Materials Handling Handout

Material Handling (MH)
Classical Definition (Material Handling Industry of America):

The movement, storage and protection of materials
throughout the manufacturing and the distribution
process including their consumption and disposal.
The cost of material handling in the USA is around 20 25% of the

total manufacturing labour cost.
Facilities Planning
Dr. A. K. Sharma, IIT Roorkee

Objectives : To perform handling of material
Safely,
Efficiently
Timely
Accurately
At low cost and
Without damage to the materials.
Facilities Planning
Facilities Planning
Material Handling Equipment
Material Handling Equipment
Material
Handling
Equipment
Storage
Equipment
Industrial
Trucks
AGVs
Transport
Equipment
Utilizing
Equipment
Identification
& Testing
Equipment
Monorail &
Other RGVs
Conveyors
Cranes and
Hoists
Facilities Planning
Considerations in Material Handling System Design

1. Material Characteristics

Material Characteristics :
2. Flow Rate, Routing and Scheduling
Category
3. Plant Layout
Facilities Planning
Facilities Planning
Measures or Descriptors
Physical state
Solid, liquid or gas
Size
Vol., length, width, and height
Weight
Wt/piece, wt/vol
Shape
Long and flat, round, square
Condition
Hot, cold, wet, dirty, sticky
Risk of damage
Fragile, brittle, sturdy
Safety risk
Toxic, Corrosive Explosive, flammable etc.
Facilities Planning

Flow Rate, Routing and Scheduling :

Flow Rate, Routing and Scheduling :
For determining the type of appropriate MH equipment, the

following factors are considered :
1. Quantities and flow rate of the materials to be moved
2. Routing factors
Quantities of
material
moved
High
3. Scheduling of the moves
Low
Conveyors
Manual handling,
hand trucks
Short
Facilities Planning
Different Material Transport Systems :

1. Industrial Trucks
Cranes, hoists, industrial

trucks
2. AGVS
Process
Variations in product and

processing, low and
medium production rate
Hand trucks, forklift

trucks,, AGVs
Product
Limited product variety,

high production rate
Conveyors for product

flow, trucks to deliver
components to stations.
Facilities Planning
Move distance
Material Transport Systems
Typical MH Equipment
Characteristics
Long
Fixed position Large product size, low

production rate
Layout Type
Powered trucks,
Unit load AGVs
Facilities Planning

Plant Layout :
Conveyors & AGVs
3. RGVs
4. Conveyor Systems
5. Cranes and Hoists
Facilities Planning

Different Material Transport Systems :

Industrial Trucks :
Non-powered trucks: (a) Two-wheel hand truck, (b) fourwheel dolly, and (c) hand operated low-lift pallet truck.
Facilities Planning
Facilities Planning

Industrial Trucks :

AGVs :
Powered trucks: (a) Walkie truck, (b)

fork lift truck, and (c) towing tractor.
Facilities Planning
AGVs: (a) automated guided trains, (b) AGV pallet truck, and (c) unit load carrier.
Facilities Planning

AGVs : Vehicle Guidance Technology

Monorails and Rail Guided Vehicles (RGVs):
1. Imbedded Guide Wire
Motorised Vehicles
2. Paint Strips
Guided by fixed rail system
3. SGVs
Routing variations are possible through switches, turntables.
Facilities Planning
Facilities Planning

Conveyor Systems:
Facilities Planning

Conveyor Systems:
Facilities Planning

Conveyor Systems:

Conveyor Systems:
1. Single direction,
2. Continuous loop, and
3. Recirculating.
Facilities Planning
Facilities Planning

Cranes and Hoists:
Facilities Planning

Cranes and Hoists:
Facilities Planning
Analysis of Material Transport Systems:
Analysis of Material Transport Systems:
Charting Technique
Charting Technique
Flow diagram showing material deliveries between load/unload stations

Facilities Planning
Facilities Planning
Analysis of Vehicle-Based Systems:
Equipment used in such systems include
ASSUMPTIONS
1. Industrial Trucks (both manual and powered),

2. AGVS
1. The vehicle operates at a constant velocity throughout its

operation,
2. Ignores effects of acceleration, deceleration and other speed
differences that might depend on whether the vehicle is
traveling loaded or empty, or other reasons.
3. RGVs and other Guided vehicles,

4. Certain types of Conveyor systems, and
5. Certain Crane Operations.
Facilities Planning
Facilities Planning


The time for a typical delivery cycle in the operation of a

vehicle-based transport system consists of
1. Loading at the pickup station,
Thus, the total cycle per delivery per vehicle is
Tc = TL + Ld / vc + TU + Le / ve
where,
2. Travel time to the drop-off station,,
Tc = delivery cycle time (min/del),
3. Unloading at the drop-off station,

4. Empty travel time of the vehicle between deliveries.
TL = time to load at load station (min),

Td = distance the vehicle travels between load and unload station
(m),
vc = ve = carrier velocity (m/min),
TU = Unloading time (min),
Le = distance the vehicle travels empty untill the start of the next
delivery cycle (m).
Facilities Planning
Facilities Planning


The Possible time losses include

1. Availability (A) : It is a reliability factor defined as the
proportion of total shift time that the vehicle is operational
and NOT broken down or being repaired.,
2. Traffic congestion, and
3. Efficiency of manual drivers in case of manually operated
systems.
Thus, the Available Time (AT) of 60 minutes per hour per vehicle
is adjusted as
AT = 60 A Tf E
where,
AT = available time (per hour/vehicle)
A = Availability,
Tf = Traffic Factor, and
E = workers efficiency.
NOTE: Parameters A, Tf and E do not take into account poor
vehicle routing, poor guide path, or poor vehicle management
system.
Facilities Planning
Facilities Planning


The TWO performance parameters are defines as
2. Number of Vehicles Required (nc) :
1. Rate of Deliveries per Vehicle:
nc = WL / AT
where,
AT = available time (min per hour/vehicle)
Rdv = AT / Tc
where,
WL= Work load (min / hour).
Rdv = hourly delivery rate per vehicle (del./ hour per vehicle)
where,
WL = Rf Tc
AT = Available time (min/hour), and
Rf = Flow rate of total deliveries per hour for the system (del / hr), or
delivery requirements in the system.
Thus,
Tc = Delivery / Total cycle time (min / del.).
nc = Rf / Rdv
Facilities Planning
Facilities Planning

Conveyor Analysis : Single Direction Conveyors
Let us consider a single direction conveyor as in Fig.1.

1. The flow rate of materials on the conveyor is determined by
the rate of loading at the load station.
2. The loading rate is limited by the reciprocal of the time
required to load the materials.
Assuming that the conveyor operates at a constant speed,

the time required to move materials from load station to
unload station is given by
3. For a given conveyor speed, the loading rate establishes the

spacing of materials on the conveyor. Thus,
Rf = RL = ( vc / sc ) (1 / TL)
Td = Ld / vc
where,
Td = delivery time (min),
Ld = length of conveyor between load and unload stations (m),
vc = conveyor velocity, (m/min).
Facilities Planning
where,
sc = centre-to-centre spacing of materials on the conveyor (m/part)
TL = loading time (min/part), restricted by ergonomic constraints.
Facilities Planning

4. An additional requirement for loading and unloading is that
the ti me required to unload the conveyor must be equal to
less than the loading time. Thus,
TU T L
Conveyor Analysis : Continuous Loop Conveyors

1. The total length of the conveyor is
L = Ld + Le
where,
5. The relationships apply to other unit loads as well.

Accordingly, the flow rate can be written as
Rf = RL = ( np . vc / sc ) (1 / TL)
where,
np = number of parts per carrier.
Facilities Planning

np = number of parts per carrier.
2. The total time required to travel the complete loop is given by

Tc = L / vc
where,
Tc = Total cycle time (min)
vc = speed of the conveyor (m/min).
Facilities Planning

3. The time a load spends in the forward loop is
Td = Ld / vc
where,
Td = delivery time on the forward loop (min)

5. Each carrier is capable of holding np parts on the delivery loop,
and it holds no parts on the return trip. Since only the carriers
on the forward loop contain parts, the maximum number of
parts in the system at any one time is
Total parts in the system = np. nc . Ld / L
4. The carriers are equally spaced along the chain at a distance

sc apart. Thus, the total number of carriers in the loop is given
by
nc = L / sc
Facilities Planning
4. The maximum flow rate between the load and unload station is
Rf = np . vc / sc
where,
Rf = parts per minute.
Facilities Planning
10
Conveyor Analysis : Recirculating Conveyors
Kwo Analysis :
Kwo Analysis :
According to Kwo, there are three basic principles that must be

obeyed in designing such a conveyor system:
2. Capacity Constraint :
1. Speed Rule:
(np . vc / sc) Max { RL, RU }
(np . vc / sc) Rf
where,
RL and RU are the required loading and unloading rates (parts / min)
Facilities Planning
where,
Rf must be interpreted as a system specification required of the
recirculating conveyor.
Facilities Planning

Kwo Analysis :
3. Uniformity Principle :
Facilities Planning
11

Materials Handling Handout

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Material Handling (MH)

Material Handling (MH)

Classical Definition (Material Handling Industry of America):

The cost of material handling in the USA is around 20 25% of the

Material Handling (MH)

Dr. A. K. Sharma, IIT Roorkee

Material Handling (MH)

Dr. A. K. Sharma, IIT Roorkee

Dr. A. K. Sharma, IIT Roorkee

Material Handling Equipment

Material Handling Equipment

Dr. A. K. Sharma, IIT Roorkee

Considerations in Material Handling System Design

Dr. A. K. Sharma, IIT Roorkee

Considerations in Material Handling System Design

2. Flow Rate, Routing and Scheduling

Dr. A. K. Sharma, IIT Roorkee

Solid, liquid or gas

Vol., length, width, and height

Long and flat, round, square

Hot, cold, wet, dirty, sticky

Fragile, brittle, sturdy

Toxic, Corrosive Explosive, flammable etc.

Dr. A. K. Sharma, IIT Roorkee

Considerations in Material Handling System Design

Considerations in Material Handling System Design

For determining the type of appropriate MH equipment, the

3. Scheduling of the moves

Dr. A. K. Sharma, IIT Roorkee

Different Material Transport Systems :

Cranes, hoists, industrial

Variations in product and

Hand trucks, forklift

Limited product variety,

Conveyors for product

Material Transport Systems

Dr. A. K. Sharma, IIT Roorkee

Fixed position Large product size, low

Considerations in Material Handling System Design

Conveyors & AGVs

Dr. A. K. Sharma, IIT Roorkee

Dr. A. K. Sharma, IIT Roorkee

Material Transport Systems

Material Transport Systems

Dr. A. K. Sharma, IIT Roorkee

Material Transport Systems

Material Transport Systems

Powered trucks: (a) Walkie truck, (b)

Dr. A. K. Sharma, IIT Roorkee

Dr. A. K. Sharma, IIT Roorkee

Dr. A. K. Sharma, IIT Roorkee

Material Transport Systems

Material Transport Systems

1. Imbedded Guide Wire

Guided by fixed rail system

Routing variations are possible through switches, turntables.

Dr. A. K. Sharma, IIT Roorkee

Material Transport Systems

Dr. A. K. Sharma, IIT Roorkee

Material Transport Systems

Dr. A. K. Sharma, IIT Roorkee

Dr. A. K. Sharma, IIT Roorkee

Material Transport Systems

Material Transport Systems