Facility Layout Chapter 4: Material Handling
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Questions and Answers

What are the three major types of cranes?

  • Cranes, hoists, industrial trucks
  • Bridge crane, Gantry crane, Stacker crane
  • Jib crane, Bridge crane, Stacker crane (correct)
  • Jib crane, Bridge crane, Gantry crane

    • Material handling is an integral part of the overall facility design process.

    True

    What does a material handling plan define?

    It defines the material, the moves and the methods.

    What is the measure of work in material handling?

    <p>Material flow (volume, weight, or count per unit of time) multiplied by the distance moved.</p> Signup and view all the answers

    What are the components of material handling?

    <p>The materials, the move, the method</p> Signup and view all the answers

    Space in material handling is three-dimensional and therefore is counted as ______

    <p>cubic space</p> Signup and view all the answers

    What does a 'unit load' mean?

    <p>A unit load is one that can be stored or moved as a single entity at one time, such as a pallet, container, or tote.</p> Signup and view all the answers

    What are the three subcategories of transport equipment in material handling?

    <p>Conveyors, cranes, Industrial trucks</p> Signup and view all the answers

    Material can also be transported manually without using any equipment.

    <p>True</p> Signup and view all the answers

    What is the primary function of positioning equipment in material handling?

    <p>To handle materials at a single location to ensure correct positioning for storage and further processes</p> Signup and view all the answers

    What qualifies a material as self-restraining?

    <p>Materials that are self-restraining are typically single parts or interlocking parts.</p> Signup and view all the answers

    What are the two main types of storage equipment in material handling?

    <p>Selective pallet rack, Drive-through rack</p> Signup and view all the answers

    Identification and control equipment is used to collect and communicate important information about material movement, which allows for better coordination of material flow.

    <p>True</p> Signup and view all the answers

    What are the five important terminologies in material handling equipment?

    <p>Conveyors, Trolleys, Pallets, Chutes and magazines, Robots</p> Signup and view all the answers

    Conveyor systems are commonly used to move heavy or bulky materials from one location to another.

    <p>True</p> Signup and view all the answers

    Trolleys are a common piece of material handling equipment that uses wheels to move materials from one location to another.

    <p>True</p> Signup and view all the answers

    A 'pallet' is a flat structure that supports goods, allowing for stable lifting by various machinery.

    <p>True</p> Signup and view all the answers

    Pallets are the structural foundation of unit loads, facilitating handling and storage efficiencies.

    <p>True</p> Signup and view all the answers

    'Chutes' are structures designed to allow material movement using a roller system.

    <p>False</p> Signup and view all the answers

    Industrial robots, capable of being programmed to perform multiple tasks, have applications in welding, painting, assembly, pick and place, inspection, and testing.

    <p>True</p> Signup and view all the answers

    When selecting containers, size progression is an important consideration for efficient load utilization.

    <p>True</p> Signup and view all the answers

    What is the 'container space utilization' when determining the usable cube by the exterior envelope of the container?

    <p>The usable cube divided by the exterior envelope</p> Signup and view all the answers

    How is the 'storage space efficiency' determined?

    <p>It is determined by dividing the usable cube by the storage cube.</p> Signup and view all the answers

    The 'container nesting ratio' is determined by dividing the overall container height by the nested height, illustrating how many nested containers can fit into the space of a single container.

    <p>True</p> Signup and view all the answers

    When determining the trailer space utilization, the containers are assumed to be stacked vertically in only one orientation.

    <p>True</p> Signup and view all the answers

    The 'trailer return ratio', which indicates the proportion of empty containers to loaded containers per trailer, plays a critical role in the overall efficiency of the distribution function, often leading to potential cost reductions.

    <p>True</p> Signup and view all the answers

    Study Notes

    Facility Layout and Operations

    • Chapter 4 focuses on Material Handling

    • Material handling is a critical aspect of facility design, integral to the overall process

    • Layout design and material handling system design are inseparable

    • Material handling accounts for 25% of employees, 55% of factory space, and 87% of production time in typical industrial facilities

    Material Handling

    • Material handling is the art and science of moving, storing, controlling, and protecting goods and materials throughout production, distribution, consumption, and disposal

    • This includes providing the correct amount of the right material in the right condition, at the right place, in the right position, and sequence for the right cost and method

    Material Handling Principles

    • There are 10 Material Handling Principles:

      • Planning Principle: A pre-defined action plan outlining material, movements, and methods

      • Standardization Principle: Reduced variety and customization in methods and equipment

      • Work Principle: Material flow, volume, weight, or count per unit of time multiplied by the distance moved to measure work

      • Ergonomic Principle: Adapting work/working conditions to accommodate worker abilities

      • Unit Load Principle: A single entity for storage or movement (like pallets, containers, totes)

      • Space Utilization Principle: Material handling space is three-dimensional (cubic)

      • System Principle: Interacting entities forming a unified whole

      • Automation Principle: Application of electromechanical devices/electronics/computer based systems to operate, control services and production activities

      • Environmental Principle: Avoiding natural resource wastage and mitigating negative environmental impacts

      • Life-Cycle Cost Principle: Cash flows from planning to equipment replacement/method implementation

    Designing Material Handling Systems

    • Key components of material handling include:

      • Materials, including products, items, substances, or people moved, transported, or physically relocated
      • The move, including origin, travel path, destination, frequency
      • The method, including equipment, people, procedures, and physical facilities to enact the move

    • The "What Question": Material types, characteristics, quantities moved/stored

    • The "Where Question": Material origin, delivery points, storage locations, optimization of tasks

    • The "When Question": Material need timing, automation/mechanization timing points

    • The "How Question": Methods of movement/storage, inventory maintenance, and analytical process

    • The "Who Question": Material handlers, maintenance personnel, and design team involvement

    • The "Which Question": Necessary operations, equipment options, cost-effectiveness, preferred alternative selection

    Material Handling Equipment

    • Major categories:

      • Containers & Unitizing Equipment (containers, unitizers)
      • Material Transport Equipment (Conveyors, industrial vehicles, monorails, hoists, and cranes)
      • Storage & Retrieval Equipment (unit load, small load storage, retrieval, automatic data collection, communication equipment, and automatic identification/recognition)
      • Positioning Equipment (used at a single location to align items for storage/machining/transport)

    • Equipment for Transport includes conveyors, cranes, industrial trucks (hand trucks, forklifts)

    • Positioning equipment includes lift tables and dock levelers

    • Storage equipment includes pallet racks, split case order picking systems, and drive-through racks.

    Unit Load Design

    • Unit load principle is crucial for material handling efficiency in larger shipments

    • Unit load design involves defining load specifications (type, size, weight, configuration).

    • This determines handling equipment, forming, and breaking down the loads.

    • Proper size progression of containers in a system is important for more efficient operation.

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    Facility Layout and Operations, Chapter 4 PDF

    Description

    Explore Chapter 4 on Material Handling, where we delve into its vital role in facility design and operations. Learn about the significant impact of material handling on employee efficiency, factory space usage, and production time. Understand the 10 essential principles of material handling that guide effective materials management.

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