Advance

Manufacturing
Systems
Introduction; MATERIAL HANDLING;
WAREHOUSING; AUTOMATED STORAGE
AND RETREIVAL SYSTEM (ASRS)
Lecture. 02
Engr. Muhammad Noman
Lecturer
Industrial Engineering Department, UET,
Taxila
Introduction

Dimensions of Material
Basic Definition Handling:-
The movement, storage,
protection and control of 1: Movement.
materials throughout the 2: Quantity.
manufacturing and
distribution process including 3: Time.
their consumption and 4: Space.
disposal.
5: Control.
Consideration in Material Handling System
Design

Design of the system depends on the materials to be handled,

quantities and distances to be moved, type of production facility
served by the handling system and the available budget.

The factors which influence the design of the material handling system:

1: Material Characteristics.

2:Flow Rate, Routing and Scheduling.

3: Plant Layout.
1: Material Characteristics

Category Measures or description

Physical Solid, liquid or gas

state
size Volume, length, width, height
For handling purposes, materials can
be classified by the physical weight Wt per piece, per unit volume
characteristics presented in the
table: shape Long, flat, round, square

condition Hot, cold, wet, dirty, sticky

Risk of Fragile, brittle, sturdy

damage
Safety risk Explosive, flammable, toxic,
corrosive
2: Flow Rate, Routing and Scheduling

A: Flow Rate: B: Routing:

The amount or quantity of material to be It includes:
moved affects the type of handling 1: pickup and drop-off locations.
system that should be installed.
2: move distances.
The amount of material moved must be
considered in the context of time, 3: routing variations.
that is how much material is moved 4: conditions that exist along the routes.
within a given time period. We refer
to the amount of material moved per Handling cost directly relate to the
unit time as the Flow Rate. distance moved.

Flow rate is measured in pieces/hr, pallet Routing variations occur because

loads/hr, tons/hr. different materials follow different
flow patterns in the factory or
Quantities of warehouse.
Material moved
Conveyors
conveyors AGV trains
High

Low Manual handling Powered trucks

Hand trucks Unit load AGV
Short Long Move distance
2: Flow Rate, Routing and
Scheduling

Conditions along the route C: Scheduling:

includes
It relates to the timing of each
a) Floor surface condition. individual delivery. The
b) Traffic congestion. handling system must be
responsive to this need for
c) Whether a portion of the timely pickup and delivery
move is outdoor of the items.
d) Whether the path is st.
line or involves turns.
e) Presence or absence of
people along the path.
 3: Plant Layout
Plant layout is an important factor in the design of a material handling system. In the case
of a new facility, the design of the handling system should be considered part of
the layout design.

The plant layout design should provide the following data for use in the design of the
handling system:

a) Total area of the facility and areas within specific departments in the plant.
b) Arrangement of equipment in the layout.
c) Locations where materials must be picked up and delivered.
d) Possible routes between these locations.
e) Distance traveled.
Overview of Material Handling
Equipment

A great variety of material handling equipment is available

commercially. Material handling equipment includes:

1: transport equipment.

2: storage equipment.

3: unitizing equipment.

4: identification and tracking system.

1: Material Transport Equipment

Material transport include equipment that is used to move materials

inside a factory, warehouse or other facility. This equipment is
divided into the following five categories:

A: Industrial trucks.

B: Automated guided vehicles (AGV’s).

C: Monorails and other rail guided vehicles.

D: Conveyors.

E: Cranes and hoists.

 1: Material Transport Equipment
A: Industrial Trucks

Non- Powered Trucks / Hand

Trucks: these are the platforms
or containers with wheel that are
pulled by human workers to move
materials. Hand trucks are
classified as:
a) two-wheel, they are easy to
manipulate by the worker but
limited to lighter loads.

b) Multiple wheel, these trucks are STEEL HANDTRUCK

available in several types and sizes. PALLET TRUCK
i. Dollies are simple frames or
platforms.
ii. Pallets trucks have fork that can
be inserted through the openings in
a pallet.

STEEL PLATFORM DOLLY

 1: Material Transport Equipment

A: Industrial Trucks
Powered Trucks: are self
propelled to relieve the
worker of manually having to
move the truck. Three
common types are used in
factories:
a) Walkie trucks are battery
powered vehicle equipped
with wheeled forks for
insertion into the pallet
openings but with no
provision for a worker to ride
on the vehicle.
b) Forklift rider trucks have a FORK LIFT
cab for the worker to sit in
and drive the vehicle. Load
carrying capacity ranges from
450kg up to more than
4500kg.
c) Industrial towing trucks are
designed to pull one or more
trailing carts over the
relatively smooth surface
found in factories and
warehouse.

TOW TRUCK
 1: Material Transport Equipment

B: Automated Guided Vehicle Systems

AGVS is a material handling system

that uses independently
c) AGV unit load carriers are
used to move unit loads from
operated, self-propelled one station to another. They
vehicles guided along defined are often equipped for
pathways. The vehicles are automatic loading and
powered by on board unloading of pallets or tote
batteries that allow many pans by means of powered
hours of operation between rollers, moving belts,
recharging. They can be divided
into following three categories: mechanized lift platforms or
other devices built into the
a) Driverless train consists of a vehicle deck.
towing vehicle that pulls one or
more trailers to form a train.
b) Automated guided pallet trucks
are used to move palletized loads
along predetermined routes. The
capacity ranges up to several
thousand kg, and dome trucks are
capable of handling two pallets
rather than one.
B: Automated Guided Vehicle Systems

DRIVERLESS FORK
LIFTER

AGV

AGV PALLET TRUCK AGV UNIT LOAD CARRIER

 1: Material Transport Equipment

C: Monorails and other rail guided vehicles

 These are self-propelled vehicles that ride on a fixed rail

system that is either on the floor or suspended from ceiling.

 The vehicles operate independently and are usually driven by

electric motors that pick up power from an electrified rail.

 Routing variations are possible in rail guided vehicle systems

through use of switches, turntables and other specialized track
sections.

 This system is more versatile then the conveyor system but less
than AGVS.
 1: Material Transport Equipment

E: Cranes and Hoists

Cranes are used for horizontal movement i. Double gantry crane has two
of materials in a facility, and hoist legs.
are used for vertical lifting.
ii. Half gantry crane has a single
The load carrying capacity ranges over leg on one end of the bridge.
100 tons. Principal types of cranes
found in factories include: iii. Cantilever gantry crane has
bridge extended beyond the span
a. Bridge cranes consists of one or created by the support legs.
two horizontal girders or beam
suspended between fixed rails on
either end which are connected to
the structure of the building . The c. Jib crane consists of a hoist supported
load carrying capacity ranges over on a horizontal beam that is
90,000kg. cantilevered from a vertical
column or wall support. The load
b. Gantry crane distinguished from carrying capacity range up to
a bridge crane by the presence of about 5000kg.
one or two vertical legs that
support the horizontal bridge. The
load carrying capacity is about
136,000kg. Gantry crane have
further two types:
2: Storage System

The function of the material storage system is to store materials

for a period of time and to permit access to those materials
when required.
 Storage System Performance
1: Storage capacity: which can be
measured in two ways:
a: as the total volumetric space
available.
b: as the total number of storage
compartments in the system
available for items or loads.
2: Storage density: is defined as
volumetric space available for
actual storage relative to the total
volumetric space in the storage
facility.
3: System through put:
is defined as the hourly rate at which
the storage system;
a: receives and put load in the storage
system.
b: retrieves and delivers load to the
output station.
4: Utilization: is defined as the
proportion of time that the system is
actually being used for performing
storage and retrieval operation
compared with the time it is
available.
5: Availability: is a measure of system
reliability, defined as the proportion
of time the system is capable of
operating compared with the
normally scheduled shift hours.
Conventional storage methods and
equipment

A: Bulk Storage: B: Rack Systems:

It refers to the storage of Provides a method of stacking
stock in an open floor
area. The stock is
generally contained in
unit loads on pallets or
similar containers, and i.
unit loads are stacked ii.
on top of each other to
iii.
increase storage density.
iv.
v.
unit loads vertically
without the need for the
loads themselves to
provide support.
Pallet rack:
Cantilever racks:
Portable racks:
Drive though racks:
Flow through racks
 Conventional storage methods and
equipment
C: Shelving and Bins:
A shelf is a horizontal platform
supported by a wall or frame on
which materials are stored.
Conventional storage methods and equipment

D: Drawer Storage:
Storage drawer can alleviate the problem
of finding the things on the shelf
because each drawer pulls out to
allow its entire contents to be readily
seen.
Conventional storage methods and
equipment

E: Automated Storage
System:
This system is available to reduce
or eliminate the human
intervention required to
operate the system. the level
of automation varies:
 Less automated
 Highly automated

Automated storage system can be

divided into two basic types:
i. Automated storage and
retrieval systems
ii. Carousel storage system
 Conventional storage methods and equipment

Automated storage/retrieval
system:

It performs storage and retrieval

operations with speed and accuracy
under a defined degree of
automation.
 Conventional storage methods and equipment

Carousel Storage System:

This system consist of a series of bins or
baskets suspended from an
overhead chain conveyor that
revolves around a long oval rail
system.
They can be classified as:
i. Horizontal
ii. Vertical carousel.
Application Characteristics of the types
of storage equipment and methods

Storage Equipment Advantage and disadvantages Typical application

Bulk Storage Highest density is possible storage of large

Low accessibility stock or unit load.

Lowest possible cost

Rack Systems Low cost Palletized loads in

Good storage density warehouse.

Good accessibility

Shelves and bins Some stock items not storage of individual

clearly visible items on shelves.

Drawer Storage contents of drawer visible Small tools

Good accessibility small stock items

relatively high cost repair parts

Automated Storage high throughput rate work in process storage

System inventory control system order picking

highest cost equipment final product warehousing

 3: Unitizing equipment.

1: containers to hold individual

items during handling.
2: equipment used to load and
package the containers.
This equipment is important for
moving material as a unit
load.

Loading and packaging

equipment includes
palletizers, to load the
cartons on pallets,
depalletizers are used to
unload cartons from pallets.
Conventional Automatic
Palletizer

Robotic Palletizer

Turntable Stretch wrapper

4: Identification and tracking system.

Why it is important: Automatic Identification

Material handling must include and Data Capture
a mean of keeping track of (AIDC):
the materials being moved
This refers to the technologies
or stored. This is done by
that provide direct entry of
labeling the items, cartons
data into a computer or
or unit load.
other microprocessor
controlled system without
using keyboard.
Overview of Automatic Identification Methods

1: Encoded data
A code is a set of symbols or signals
representing alphanumeric
characters.

2: Machine reader or scanner

This device reads the encoded data
converting them to alternative form
usually an electrical analog signal.

3: Decoder
This component transforms the electrical
signals into digital data and finally
back into the original alphanumeric
characters.
Bar code technology

1: Linear (one 1:Linear (one-

dimensional) bar dimensional bar
codes: codes)
Data is read using a linear A: width modulated
sweep of scanner.
In which symbols consist of
bars and spaces of varying
width.
2: Two dimensional bar
B: height modulated:
codes;
Symbols have evenly spaced
In which encoded data can be
bars of varying heights.
read in both directions.
1:Linear (one-dimensional bar codes)

Bar code readers:

A: Scanner
It emits a beam of light that is swept past
the bar code and senses light
reflections to distinguish between the
bars and spaces.

B: Photo detector
The light reflection is sensed by it.

C: Decoder
Analyzes the pulse train to validate and
interpret the corresponding data.
2: Two-dimensional Bar Codes
A: Stacked Bar Codes
It can contain significantly
greater amount of data. It
consist of multiple rows of
conventional linear bar
codes stacked on top of
each other.
B: Matrix Symbologies:
It consists of 2-D patterns of
data cells that are usually
square and are colored dark
or white.
Bar code readers
1: Contact Bar Codes
Readers
A: Hand held wands
They are operated by moving the
tip of wand quickly past the
bar code on the object or
document.
B: Portable unit
They can be easily carried around
the factory or warehouse by
the worker. they are battery
powered and includes a solid
state memory device.
2: Non Contact Bar Code
Readers
A: Fixed beam
They uses a fixed beam of light
and are usually mounted
beside a conveyor.
B: Moving beam
It uses a highly focused beam of
light; actuated by a rotating
mirror to traverse an angular
sweep in search of the bar
code on the object. Lasers
are used to achieve the
highly focused light beam.
Bar code readers
Bar code readers
Manufacturing Facility Design Procedure
The quality of our manufacturing facilities design will depend on how well we collect and
analyzed the basic data. We must resist jumping into the layout before collecting and
analyzing the basic data. The following is a systematic way of thinking about the project:

1: Determine What will be produced, for 8: determine the number of machines

example, a toolbox or swing set or lawn
mower.
2: determine How many will be made per
unit of time, for example, 1500 per 8-
hour shift.
needed.
9: balance assembly line or work cells.
10: study the material flow patterns to
establish the best flow possible.

3: Determine what parts will be made or

purchased complete.
4: determine how each part will be
fabricated.
5: determine the sequence of assembly.
6: Set time standards for each operations.
7: Determine the plant rate (TAKT TIME).
This is how fast the facility needs to
produce.
Manufacturing Facility Design
Procedure

11: determine activity relationship. 24: adjust as needed and finalize project
report and budget performance.
12: layout each workstation.
13: identify needs for personal and plant
services, and provide the space
needed.
14: identify office needs and layout
needs.
15: develop total space requirements
from the above information.
16: select materials handling equipment.
17: allocate area according to space
needed and activity relationship
established in item 11 above.
18: develop a plot plan and building
shape.
19: construct a master plan.
20: seek input and adjust.
21: seek approval.
22: install the layout.
23: start production.
 The Cost Reduction Formula

ASK For So We
 New manufacturing plant construction
is one of the largest expenses that a Every Can
company will ever undertake and Why Operation Eliminate
layout of that plant will affect the
people for years to come.
Who Transportat Combine
ion
 The cost of the product will be
What Inspection Change
affected by the initial layout as well.
The Cost reduction formula is sequence
valuable when working with Where Storage Simplify
manufacturing facilities design and
material handling. The cost reduction
formula is a word formula that looks When Delay
like:
How
The 5S’s and 5Why’s Principles
The five (5)S’s and (5)Why’s are also cost reduction attitudes that will help
to reduce costs.

5S’s Principles are:

1: Sifting (organization). Keeping the 4: Spick and Span (hygiene). A safe
minimum of what is required will save plant is a result of good layout
space, inventory and money. planning.

2: Sorting (arrangement). Everything has 5: Strict (discipline). Following the

a specific place, and everything in its procedures and standardized methods
place is a visual management and making them a habit will keep
philosophy that affects the facility the plant operating efficiently and
layout. safely.

3: Sweeping (cleaning). A clean plant is a

result of a facility layout that has
been thought to provide room for
everything.
The 5Why’s is a way of thinking that will ensure that the solution
to a problem is not a symptom of the problem, but rather, the
base cause. For example: we had a machine break down. Why?

1: the machine jammed up. Why?

2: the machine was not cleaned. Why?

3: the operator didn’t clean it out at regular intervals. Why?

4: lack of training? Why?

5: the supervisor forgot. They make a written instruction to be

mounted on the machine. It will not happen again.