Facility Layout and Operations, Chapter 4 PDF

Facility Layout and Operations CHAPTER 4 Material Handling ISE Department Year 5/ Level 9 Instructor : Dr. Imen Safra 1  Outline 1. Introduction 2. Scope and D...

Facility Layout and Operations CHAPTER 4 Material Handling ISE Department Year 5/ Level 9 Instructor : Dr. Imen Safra 1  Outline 1. Introduction 2. Scope and Definitions of Material Handling 3. Material Handling Principles 4. Designing Material Handling systems 5. Material Handling Equipment 6. Unit Load Design Dr. Imen Safra 2  1.Introduction The design of the material handling system is an important component of the overall facilities design. The layout design and the material handling system design are inseparable. The integration between these two design functions is particularly critical in the design of a new facility. Material handling is an integral part of the overall facility design process Dr. Imen Safra 3  2.Scope and definition of Material Handling In a typical industrial facility, material handling accounts for 25% of all employees, 55% of all factory space, and 87% of production time Material handling is the art and science associated with the movement, storage, control, and protection of goods and materials throughout the process of their manufacture, distribution, consumption, and disposal. (Material Handling Institute of America) Material handling 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 method(s). Dr. Imen Safra 4  3. Material Handling Principles There are 10 material handling principles recognized by the College-Industry Council on Material Handling Education. They are as follows: 1- Planning Principle: A plan is a prescribed course of action that is defined in advance of implementation. In its simplest form, a material handling plan defines the material (what) and the moves (when and where); together they define the method (how and who). 2. Standardization Principle: Standardization means less variety and customization in the methods and equipment employed. 3. Work Principle: The measure of work is material flow (volume, weight, or count per unit of time) multiplied by the distance moved. 4. Ergonomic Principle: Ergonomics is the science that seeks to adapt work or working conditions to suit the abilities of the worker. Dr. Imen Safra 5  3. Material Handling Principles 5. Unit Load Principle: 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, regardless of the number of individual items that make up the load. 6. Space Utilization: Space in material handling is three-dimensional and therefore is counted as cubic space. 7. System Principle: A system is a collection of interacting and/or interdependent entities that form a unified whole. 8. Automation Principle: Automation is a technology concerned with the application of electromechanical devices, electronics, and computer-based systems to operate and control production and service activities. It suggests the linking of multiple mechanical operations to create a system that can be controlled by programmed instructions. 3. Material Handling Principles 9. Environmental Principle: Environmental consciousness stems from a desire not to waste natural resources and to predict and eliminate the possible negative effects of our daily actions on the environment. 10. Life-Cycle Cost Principle: Life-cycle costs include all cash flows that will occur from the time the first dollar is spent to plan or procure a new piece of equipment, or to put in place a new method, until that method and/or equipment is totally replaced. Dr. Imen Safra 7  4. Designing Material Handling systems Components of Material Handling : - The Materials : products, items, substances and/or people which are beig moved, transported or physically relocated - The Move (Origin, Travel Path, Destination, Frequency) to be made - The Method (Equipment, people, procedures, physical facilities) to be used to make the move. Dr. Imen Safra 8  4. Designing Material Handling systems The What Question 1. What are the types of material to be moved? 2. What are their characteristics? 3. What are the amounts moved and stored? The Where Question 1. Where is the material coming from? Where should it come from? 2. Where is the material delivered? Where should it be delivered? 3. Where is the material stored? Where should it be stored? 4. Where can material handling tasks be eliminated, combined, or simplified? 5. Where can you apply mechanization or automation? The When Question 1. When is material needed? When should it be moved? 2. When is it time to mechanize or automate? 3. When should we conduct a material handling performance audit? Dr. Imen Safra 9 4. Designing Material Handling systems The How Question 1. How is the material moved or stored? How should the material be moved or stored? What are the alternative ways of moving or storing the material? 2. How much inventory should be maintained? 3. How is the material tracked? How should the material be tracked? 4. How should the problem be analyzed? The Who Question 1. Who should be handling material? What are the required skills to perform the material handling tasks? 2. Who should be trained to service and maintain the material handling system? 3. Who should be involved in designing the system? The Which Question 1. Which material handling operations are necessary? 2. Which types of material handling equipment, if any, should be considered? 3. Which material handling system is cost effective? Dr. Imen Safra 10 4. Which alternative is preferred?  5. Material Handling Equipment Material Handling Equipment (MHE) is used for the movement and storage of material within a facility or at a site MHE can be classified into the following majors categories: 1. Containers and unitizing equipment 3. Storage and retrieval equipment Containers Unit load storage and retrieval Unitizers Small load storage and retrieval 2. Material transport equipment 4. Automatic data collection and communication Conveyors equipment Industrial vehicles Automatic identification and recognition Monorails, hoists, and cranes Automatic paperless communication Dr. Imen Safra 11  5. Material Handling Equipment Material Transport equipment : Equipment used to move material from one location to another (e.g. between workplaces, between a loading dock and a storage area, etc.) The major subcategories of transport equipment are : 1. Conveyors 2. Cranes 3. Industrial trucks 4. Material can also be transported manually without using any equipment Dr. Imen Safra 12 5. Material Handling Equipment 13 Dr. Imen Safra 5. Material Handling Equipment Dr. Imen Safra 14 5. Material Handling Equipment Dr. Imen Safra 15 5. Material Handling Equipment Dr. Imen Safra 16 5. Material Handling Equipment Dr. Imen Safra 17 5. Material Handling Equipment Dr. Imen Safra 18 5. Material Handling Equipment Dr. Imen Safra 19 5. Material Handling Equipment Dr. Imen Safra 20 5. Material Handling Equipment 2- Positioning equipment : Equipment used to handle material at a single location so that it is in the correct position for subsequent handling, machining, transport or storage.  Unlike transport equipment, positioning equipment is usually used for handling at a single workplace.  Material can also be positioned manually using no equipment Dr. Imen Safra 21 5. Material Handling Equipment Dr. Imen Safra 22 5. Material Handling Equipment 3- Unit Load Formation equipment : Equipment used to restrict materials so that they maintain their integrity when handled as a single load during transport and for storage  If materials are self-restraining (single part or interlocking parts), then they can be formed into a unit load with no equipment. Dr. Imen Safra 23 5. Material Handling Equipment Dr. Imen Safra 24  5. Material Handling Equipment 4- Storage equipment : Equipment used for holding or buffering materials over a period of time Some storage equipment may include the transport of materials (e.g. storage carousels). If Materials are block stacked directly on the floor, then no storage equipment is required Dr. Imen Safra 25 5. Material Handling Equipment Dr. Imen Safra 26  5. Material Handling Equipment 5- Identification and control equipment : Equipment used to collect and communicate the information that is used to coordinate the flow of materials within a facility and between a facility and its suppliers and customers Dr. Imen Safra 27 5. Material Handling Equipment Dr. Imen Safra 28 5. Material Handling Equipment Dr. Imen Safra 29 5. Material Handling Equipment Dr. Imen Safra 30 5. Material Handling Equipment Dr. Imen Safra 31 5. Material Handling Equipment Dr. Imen Safra 32 5. Material Handling Equipment Dr. Imen Safra 33 5. Material Handling Equipment Dr. Imen Safra 34 5. Material Handling Equipment –Selection criteria Dr. Imen Safra 35 5. Material Handling Equipment –Selection criteria Dr. Imen Safra 36 5. Material Handling Equipment –Selection criteria Dr. Imen Safra 37 38 39  6. Unit Load Design  Of the 10 principles of material handling, the unit load principle deserves special attention.  Bright defines a unit load as a number of items, or bulk material, so arranged or restrained that the mass can be picked up and moved as a single object too large for manual handling, and which upon being released will retain its initial arrangement for subsequent movement.  Unit Load Design involves determining the : Type, size, weight and configuration of the load Equipment and method used to handle the load Methods of forming and breaking down the load Dr. Imen Safra 40 6. Unit Load Design The figure shows several stages in the material flow process where dimensional relationships play a major role. In this illustration, we assume that the cartons are stacked on pallets and the full pallet loads are loaded directly on trailers or are block-stacked in a warehouse before they are loaded on trailers for shipment to customers. Dr. Imen Safra 41 6. Unit Load Design Exemple: 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 2” 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. Determine the following: 1. Container space utilization 2. Storage space efficiency (if the dimension of the storage opening is 24”x16”x 14”) 3. Container nesting ratio 4. Trailer space utilization if all containers are stacked vertically in only one Orientation 5. Trailer return ratio Dr. Imen Safra 42 6. Unit Load Design Exemple: 1. Container space utilization Container space utilization is obtained by dividing the usable cube by the exterior envelope of the container. For this example, the container efficiency is (18” x 11” x 11”)/(20” x 12” x 12”) = 0.76 or 76% 2. Storage space efficiency (if the dimension of the storage opening is 24”x16”x 14”) The Storage space efficiency is the ratio of usable cube divided by the storage cube. If the dimension of the storage opening is 24” x 16” x 14, then the storage efficiency is (18” x 11” x 11”)/(24” x 16” x 14”)= 0.45 or 45% Dr. Imen Safra 43 6. Unit Load Design Exemple: 3. Container nesting ratio The container nesting ratio is determined by dividing the overall container height by the nested height; that is, 12”/2” = 6 the ratio is 6 Six nested containers use the same space as one closed container. 4. Trailer space utilization if all containers are stacked vertically in only one Orientation The container takes up all the space in the trailer with 240”/20”= 12 containers along the length of the trailer, 120”/12” = 10 containers along the width of the trailer, and 120”/12” = 10 containers stacked vertically. The total number of containers is 12 x 10 x 10=1200. The trailer space utilization is (18” x 11” x 11”)x(1200)/(240” x 120” x 120”) = 0.76 or 76% Dr. Imen Safra 44 6. Unit Load Design Exemple: 5. Trailer return ratio One stack of loaded containers has 120”/12” = 10 containers. One stack of empty containers has 55 containers; that is, 1+ (120” – 12”)/2 = 55 Thus, the total number of empty containers per trailer is 55 x (240”/20”) X (120”/12”) = 6600 The trailer return ratio is 6600/1200 = 5.5 The impact of trailer return ratio on the overall efficiency of the distribution function cannot be overlooked. Significant cost reductions may be achieved with higher trailer return ratios. Dr. Imen Safra 45  6. Unit Load Design  In selecting containers, size progression is one of the important considerations.  Figure 5.6 shows a container system with progressive dimensions (e.g., a smaller container is half the size of the larger container). The progression here is 1, 1/2, 1/4, 1/8, 1/16 and so on.  The use of these types of containers allows the efficient utilization of the load deck of an automated guided vehicle as the vehicle picks up and delivers containers to stations along its route. Dr. Imen Safra 46