Material Handling System Design

Outline Definitions Unit Load Material Handling Equipment

Importance of Material Handling In a typical factory, material Handling accounts for: MH MH 55% Factory Space 87% Production time 15% 70% Product Cost

Material Handling Definitions Right amount MH is the art and science of moving, storing, protecting, and controlling material. Right material Right time Right condition PROVIDE Right place Right position Right methods Right cost Right sequence Material Handling means providing: the right amount of the right material, at the right time (not early OR late) in the right condition (quality, what else?) at the right place in the right position (orientation) in the right sequence for the right cost (does this mean minimal?) using the right method(s).

New MHI Material Handling Definition Operations Material Handling is the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal.  The focus is on the methods, mechanical equipment, systems and related controls used to achieve these functions. Source: MHI website - Glossary http://www.mhia.org/keywords/keyworddescr_template.cfm?keyword_id=762 Subjects Business Processes Aligns with “progressive view” of scope of material handling defined by Apple, that is a total system view (p. 166 text)

Objectives of Material Handling Increase the efficiency of material flow Reduce MH cost Improve facilities utilization Safety and working conditions Manufacturing process Increase productivity Source: D.R.Sule, Manufacturing facilities

Highlights of Definitions Art and science Right stuff in the right way Efficient Storage and Movement Movement of “parts” with machines Methods/Controls of movement to meet facility objectives Throughout the supply chain

MH Examples Material Handling is not restricted to the manufacturing or distribution environment Mass Transportation Hospitals Mail Delivery Construction

Material Handling Principles Defined by the Material Handling Institute and the College-Industry Council on Material Handling Education (CICME) (p.167 text): Planning (what,when,where) Standardization Work (cost x flow) Ergonomic *Unit Load 6. Space Utilization (3-D) 7. System 8. Automation 9. Environmental 10. Life Cycle Cost (procurement-removal) *Most important according to textbook authors

Material Handling Systems Design Define the objectives & scope Analyze the requirements Generate alternative designs Evaluate alternative designs Select the preferred design Implement the preferred design

Work simplification in MH Framework for identifying MH solutions Evaluate each movement: 1. Can the move be eliminated ? 2. Can the move be combined with another or within an in-transit operation ? 3. Can the move be simplified ? 4. Can the sequence of moves be changed to advantages ? Why?

Analyzing MH solutions MH Planning Chart: (Figure 5.2, pg 173) Information w.r.t. a specific MH solution Record ALL movements (people + machines) Reveals unnecessary movements and storage

Unit Loads Pallet sized by Stacking ANSI (American National A unit load is the unit to be moved or handled at one time. A unit load includes the container, carrier, or support that will be used to move materials. Unit Load Pallet sized by ANSI (American National Standard Institute) Stacking Pallet Forklift

Unit Load Examples: tote boxes, “cassette”, cartons, skids, pallets, pallet boxes, intermodal container, one unit of product, etc. Most popular: plastic containers and pallets Factors for determining unit load/ container: Size of carrier Size and weight of items Space for storing loaded/unloaded container Equipment used for moving Cost, supply and maintenance Aisle widths, door sizes, and clear stacking heights Environmental regulations

Unit Load and Handling System The unit load is an integral part of the material handling system and a “simultaneous” determination should be made. Design the Handling/Storage system Design the Unit Load

In-class Exercise: Unit Load and Cycle Time We have a system with two machines. Every unit of the product has to go through Machine 1 first and then through Machine 2. Machine 1 1 min/unit Machine 2 1 min/unit We move the product using forklift trucks. The company has several of them going around permanently. We can use one whenever we need. The move from Machine 1 to Machine 2 takes two minutes. How many units should we move at a time using the forklift truck to minimize the time of completion of an order of 16 units? In other words, how big should the unit load be to minimize completion time? The forklift truck moves a batch (or a lot) of units at a time.

Unit Load and Cycle Time MH M2 16 34 UL = 16 units Unit Load and Cycle Time M1 MH M2 18 26 UL = 8 units Lot size = 16 units Machining = 1 min/unit Operations 1 and 2 MH = 2 min/trip M1 MH M2 6 20 UL = 2 units Large unit loads: longer cycle times, fewer moves M1 MH M2 4 34 UL = 1 unit Small unit loads: lower cycle time, lower WIP, more frequent handling MH time > processing time => MH constrained

Unit Load Disadvantages Time spent forming and breaking down the unit load. Empty containers/pallets may need to be returned to their point of origin. Cost of containers/pallets and other load restraining materials used in the unit load

Review Questions The Unit Load remains the same throughout the facility. True or False? Which statement is the most accurate? Material Handling should be reduced as much as possible. The materials, movements, and methods define the MH system. The unit load should be decided before any other MH decisions. The what, where, and when, defines the how and who.

Classification of M.H. Equipment I. Containers & unitizers II. Material Transport Equipment 1. Conveyors 2. Industrial Trucks & Vehicles 3. Monorails, Hoists & Cranes III. Storage & Retrieval Equipment IV. Automatic Identification & Communication Equipment

MH Equipment Resources MHE Taxonomy (http://www.ise.ncsu.edu/kay/mhetax/index.htm) The Material Handling Multimedia Bank (http://www.centor.ulaval.ca/MHMultimediaBank) Textbook (Appendix 5b) Material Handling Industry of America (http://www.mhia.org) CICMHE Website (http://www.mhia.org/cicmhe/) MaterialHandlingInfo.com (http://208.226.12.140/mhi/)