1. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 MATERIAL HANDLING (Textbook Chapter 5)

2. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Toward a definiton Material Handling accounts for: –25% of all employees, –55% of all factory space, –87% of production time –15-70% of the total cost of a manufactured product 3-5% of all material handled becomes damaged –“Totally eliminate” –However, handling less is not the answer.

3. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Motivations: Material handling is a means by which: –Total manufacturing costs are reduced through Reduced inventory Improved safety Reduced pilferage Improved material control. –Manufacturing quality is improved by: Reducing inventory Reducing damage –Any production strategy is executed.

4. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Definitions: Material handling is the art and science of moving, storing, protecting, and controlling material –Moving: Required to create time and place utility. The value of having the material at the right time and the right place. –Storing: Provides a buffer between operations, facilitates the efficient use of people and machines. –Protecting: Includes the packaging, packing against damage and theft. –Controlling: Physical: Orientation, sequence and space between material. Status: Real-time awareness of the location, amount, destination, origin, ownership, and schedule of material.

5. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 MH-Principles MH 1. Planning 2. Standardization 3. Work principle 4. Ergonomic 5. Unit load 6. Space Utilization 7. System 8. Automation 9. Environmental 10. Life Cycle Cost

6. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Conditions for improvement MH Idle production equipment due to material shortage Material piled directly on floor In-plant containers not standardized Operators travel excessively for materials and supplies Excessive demurrage Misdirected material Backtracking of material Automatic data collection system not used No pre-kitting of work System not capable of change or expansion

7. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Six-step engineering desing process 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, and controlling material. 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.

8. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Developing Alternative MHS Designs NADLER’s IDEALS approach: 1.Aim for the theoretical ideal system. 2.Conceptualize the ultimate ideal system. 3.Design the technologically workable ideal system. 4.Install the recommended system.

9. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

10. 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 Where is the material coming from? Where should it come from? Where is the material delivered? Where should it be delivered? Where is the material stored? Where should it be stored? Where can material handling tasks be eliminated, combined or simplified? 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? The How Question 1. How is the material moved or stored? How should 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 type of material handling equipment, if any, should be considered? 3. Which material handling system is cost effective? 4. Which alternative is preferred?

11. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 UNIT LOAD “ picked up and moved between two locations as a single mass” Example: 1.a single item picked up and moved manually between two locations 2.Two tote pans with identical components picked up moved by a dolly from one machine to another 3.One pallet load of nonuniform-size cartons with different products picked up and moved by a lift truck from the packaging area to the shipping dock 4.One full load of products delivered by a trucktrailer from a warehouse to a customer store If the trailer is half full, it is still one unit load. Larger unit load: + fewer moves - bigger and heavier equipment -wider aisles -higher floor load capacities -increased work-in-process inventory Smaller unit load: + reduced work-in-process inventory +simple material handling methods (i.e., push carts) +reduced completion time (How??) -more moves -increased material handling time “Achieving single unit production requires the materail handling time to be shorter than the unit processing time.”

12. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

18. Categories of Material Handling Equipment 1. Containers and Unitizing Equipment Containers Unitizers 2. Material Transport Equipment Conveyors Industrial Vehicles Monorails, Hoists, and Cranes 3. Storage and Retrieval Equipment Unit Load Storage and Retrieval Unit Load Storage Equipment Unit Load Retrieval Equipment Small Load Storage and Retrieval 4. Automatic Data Collection and Communication Equipment Automatic Identification and Recognition Automatic Paperless Communication

19. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Containers: Tote pans

20. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Containers: Pallets

21. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Unitizers: Palletizer

22. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Unitizers: Stretchwrapper

23. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Conveyors

24. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Conveyors

25. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Industrial Vehicles

26. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Industrial Vehicles

27. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Storage and Retrieval

28. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Storage and Retrieval

29. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Monorails, Hoists and Cranes

30. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Stock to operator: Carousels

31. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 Stock to operator: Carousels

32. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 MH-Principles MH 1. Orientation 2. Planning 3. Systems 4. Unit load principle 5. Space utilization 6. Standardization 7. Ergonomic 8. Energy9. Ecology 10. Mechanization 11. Flexibility 12. Simplification 13. Gravity 14. Safety 15. Computerization 16. System Flow 17. Layout 18. Cost 19. Maintenance 20. Obsolescence

33. Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003 MATERIALS HANDLING TEKS 130.403 (c) 12 d Shared by Ryan Patton, Irving ISD