, protecting
6. Implement the preferred design, including the selection of
suppliers, training of personnel, installation, debug and
startup of equipment and periodic audits of system
performance.
Material Handling Equation
Why?
What? Where? When? How? Who? Which?
Preferred
Materials + Moves + Methods = Systems
Material Handling Systems Alternatives

Material Handling Equation

Definition of Unit Load Principle
• Unit load : number of items or bulk material
arranged so they can be picked up and delivered as
one load
• Large or small?
 Often a unit load is a batch of items from a
production process
 Large unit loads
• Less movement
• Larger equipment needed for the move
• May need larger aisles
• Larger floor load capacity
 Smaller unit loads
• Opposite of above

Definition of Unit Load Principle
• If large, cost/unit handled decreases
• But, depending upon
– cost of unitizing, de-unitizing
– space required for material handling
– material handling carrier payload
– work-in-process inventory costs
– storage and return of empty pallets or containers
used to hold the unit load
• smaller unit load may be desired
 A unit load may contain many items
• Not necessarily identical
 A unit load may be different in different parts of the
system
Example – Sheet metal stamping
 Delivery and storage of raw material

• Unit load = A coil of steel
 Blanking operation
• Unit load = Pallet of blanks. One coil generates
multiple unit loads of blanks
 Stamping operation
• Unit load = A rack of stamped parts. One pallet
of blanks generates multiple unit loads of racks
 Assembly operation
• Unit load = One vehicle body. One rack of parts is
moved on multiple vehicle bodies

Effect of unit
load size on job
completion
times

Dimensional
relationships
among various
elements in a
distribution
systems

Examples of
stackable and
nestable
containers
Stackability: a full
container can be
stacked on top of
another full container
in the same spatial
orientation
Nestability: the shape

of the containers
permits an empty
container to be
inserted into another
empty container.
Efficiency of Returnable Containers
• The importance of selecting the right kind of
returnable containers.
• Given the following dimensions of a particular type of
plastic reusable containers
• Inside dimensions 18” x 11” x 11”
• Outside dimensions 20” x 12” x 12”
• Each nested container 20” x 12” x 12”
• A trailer with inside dimensions of 240” x 120” x 120” is
used to transport these containers.
• The containers are not palletized.
• Assume that no clearance is needed between
containers or between containers and the walls of the
trailer.

Efficiency of Returnable Containers
Determine the following:
1. Container space utilization
2. Storage space efficiency
3. Container nesting ratio
4. Trailer space utilization if all containers are
stacked vertically in only one orientation
5. Trailer return ratio

Solutions

Solutions
• One stack of loaded containers has 120”/12” =
10 containers.
• One stack of empty container has
1 + (120”-12”)/2” = 55 containers
• Thus, the total number of empty containers
per trailer is 55 x (240”/20”) x (120”/12”) =
6600 containers.
• The trailer return ratio is 6600/1200 = 5.5
• Significant cost reductions may be achieved
with higher trailer return ratio.
A Comparison of The Difference Pallet Types

Systematic layout of
a manufacturing subsystem
of packaging, palletization,
storage and shipping.

System Component Specifications

Material Handling Equipment
• Material Handling Equipment Classifications:

Container and Unitizing Equipment
• Container
– Pallet
– Skids and Skid Boxes
– Tote Pans
• Unitizing
– Stretchwrap
– Palletizers

Material Transport Equipments
Conveyors
• Chute Conveyor
• Belt Conveyor
– Flat Belt Conveyor
– Telescoping Belt Conveyor
– Troughed Belt Conveyor
– Magnetic Belt Conveyor
• Roller Conveyor
• Wheel Conveyor
• Slat Conveyor
• Chain Conveyor

Conveyors (2)
• Tow Line Conveyor
• Power and Free Conveyor
• Cart on Truck Conveyor
• Sorting Conveyor
– Deflector
– Push Diverter
– Rake Puller
– Moving Slat Conveyor
– Pop-up Skewed Wheels
– Pop up Belts and Chains
– Pop Up Rollers
– Tilting Slat Conveyor
– Tilt Tray Sorter
– Cross Belt Sorter
– Bombardier Sorter

Industrial Vehicles
Monorails, Hoists and Cranes
• Monorail
• Hoist
• Cranes
– Jib Crane
– Bridge Crane
– Gantry Crane
– Tower Crane
– Stacker Crane

Storage and Retrieval Equipments
Unit Load Storage Equipment
• Block Stacking
• Pallet Stacking Frame
• Single Deep Selective Rack
• Double Deep Rack
• Drive in Rack
• Drive thru Rack
• Pallet Flow rack
• Push Back Rack
• Mobile Rack
• Cantilever Rack

Unit Load Retrieval Equipment
• Walkie Stacker
• Counterbalance Lift Truck
• Narrow Aisle Vehicles
– Straddle Truck
– Straddle Reach Truck
– Sideloader Truck
– Turret Truck
– Hybrid truck
• Automated Storage/Retrieval Machines
Small Load Storage and Retrieval
Equipment
Automatic Identification and
Communication Equipments
MHD Selection and Assignment Model
• Minimizes operating and annualized
investment costs of MHD
• Variables and parameters
– i part type index, i=1,2,...,p
– j machine type index, j=1,2,...,m
– l MHD type index, l=1,2,...,n
– Li set of MHDs that can transport part i
– H length of planning period
– Di # of units of part type i to be produced
– Kij set of machines to which part type i can
be sent from machine j for next process
– Mij set of machines from which part type i
can be sent to machine j for next process
– Ai set of machine types required for the first
operation on part type i
– Bi set of machine types required for last
operation on part type i
– Vl purchase cost of MHD Hl
– Tijkl time required to move one unit of part
type i from machine type j to k using MHD l
– Cijkl unit transportation cost to move part
type i from machine j to k using MHD l
– Xijkl number of units of part type i to be
transported from machine j to k using MHD
l
– Yl number of units of MHD type l selected
n p m
Min∑ VlYl + ∑∑ ∑ ∑C ijkl X ijkl
l =1 i =1 j =1 k∈K ij l∈Li
Subject to
∑ ∑ ∑X
j∈ Ai k∈K ij l∈Li
ijkl = Di i = 1,2,..., p
∑ ∑X
k∈M ij l∈Li
ijkl − ∑ ∑X
k∈K ij l∈Li
ijkl =0 i = 1,2,..., p; j : j ∉ Ai  Bi
∑ ∑ ∑X
j∈Bi k∈M ij l∈Li
ijkl = Di i = 1,2,..., p
p m
∑∑ ∑ X
i =1 j =1 k∈K ij
T
ijkl ijkl ≤ HYl l = 1,2,..., n
X ijkl ≥ 0, Yl ≥ 0 and integeran i = 1,2,..., p; j = 1,2,..., m; k , l = 1,2,..., n

Example for
MHS Selection and Assignment
• Small manufacturing system
• Processes two high volume parts P1 and P2- 50
and 60 units, respectively
• Part P1 processed first on machine M1, and on
machines M2 or M4 for second step and to
machine M3 for final step
• Of the 60 units of part P2, 30 are processed first
on machine M1 and then on machine M2.
• The remaining 30 units of part P2 are processed
first on machine M3 and then sent to machine M2
for final processing
Example for
• Two candidate MHDs - H1 and H2 with purchase
costs of $100,000 and $140,000 available
• Unit cost for transporting P1 and P2 on each of
the MHDs as well as transportation times given
• Assume there are 7150 seconds in the planning
period
• Each handling device is expected to make empty
trips 30% of the time
• Determine the required MHDs and assign
departmental moves to them
Example for
M2 M1
P1
M1 M3 P2 M2
M4 M3
Fm To M1 M2 M3 M4
P1 M1 H1 7(10) 8(5)
H2 5(8) 2(2)
P1 M2 H1 8(6)
H2 4(5)
P1 M4 H1 8(8)
H2 4(5)
P2 M1 H1 2(4)
H2 1(2)
P2 M3 H1 20(6)
H2 12(2)
MILP Model for Example 1
MIN 100000 Y1 + 140000 Y2 + 7 X1121 + 5 X1122 + 8 X1141 + 2
X1142 + 8 X1231 + 4 X1232 + 2 X2121 + X2122 + 20 X2321 + 12
X2322 + 8 X1431 + 4 X1432
SUBJECT TO
2) X1121 + X1122 + X1141 + X1142 = 50
3) X2121 + X2122 = 30
4) X2321 + X2322 = 30
5) X1121 + X1122 - X1231 - X1232 = 0
6) X1141 + X1142 - X1431 - X1432 = 0
7) X1231 + X1232 + X1431 + X1432 = 50
8) - 5005 Y1 + 10 X1121 + 5 X1141 + 6 X1231 + 4 X2121 + 6
X2321 + 8 X1431 <= 0
9) - 5005 Y2 + 8 X1122 + 2 X1142 + 5 X1232 + 2 X2122 + 2
X2322 + 5 X1432 <= 0
END INTE 2
Solution for Example 1
OBJECTIVE FUNCTION VALUE 101410.0

Y1 1.000000
X1121 50.000000
X1231 50.000000
X2121 30.000000
X2321 30.000000
Models for Conveyor Performance
Analysis
• There are m stations which load or unload n
carriers
• Amount of material loaded on the jth carrier as
it passes station i is fij
• If material unloaded, assign a negative value
to fij
• Load/unload cycle is a period of length p
Analysis
• Construct a set Fi = {fi1, fi2, ..., fip} including
load/unload activities carried out in p
successive carriers
• For e.g., if add one load to one carrier at the
first station, unload two from the next and let
the third one go by without loading or
unloading and repeat, cycle has a period of
length 3
• F1 = {1, -2, 0}
Analysis
• p need not be equal to n.
• In a cycle, total material loaded must be equal
to total unloaded
∑ (fi 1 + fi 2 + ...+ fip )= 0

i=1
Analysis
• One round completed when all m carriers have gone
around the conveyor once
• So, n/p load and unload cycles in the first round
• If carrier j is in some position of the load/unload
sequence (with respect to station i) during one round,
it need not be in same position in subsequent rounds
• It can be shown that if n mod p is not equal to 0, load
picked up or dropped off will change from one round
to the next, for the same carrier at the same station
• Let Pijk be the load/unload sequence position of a
carrier j, with respect to station i in round k
Analysis
• Given Pij1, Pijk can be determined using the
following formula, for k=2, 3, ..., p
• Pijk = [Pijk-1 + n mod p] mod p
• After p rounds, the position sequence repeats
itself
• If Pijk=0, set Pijk=p
• Load/unload cycle length has a period 5
• F1={2, 0, 2, 0, 3}; F2={-2, 0, 0, -1, -4}
• Determine the conveyor capacity.
Analysis-Example
52413 13524
41352 53142
35241 14253
31425 25314
2
Analysis-Example
Analysis-Example
• Change conveyor capacity requirement in one
of three ways
– Change number of carriers n. Pijk will change
resulting in different cumulative loads and hence,
carrier capacity
– Change load/unload sequence of one or more
stations
– Change the location of one or more stations
Queuing Network Model for Analysis
of MHS Systems
Mean Value Analysis Algorithm
Step 1: The first step is to estimate an initial value of Lij. The best method
is to evenly distribute a part over all the stations it visits.
Step 2: Determine the throughput time Wij using the equation
1  N j − 1   Lij  Lir
Wij = +    ∑ +
µi j  N j   µi j  r ≠ j µir
Step 3: Determine the production rate Xj using the equation
Xj=N j/[∑i=1,..m(vijWij)]
Step 4: Determine the queue length Lij using the equation Lij=Xj(vijWij).
Step 5: Compare the Lij value calculated in step 4 with the previous value.
If the new value is within a desired range of the previous value, stop.
If not, go to step 2.
Safety Considerations
• Many material handling equipment suppliers are reputable
and provide OSHA-compliant equipment, but having “safe”
equipment does not ensure a “safe” work environment.
• The key to a safe facility is concentrating on the interface
between the workforce and the equipment.
• One interface between the workforce and equipment that
needs particular attention is the use of aisles by both
pedestrians and industrial lift trucks.
• If common aisles are to be used, make them an extra three
feet wide and mark off a pedestrian walk-way other along
the left- or right-hand side.
• Provide lounge areas for incoming and outbound truck
drivers, and restrict access to the dock area so that vehicles
operators can do their jobs without unnecessary distraction
from wandering pedestrians.
Recommended Aisle Widths for Facility Design
Equipment Type Pick Aisle Gross Aisle
3-wheel counterbalance 9’ - 10’ 10’
4-wheel counterbalance 10’ - 12’ 12’
Reach truck 8’ 6” 10’
Double deep reach 8’ 6” 10’
Order picker truck 5’ 10’
Turret truck 5’ 12’
Swing mast truck 5’ – 6’ 12’
Side loader 6’ 15 ‘ – 20’
Fixed mast truck 5’ 20’
Counterbalance with attachment 12’ 14’ – 20’
Manual pallet pick 6’ 8’ – 10’
Powered pallet jack 7’ – 8’ 8’ – 10’

Resources
 MHIA – Materials Handling Institute of America
• http://www.mhia.org/
Materials handling classics
Case studies
 CICMHE – College Industry Council on Materials Handling
Education
• http://www.mhia.org/et/ET_MHI_CICMHE_Home.cfm
Materials handling taxonomy
 Materials Handling Institute
• http://www.mhia.org/et/et_mhi_home.cfm
Books, seminars targeted toward practicing engineers
 The Material Handling Education Foundation, Inc
• http://www.mhia.org/et/ET_MHEF_Home.cfm
Scholarships
References
1. Heragu, Sunderesh S., 2008, Facilities Design,
Third Edition, Taylor and Francis Group, LLC,
CRC Press, Chapter 9.
2. Tompkins, James A., White, John A., Bozer,
Yuvuz A., Tanchoc, 2010, Facilities Planning,
Fourth Edition, John Wiley and Sons, Inc.,
Chapter 5.

Material Handling

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Material Handling

Uploaded by

Copyright:

Available Formats

Material Handling

9/13/2015 TLF week 5: Material Handling 4

9/13/2015 TLF week 5: Material Handling 7

9/13/2015 TLF week 5: Material Handling 9

What? Where? When? How? Who? Which?

Material Handling Systems Alternatives

9/13/2015 TLF week 5: Material Handling 12

9/13/2015 TLF week 5: Material Handling 13

9/13/2015 TLF week 5: Material Handling 14

 Delivery and storage of raw material

9/13/2015 TLF week 5: Material Handling 16

9/13/2015 TLF week 5: Material Handling 17

9/13/2015 TLF week 5: Material Handling 18

Nestability: the shape

9/13/2015 TLF week 5: Material Handling 20

9/13/2015 TLF week 5: Material Handling 21

9/13/2015 TLF week 5: Material Handling 22

9/13/2015 TLF week 5: Material Handling 25

9/13/2015 TLF week 5: Material Handling 27

9/13/2015 TLF week 5: Material Handling 28

9/13/2015 TLF week 5: Material Handling 30

9/13/2015 TLF week 5: Material Handling 31

9/13/2015 TLF week 5: Material Handling 33

9/13/2015 TLF week 5: Material Handling 37

9/13/2015 TLF week 5: Material Handling 41

9/13/2015 TLF week 5: Material Handling 45

X ijkl ≥ 0, Yl ≥ 0 and integeran i = 1,2,..., p; j = 1,2,..., m; k , l = 1,2,..., n

OBJECTIVE FUNCTION VALUE 101410.0

∑ (fi 1 + fi 2 + ...+ fip )= 0

9/13/2015 TLF week 5: Material Handling 78

9/13/2015 TLF week 5: Material Handling 80

You might also like