IE271_Lecture11 - IE271OperationsAnalysis andDesign Lecture...

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IE271 – Operations Analysis  and Design Lecture Notes 11 – Material Handling
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Material Handling Defined as “the movement, storage, protection and control of materials throughout the manufacturing and distribution process including their consumption and disposal” (The Material Handling Industry of America) Estimated to represent 20-25% of total manufacturing labor cost in US
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Material Handling Objectives To move materials within a facility Safely Efficiently At low cost In a timely manner Accurately Without damage Material handling is often an overlooked issue in industry
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Material Handling Equipment 1. Material transport 2. Storage 3. Unitizing equipment 4. Identification and tracking systems
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Material Transport Equipment Five categories: 1. Industrial trucks 2. Automated guided vehicles 3. Monorails and other rail guided vehicles 4. Conveyors 5. Cranes and hoists
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Industrial Trucks Two basic categories: 1. Non-powered Human workers push or pull loads Low volume Short distances 1. Powered Self-propelled Larger loads Greater distances Common example: forklift truck
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Forklift Truck Forks are used to move pallet loads
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INDUSTRIAL TRUCK
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Advantages of Industrial Trucks Path not fixed Can handle loading, unloading, lifting, transfer Their unrestricted mobility leads to high utilization
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Disadvantages of Industrial Trucks Cannot handle heavy loads Limited capacity per trip Need for aisles Need for an operator Handling cannot be combined with processing or inspection
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Automated Guided Vehicle Systems Material handling system that uses independently operated, self-propelled vehicles guided along defined pathways in the facility floor Types of AGV: Driverless trains Pallet trucks Unit load AGVs
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Automated Guided Vehicle A unit-load automated guided vehicle
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Rail-Guided Vehicles Fixed rail system Overhead monorail - suspended overhead from the ceiling On-floor - parallel fixed rails, tracks generally protrude up from the floor Powered by electrified rail
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Overhead Monorail
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In-floor Towline
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Conveyor Systems 1. Non‑powered Materials moved by human workers or by gravity 1. Powered Power mechanism for transporting materials is contained in the fixed path, using chains, belts, rollers or other mechanical devices
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Conveyor Types Roller: can be powered or non‑powered Skate‑wheel Belt In‑floor towline Overhead trolley conveyor
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Roller Conveyor Common conveyor type Can be powered or unpowered
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CONVEYOR
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Advantages of Conveyors High capacity Adjustable speed Handling combined with processing and inspection Versatile on-floor or overhead Temporary storage between stations Automatic transfer (no MH operators) No need for aisles Utilization of the cube – overhead conveyors
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Disadvantages of Conveyors Fixed path Possible development of bottlenecks
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IE271_Lecture11 - IE271OperationsAnalysis andDesign Lecture...

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