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CIM unit-4 | PPTX - SlideShare

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Jul. 21, 2025

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CIM unit-4 | PPTX - SlideShare

  • 2. Contents Types of Flexibility - FMS – FMS Components – FMS Application & Benefits – FMS Planning and Control– Quantitative analysis in FMS – Simple Problems. Automated Guided Vehicle System (AGVS) – AGVS Application – Vehicle Guidance technology – Vehicle Management & Safety.
  • 3. FMS FMS may be defined as “a highly automated GT machine cell, consisting of a group of processing workstations (usually CNC machine tools), interconnected by an automated material handling and storage system, and controlled by a distributed computer system.” FMS employs a fully integrated handling system with automated processing stations.
  • 6. Flexibility and its Types Flexibility is an attribute that allows a manufacturing system to cope up with a certain level of variations in part or product type, without having any interruption in production due to changeovers between models. Flexibility measures the ability to adopt “to a wide range of possible environment”
  • 7. Tests of Flexibility Part variety test Schedule change test Error recovery test New part test
  • 9. Types of Flexibility  Machine flexibility  Production flexibility  Mix (or Process) flexibility  Product flexibility  Routing flexibility  Volume (or capacity) flexibility  Expansion flexibility
  • 10. Machine flexibility  Definition: Machine flexibility is the capability to adapt a given machine in the system to a wide range of production operations and part types.  Influencing factors: Setup or change over time Ease with which part-programs can be downloaded to machines Tool storage capacity of machine Skill and versatility of workers in the systems
  • 11. Production flexibility  Definition: Production flexibility is the range of part types that can be produced by a manufacturing system.  Influencing factors: Machine flexibility of individual stations Range of machine flexibilities of all stations in the system
  • 12. Mix (or Process) flexibility  Definition: Mix flexibility, also known as process flexibility, is the ability to change the product mix while maintaining the same production quantity. i.e., producing the same parts only in different proportions  Influencing factors: Similarity of parts in the mix Machine flexibility Relative work content times of parts produced
  • 13. Product flexibility  Definition: Product flexibility is the ability to change over to a new set of products economically and quickly in response to the changing market requirements.  Influencing factors: Relatedness of new part design with the existing part family Off-line part program preparation Machine flexibility
  • 14. Routing flexibility  Definition: Routing flexibility is the capacity to produce parts on alternative workstation in case of equipment breakdowns, tool failure, and other interruptions at any particular station.  Influencing factors: Similarity of parts in the mix Similarity of workstations Common testing
  • 15. Volume (or capacity) flexibility  Definition: Volume flexibility, also known as capacity flexibility, is the ability of the system to vary the production volumes of different products to accommodate changes in demand while remaining profitable.  Influencing factors: Level of manual labour performing production Amount invested in capital equipment
  • 16. Expansion flexibility  Definition: Expansion flexibility is the ease with which the system can be expanded to foster total production volume.  Influencing factors: Cost incurred in adding new workstations and trained workers Easiness in expansion of layout Type of part handling system
  • 17. Four Tests of Flexibility Vs Seven Types of Flexibility Sl No Flexibility Test Type of Flexibility 1 Part Variety  Machine  Production 2 Schedule Change  Mix  Volume  Expansion 3 Error recovery  Routing 4 New part  Product
  • 18. Types of FMS  Classification based on the kinds of operations they perform Processing operation Assembly operation  Classification based on the number of machines in the system Single machine cell (SMC) Flexible machine cell (FMC) Flexible manufacturing system (FMS)  Classification based on the level of flexibility associated with the system Dedicated FMS Random order FMS
  • 19. Classification based on the kinds of operations they perform  Processing operation Processing operation transforms a work material from one state to another moving towards the final desired part or product. It adds value by changing the geometry, properties or appearance of the starting materials.  Assembly operation Assembly operation involves joining of two or more components to create a new entity which is called an assembly. Permanent joining processes include welding, brazing, soldering, adhesive banding, rivets, press fitting and expansion fits.
  • 20. Classification based on the number of machines in the system  Single Machine Cell (SMC)
  • 21. Flexible machine cell (FMC)
  • 22. Flexible manufacturing system (FMS)
  • 23. Summary
  • 25. Classification based on the level of flexibility associated with the system Dedicated FMS A dedicated FMS is designed to produce a limited variety of part configurations. Thus the dedicated FMS usually consists of special purpose machines rather than general purpose machines. Random order FMS The random order FMS is equipped with general purpose machines so as to meet the product variations. Also FMS type requires a more sophisticated computer control system.
  • 28. Components/Elements of FMS  Workstations  Material handling and storage system  Computer control system  Human resources
  • 29. FMS Workstations  The workstations/processing stations used in FMS depends upon the type of product manufactured by the system.  The types of workstations that are usually found in a FMS are: Load/unload stations Machining stations Assembly workstations Inspection station Other processing stations
  • 30. Material handling and storage system  FMS material handling and storage system include part transportation, raw material and final product transportation and storage of workpieces, empty pallets, auxiliary materials, wastes, fixtures and tools.  Functions of the material handling system  Types of FMS layout  Types of handling equipment used in FMS
  • 31. Functions of the material handling system  Material handling may be defined as the functions and systems associated with the transportation, storage, and physical control to work-in-process material in manufacturing.  The general purpose of material handling in a factory is to move raw materials, work-in-process, finished parts, tools, and supplies from one location to another to facilitate the overall operations of manufacturing.
  • 33. Types of FMS layout Configurations  In-line layout  Loop layout  Ladder layout  Open-field layout  Robot-centered cell
  • 34. In-line layout  As the name suggests, the materials and handling systems are arranged in a straight line in the in-line layout.
  • 36. Loop layout  In the loop layout, the workstations are arranged in a loop, as shown in figure.
  • 38. Ladder layout  The ladder layout, an adaptation of the loop layout, consists of a loop with rungs on which workstations are located.
  • 40. Open-field layout  The open field layout, also an adaptation of the loop configuration, consists of multiple loops, ladders and sliding organized to achieve the desired processing requirements.
  • 42. Robot-centered cell  In the robot-centered cell, one or more robots are used as the material handling system.
  • 44. Types of handling equipment used in FMS  Primary Handling System  Secondary Handling System
  • 45. Primary Handling System  The primary handling system establishes the basic layout of the FMS and is responsible for moving work parts between work stations in the system.
  • 47. Secondary Handling System  The secondary handling system consists of transfer devices, automatic pallet changers, and similar mechanisms located at the workstations in the FMS.  The functions of the secondary handling systems are: To transfer work parts from the primary system to the machine tool or other processing stations. To position the work parts with sufficient accuracy and repeatability at the workstation for processing. To provide buffer storage of work parts at each workstation.
  • 48. Types of Material Handling Equipment  The material handling equipment commonly used to move parts between stations can be grouped under six categories,  Conveyors  Cranes and hoists  Industrial trucks  Monorails and other rail guided vehicles  Automated guided vehicles (AGVs) and  Industrial robots.
  • 49. Computer control system  In flexible manufacturing systems, computers are required to control the automated and semi-automated equipment and to participate in the over all coordination and management of the manufacturing system.  A typical FMS computer control system consists of a central computer and micro computers controlling the individual machines and other components.
  • 50. Functions of a FMS computer control system  Workstation/processing station control  Distribution of control instructions to workstations  Production control  Material handling system control  Workpiece monitoring  Tool control  Quality control  Failure diagnosis  Safety monitoring  Performance monitoring and reporting
  • 51. Structure of FMS Application software systems
  • 52. Types of FMS Data Files  Part program file  Routing file  Part production file  Pallet reference file  Station tool file  Tool life file
  • 54. Human Resources  In FMS, human labours are needed to perform the following functions To load raw work parts into the system To unload finished work parts from the system For tool changing and tool setting For equipment maintenance and repair To program and operate the computer system To accomplish overall management of the system
  • 55. Example of Flexible Manufacturing System  FMS installed at Vought Aerospace in Dallas
  • 57. FMS Applications  Machining  Assembly  Sheet-metal press working  Forging  Plastic injection moulding  Welding  Textile machinery manufacture  Semiconductor component manufacture
  • 58. Economics of FMS  5-20% reduction in personnel  15-30% reduction in engineering design cost  30-60% reduction in overall lead time  30-60% reduction in work-in-process  40-70% gain in overall production  200-300% gain in capital equipment operating time  200-500% gain in product quality  300-500% gain in engineering productivity
  • 59. Advantages of FMS (Benefits of FMS)  Increased machine utilization  Reduced inventory  Reduced manufacturing lead time  Greater flexibility in production scheduling  Reduced direct labour cost  Increased labour productivity  Shorter response time  Consistent quality  Reduced factory floor space  Reduced number of tools and machines required  Improved product quality
  • 60. Disadvantages of FMS  Very high capital investment is required to implement a FMS  Acquiring, training and maintaining the knowledgeable labour pool requires heavy investment  Fixtures can sometimes cost much more with FMS, and software development costs could be as much as 12-20% of the total expense  Tool performance and condition monitoring can also be expensive since tool variety could undermine efficiency  Complex design estimating methodology requires optimizing the degree of flexibility and finding a trade off between flexibility and specialization
  • 61. FMS Planning and Control (FMS Planning and Implementation issues)  FMS planning and design issues  FMS control (or operational) issues
  • 62. FMS Planning issues  Part family considerations  Processing requirements  Physical characteristics of the work parts  Production volume
  • 63. FMS design issues  Type of work stations  Variations in process routings and FMS layout  Material handling system  Work-in-process and storage capacity  Tooling  Pallet fixtures
  • 64. FMS operational issues  Scheduling and dispatching  Machine loading  Part routing  Part grouping  Tool management  Pallet and fixture allocation
  • 65. Quantitative analysis of Flexible Manufacturing System  Flexible manufacturing system can be analysed using different models. The four different categories of FMS analysis models are: Deterministic models Queuing models Discrete event simulation Other techniques
  • 66. Bottleneck model  The bottleneck model is a simple and intuitive approach to determine the starting estimates of FMS design parameters such as production rate, capacity and utilization.
  • 75. Automated Guided Vehicle System (AGVS)  An Automated Guided Vehicle System (AGVS) is a computer controlled, driverless vehicle used for transporting materials from point to point in a manufacturing setting.  An AGVS uses independently operated, self-propelled vehicles that are guided along pre-defined paths, and are powered by means of on-board batteries.  The AGVs are highly flexible, intelligent, and versatile material handling systems used to transport materials from various loading locations to various unloading locations throughout the manufacturing facility.
  • 76. Strengths of AGVs  Space  Economical  Agile  Flexible  Dynamic  Redundancy
  • 77. Benefits of AGVs  Labour  Damage  Shipping accuracy  Energy  Safety
  • 79. Types of AGVs  Guided driverless trains  Guided pallet trucks  Guided unit load carriers
  • 80. Guided Driverless Trains  The Guided driverless trains, also known as towing vehicles or automated guided tractors, are most commonly used for transporting large amount of bulky and heavy materials from the warehouse to various locations in the manufacturing plant.
  • 81. Guided Pallet Trucks  The guided pallet trucks are designed to lift and transport palletized loads.  It is used for picking up or dropping off loads from and on to floor level. Thus it eliminates the need for fixed load stands.  There is no need for any special accessories for loading and unloading the guided pallet except that the loads should be on a pallet.  Usually the following sequence of operations are being carried out in pallet trucks Loads are pulled off onto a pallet forks Lowering of the pallet forks to the floor Pulling out from the pallet Finally automatically returns empty to the loading area.
  • 83. Guided unit load carriers  Guided unit load carries have a deck that permits unit-load transport operation.  They are used in settings with short/medium guide paths, high volume, and need for independent and versatility.  They are used in warehousing and distribution systems.  They can operate in an environment where there is not much room and movement is restricted.
  • 85. Applications of AGVS  Automated Guided Vehicles are used in a variety of areas to support processing and handling throughout a manufacturing facility. Assembly Kitting Transportation Staging Warehousing Order picking Parts/just-in-time delivery Transfer/shuttle
  • 86. Applications of AGVs based on types of AGVs employed  Driverless train operations  Storage and distribution operations  Assembly line applications  Flexible manufacturing systems.
  • 87. Vehicle Guidance Technology  The goal of an AGVS guidance system is to keep the AGV on track or on predefined path.  Types of AGV Guidance approach Fixed-route guidance method Free – route guidance method
  • 88. Fixed-route guidance method  Fixed route guidance is to set medium guidance information in the path, AGV can drive with it, such as electromagnetic guidance, tape guidance, etc.
  • 89. Free – route guidance method  Free-route guidance stores the size of the coordinates, AGV can identify current position and decide driving path, such as laser- guidance and image recognition guidance.
  • 90. Types of vehicle Guidance Technologies  There are many AGV guidance technologies/methods available and their selection will depend on need, application, and environmental constraints. Wire guidance system Paint strips system Self-guided vehicles
  • 93. Vehicle Management  Traffic control  Vehicle dispatching
  • 94. Traffic control  The purpose of traffic control in an automated guided vehicle system is to minimise interference between vehicles and prevent collisions.  Methods of traffic control Forward-sensing control Zone sensing control Combinational control
  • 97. Vehicle Dispatching  For an effective functioning of AGVS, AGVS must be dispatched in a timely manner, as and when they are needed.  Dispatching methods: Vehicle Dispatching using On-board control panels Vehicle Dispatching using Remote call stations Vehicle Dispatching using Supervisory central computer control Combinatorial method

04 material handling - part1 | PPT - SlideShare

  • 1. Arif Rahman – The Production Systems 1 Slide 4 Material Handling Arif Rahman, ST MT
  • 2. Arif Rahman – The Production Systems Material handling is 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) Material handling is the function of moving the right material to the right place in the right time, in the right amount, in sequence, and in the right condition to minimize production cost. Material Handling 2
  • 3. Arif Rahman – The Production Systems The art and science of moving, storing, protecting, and controlling material. Providing ¤ Right amount ¤ Right material ¤ Right condition ¤ Right place ¤ Right position ¤ Right sequence ¤ Right cost ¤ Right method Material Handling 3
  • 4. Arif Rahman – The Production Systems Material-handling system is an integrated system involving such activities as handling, storing and controlling material. ¤ Handling  transportation and movement system ¤ Storage  Storage system ¤ Controlling material  Automation identification & data capture Material Handling System 4
  • 5. Arif Rahman – The Production Systems To move raw material, working process, finish parts, tools and supplies from one location to another (to facilitate the over all operation of manufacturing) Consists of: Movement of materials from sources of supply, all intra-plant handling & distribution of finished goods customers. Material Handling Scope of Movement 5
  • 6. Arif Rahman – The Production Systems Concerned with the acquisition, movement, storage, and distribution of materials and products to satisfy customer demand Two categories of logistics: External logistics - transportation and related activities that occur outside of a facility (between different geographical locations). Five traditional modes of transportation: rail truck, air, ship, and pipeline Internal logistics - material handling and storage within a facility Material Handling and Logistics 6
  • 7. Arif Rahman – The Production Systems It consumes more time It needs extra cost It triggers some troublesome. The materials can be damaged since improper movement The materials can be lost in transit Material Handling Risks 7
  • 8. Arif Rahman – The Production Systems Handling of materials must be performed ¤ Safely and smoothly ¤ Efficiently and directly ¤ At low cost ¤ In a timely manner ¤ Accurately (the right materials in the right quantities to the right locations) ¤ And without damage to the materials Material Handling Consideration 8
  • 9. Arif Rahman – The Production Systems 1. Form of material at point of origin, e.g., liquid, granular, sheets, etc. 2. Characteristics of the material, e.g., fragile, radioactive, oily, etc. 3. Original position of the material, e.g., under the earth, in cartons, etc. 4. Flow demands, e.g., amount needed, continuous or intermittent, timing, etc. 5. Final position, where material is needed, e.g., distance, elevation differences, etc. Material Handling Factors 9
  • 10. Arif Rahman – The Production Systems 6. In-transit conditions, e.g., transocean, jungle, city traffic, inplant, etc., and any hazards, perils, special events or situations that could occur during transit 7. Handling equipment available, e.g., devices, prices, reliability, maintenance needs, etc. 8. Form and position needed at destination 9. Integration with other equipment and systems 10.Degree of control required Material Handling Factors 10
  • 11. Arif Rahman – The Production Systems Reduce Unit Material Handling Cost ¤ Eliminate Unnecessary Handling ¤ Handle Material in Batch Lots ¤ Minimize Required Handling Time ¤ Replace Handling Equipment as Appropriate Reduce Production Time ¤ Minimize Delays of Machine Operations ¤ Maintain Uniform, Appropriate Movement of Material ¤ Use Automatic Processing When Appropriate Material Handling Objectives 11
  • 12. Arif Rahman – The Production Systems Reduce Overhead ¤ Minimize Non-Productive Labour ¤ Prevent and Reduce Damage to Materials ¤ Coordinate All Material Handling Systems ¤ Maintain or Improve Product Quality ¤ Control Inventory Conserve Floor Space ¤ Avoid Excessive Stock Storage ¤ Move Materials in a Position to Save Space ¤ Use Equipment Requiring No Floor Space Material Handling Objectives 12
  • 13. Arif Rahman – The Production Systems Prevent Accidents ¤ Reduce Physical Load Required ¤ Insure Handling Equipment is Safe ¤ Promote safety and improve working conditions Improve Employee Morale ¤ Provide Proper Relationship Between Employee & Work Material Handling Objectives 13
  • 14. Arif Rahman – The Production Systems Promote Productivity ¤ Material Should Flow In A Straight Line ¤ Use Gravity! It Is Free Power ¤ Move More Material At One Time ¤ Mechanize Material Handling ¤ Automate Material Handling ¤ Promote Increased Use Of Facilities Material Handling Objectives 14
  • 15. Arif Rahman – The Production Systems Increase capacity Improve working conditions Improve customer services Increase equipment and space utility Reduce Costs Material Handling Benefits 15
  • 16. Arif Rahman – The Production Systems Overview of Material Handling Equipment 16
  • 17. Arif Rahman – The Production Systems Material transport equipment ¤ to move materials inside a factory, warehouse, or other facility ¤ industrial trucks, Automated Guided vehicles (AGVs), monorails (and other rail guided vehicles), conveyors, cranes and hoists Storage systems ¤ to store materials and provide access to those materials when required ¤ bulk storage, rack systems, shelving and bins, drawer storage, automated storage systems Material Handling Equipment 17
  • 18. Arif Rahman – The Production Systems Unitizing equipment ¤ refers to (1) containers to hold materials, and (2) equipment used to load and package the containers ¤ Pallets, boxes, baskets, barrels, pails, and drums; palletizers, depalletizers Identification and tracking systems ¤ to identify and keep track of the materials being moved and stored ¤ Bar codes, magnetic stripes, radio frequency tags Material Handling Equipment 18
  • 19. Arif Rahman – The Production Systems Considerations in Material Handling System Design 19
  • 20. Arif Rahman – The Production Systems Material characteristics Flow rate, routing, and scheduling Plant layout Unit load principle Factors that influence the design 20
  • 21. Arif Rahman – The Production Systems Category Measures Physical state Size Weight Shape Condition Risk of damage Safety risk Solid, liquid, or gas Volume; length, width, height Weight per piece, weight per unit volume Long and flat, bulky, round, square, etc. Hot, cold, wet, dirty, sticky Fragile, brittle, sturdy Explosive, flammable, toxic, corrosive, etc. Material Characteristics 21
  • 22. Arif Rahman – The Production Systems Flow rate  amount of material moved per unit time ¤ Examples: pieces/hr, pallet loads/hr, tons/hr ¤ Whether the material must be moved in individual units, as batches, or continuously (pipe line) Routing  pick-up and drop-off locations, move distances, routing variations, conditions along the route (surface, traffic, elevation) Scheduling  timing of each individual delivery ¤ Prompt delivery when required ¤ Use of buffer stocks to mitigate against late deliveries Flow Rate, Routing, and Scheduling 22
  • 23. Arif Rahman – The Production Systems Manualhandling Hand trucks Powered trucks Unit load AGV Conveyors Conveyors AGV trainHigh Low LongShort Move Distance Quantity of material moved Flow Rate, Routing, and Scheduling 23
  • 24. Arif Rahman – The Production Systems In the case of a new facility, the design of handling system should be considered as part of the layout design The layout should provide the following information for use in the design of the handling system: ¤ Locations where materials must be picked up (load stations) ¤ Locations where materials must be delivered (unload stations) ¤ Possible routes between these locations ¤ Distances that must be travelled to move materials ¤ Flow patterns, opportunities to combine deliveries, possible places where congestion might occur ¤ Total area of the facility and areas within specific departments in the layout ¤ Arrangement of equipment in the layout Plant Layout: Layout Type 24
  • 25. Arif Rahman – The Production Systems Layout Type Characteristics Typical MH Equipment Fixed – position Process Product Large product size, low production rate Variation in product and processing, low and medium production rates Limited product variety, high production rate Cranes, hoists, industrial trucks Hand trucks, forklift trucks, AGVs Conveyors for product flow, trucks to deliver components to stations. Plant Layout: Layout Type 25
  • 26. Arif Rahman – The Production Systems Fixed Path ¤ Equipment: Conveyors, Elevators, Lifts, Pipes/Tubes ¤ Advantages: • More economical if large volume of material moved to same place • One power supply to drive entire “belt” – more economical • Reduction in need for lot identification tags • Can be used to pace the workers ¤ Disadvantages: Less economical if material follows diverse paths Plant Layout: Path 26
  • 27. Arif Rahman – The Production Systems Limited Area (Semi-Fixed Path) ¤ Equipment: cranes, trucks ¤ Advantages: Can cover a wider area ¤ Disadvantages: Still limited to area covered Plant Layout: Path 27
  • 28. Arif Rahman – The Production Systems Wide Area (Variable Path) ¤ Equipment: • Manual: trucks 2-wheel, trucks 4-wheel, lift truck, dolly • Powered: power lift truck, forklift truck, multiple trailer, yard truck, over-the-road truck, rail, portable conveyor ¤ Advantages: flexible ¤ Disadvantages: must have portable power supply with each piece of equipment Plant Layout: Path 28
  • 29. Arif Rahman – The Production Systems In general, the unit load should be as large as practical for the material handling system that will move and store it ¤ A unit load is the mass that is to be moved or otherwise handled at one time Reasons for using unit loads in material handling: ¤ Multiple items handled simultaneously ¤ Required number of trips is reduced ¤ Loading/unloading times are reduced ¤ Product damage is decreased Unit Load Principle (unitizing) 29
  • 30. Arif Rahman – The Production Systems Wooden pallet Pallet box Tote box Unit Load Containers 30
  • 31. Arif Rahman – The Production Systems Unit Load Containers : Wooden Pallet 31 Single faced pallet Double faced pallet Double faced reversible pallet Two-way Entry pallet Four-way Entry pallet
  • 32. Arif Rahman – The Production Systems Unit Load Containers : Pallet Box 32 Pallet Crate Skid Box Pallet Box
  • 33. Arif Rahman – The Production Systems Unit Load Containers : Pallet Box 33
  • 34. Arif Rahman – The Production Systems Unit Load Containers : Box 34 Cartoon Box Tote Pan Tote Box Crate Bins
  • 35. Arif Rahman – The Production Systems Unit Load Containers : Others 35
  • 36. Arif Rahman – The Production Systems The 10 Principles of Material Handling 36
  • 37. Arif Rahman – The Production Systems 1. Planning Principle 2. Standardization Principle 3. Work Principle 4. Ergonomic Principle 5. Unit Load Principle 6. Space Utilization Principle 7. System Principle 8. Automation Principle 9. Environmental Principle 10.Life Cycle Cost Principle The 10 Principles of Material Handling 37
  • 38. Arif Rahman – The Production Systems All material handling should be the result of a deliberate plan where the needs, performance objectives and functional specification of the proposed methods are completely defined at the outset Definition: A plan is a prescribed course of action that is defined in advance of implementation. In its simplest form a material handing plan defines the material (what) and the moves (when and where); together they define the method (how and who). 1. Planning Principle 38
  • 39. Arif Rahman – The Production Systems The plan should be developed in consultation between the planner(s) and all who will use and benefit from the equipment to be employed. Success in planning large scale material handling projects generally requires a team approach involving suppliers, consultants when appropriate, and end user specialists from management, engineering, computer and information systems, finance and operations. The plan should promote concurrent engineering of product, process design, process layout, and material handling methods, as opposed to independent and sequential design practices. The material handling plan should reflect the strategic objectives of the organization as well as the more immediate needs. 1. Planning Principle : Key Points 39
  • 40. Arif Rahman – The Production Systems Material handling methods, equipment, controls and software should be standardized within the limits of achieving overall performance objectives and without sacrificing needed flexibility , modularity and throughput 2. Standardization Principle 40
  • 41. Arif Rahman – The Production Systems Standardization means less variety and customization in the methods and equipment employed Standardization applies to sizes of containers and other load forming components as well as operating procedures and equipment The planner should select methods and equipment that can perform a variety of tasks under a variety of operating conditions and in anticipation of changing future requirements Standardization, flexibility and modularity must not be incompatible 2. Standardization Principle : Key Points 41
  • 42. Arif Rahman – The Production Systems Material handling work should be minimized without sacrificing productivity or the level of service required of the operation 3. Work Principle 42
  • 43. Arif Rahman – The Production Systems The measure of material handling work is flow rate (volume, weight or count per unit of time) multiplied by the distance moved Consider each pickup and set-down, or placing material in and out of storage, as distinct moves and components of the distance moved Simplifying processes by reducing, combining, shortening or eliminating unnecessary moves will reduce work 3. Work Principle : Key Points 43
  • 44. Arif Rahman – The Production Systems Where possible, gravity should be used to move materials or to assist in their movement while respecting consideration of safety and the potential for product damage The work principle applies universally, from mechanized material handling in a factory to over- the-road trucking The work principle is implemented best by appropriate layout planning: locating the production equipment into a physical arrangement corresponding to the flow of work. This arrangement tends to minimize the distances that must be traveled by the materials being processed 3. Work Principle : Key Points 44
  • 45. Arif Rahman – The Production Systems Human capabilities and limitations must be recognized and respected in the design of material handling tasks and equipment to ensure safe and effective operations 4. Ergonomic Principle 45
  • 46. Arif Rahman – The Production Systems Ergonomics is the science that seeks to adapt work or working conditions to suit the abilities of the worker The material handling workplace and the equipment employed to assist in that work must be designed so they are safe for people The ergonomic principle embraces both physical and mental tasks Equipment should be selected that eliminates repetitive and strenuous manual labour and which effectively interacts with human operators and users 4. Ergonomic Principle : Key Points 46
  • 47. Arif Rahman – The Production Systems Unit loads shall be appropriately sized and configured in a way which achieves the material flow and inventory objectives at each stage in the supply chain 5. Unit Load Principle 47
  • 48. Arif Rahman – The Production Systems 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 Less effort and work is required to collect and move many individual items as a single load than to move many items one at a time Large unit loads are common both pre and post manufacturing in the form of raw materials and finished goods 5. Unit Load Principle : Key Points 48
  • 49. Arif Rahman – The Production Systems Load size and composition may change as material and product moves through stages of manufacturing and the resulting distribution channels. Smaller unit loads are consistent with manufacturing strategies that embrace operating objectives such as flexibility, continuous flow and just-in-time delivery. Smaller unit loads (as few as one item) yield less in-process inventory and shorter item throughput times. 5. Unit Load Principle : Key Points 49
  • 50. Arif Rahman – The Production Systems Effective and efficient use must be made of all available space 6. Space Utilization Principle 50
  • 51. Arif Rahman – The Production Systems Space in material handling is three dimensional and therefore is counted as cubic space In storage areas, the objective of maximizing storage density must be balanced against accessibility and selectivity. When transporting loads within a facility the use of overhead space should be considered as an option. Use of overhead material handling systems serves valuable floor space for productive purposes. 6. Space Utilization Principle : Key Points 51
  • 52. Arif Rahman – The Production Systems Material movement and storage activities should be fully integrated to form a coordinated, operational system which spans receiving, inspection, storage, production, assembly, packaging, unitizing, order selection, shipping, transportation and the handling of returns Definition: A system is a collection of interacting and/or interdependent entities that form a unified whole 7. System Principle 52
  • 53. Arif Rahman – The Production Systems Systems integration should encompass the entire supply chain including reverse logistics. It should include suppliers, manufacturers, distributors and customers. Inventory levels should be minimized at all stages of production and distribution while respecting considerations of process variability and customer service. Information flow and physical material flow should be integrated and treated as concurrent activities. Methods should be provided for easily identifying materials and products, for determining their location and status within facilities and within the supply chain and for controlling their movement. 7. System Principle : Key Points 53
  • 54. Arif Rahman – The Production Systems Material handling operations should be mechanized and/or automated where feasible to improve operational efficiency, increase responsiveness, improve consistency and predictability, decrease operating costs and to eliminate repetitive or potentially unsafe manual labor Definition: Automation is a technology concerned with the application of electro-mechanical 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 8. Automation Principle 54
  • 55. Arif Rahman – The Production Systems In any project in which automation is being considered, pre-existing processes and methods should be simplified and/or re-engineered before any efforts at installing mechanized or automated systems. Such analysis may lead to elimination of unnecessary steps in the method. If the method can be sufficiently simplified, it may not be necessary to automate the process. Items that are expected to be handled automatically must have standard shapes and/or features that permit mechanized and/or automated handling. 8. Automation Principle : Key Points 55
  • 56. Arif Rahman – The Production Systems Interface issues are critical to successful automation, including equipment to equipment, equipment to load, equipment to operator, and in-control communications. Computerized material handling systems should be considered where appropriate for effective integration of material flow and information management. 8. Automation Principle : Key Points 56
  • 57. Arif Rahman – The Production Systems Environmental impact and energy consumption should be considered as criteria when designing or selecting alternative equipment and material handling systems 9. Environmental Principle 57
  • 58. Arif Rahman – The Production Systems 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 Containers, pallets and other products used to form and protect unit loads should be designed for reusability when possible and/or biodegradability after disposal Materials specified as hazardous have special needs with regard to spill protection, combustibility and other risks. 9. Environmental Principle : Key Points 58
  • 59. Arif Rahman – The Production Systems A thorough economic analysis should account for the entire life cycle of all material handling equipment and resulting systems 10. Life Cycle Cost Principle 59
  • 60. Arif Rahman – The Production Systems Life cycle costs include all cash flows that will occur between 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. Life cycle costs include capital investment, installation, setup and equipment programming, training, system testing and acceptance, operating (labor, utilities, etc.), maintenance and repair, reuse value, and ultimate disposal. 10. Life Cycle Cost Principle : Key Points 60
  • 61. Arif Rahman – The Production Systems A plan for preventive and predictive maintenance should be prepared for the equipment, and the estimated cost of maintenance and spare parts should be included in the economic analysis. A long-range plan for replacement of the equipment when it becomes obsolete should be prepared. Although measurable cost is a primary factor, it is certainly not the only factor in selecting among alternatives. Other factors of a strategic nature to the organization and which form the basis for competition in the market place should be considered and quantified whenever possible. 10. Life Cycle Cost Principle : Key Points 61
  • 62. Arif Rahman – The Production Systems Safer Operating Conditions Lower Costs Better utilization and performance of material handling systems The Principles Benefits 62
  • 63. Arif Rahman – The Production Systems One of the most important of the principles is the unit load principle In general, the unit load should be as large as practical for the material handling system that will move and store it ¤ A unit load is the mass that is to be moved or otherwise handled at one time Reasons for using unit loads in material handling: ¤ Multiple items handled simultaneously ¤ Required number of trips is reduced ¤ Loading/unloading times are reduced ¤ Product damage is decreased The Principles Most Importances 63
  • 64. Arif Rahman – The Production Systems Included in the definition of unit load is the container that holds or supports the materials to be moved These containers are standardized in size and configuration to be compatible with the material handling system Pallets are probably the most widely used, owing to their versatility, low cost, and compatibility with various types of material handling equipment The Principles Most Importances 64
  • 65. Arif Rahman – The Production Systems Depth = x Dimension Width = y Dimension 800 mm (32 in) mm (40 in) 900 mm (36 in) mm (48 in) mm (40 in) mm (48 in) mm (42 in) mm (42 in) mm (48 in) mm (48 in) The Principles Most Importances 65 Standard Pallet Sizes Commonly Used in Factories and Warehouses

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