MATERIAL HANDLING AND AUTOMATED STORAGE

SYSTEM
Kuliah Minggu-9

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 What is it?
 Material handling is defined by the Material Handling Industry of America1 as
“the movement, protection, storage and control of materials and products
throughout the process of manufacture and distribution, consumption and
disposal” .
 The handling of materials must be performed safely, efficiently, 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 is an
important yet often overlooked issue in production.
 The cost of material handling is a significant portion of total production cost,
estimates averaging around 20–25% of total manufacturing labor cost in the
United States [3]. This proportion varies, depending on type of production and
degree of automation in material handling.

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MATERIAL HANDLING

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 Categorization
The coverage is divided into three major categories:
1. material transport systems,
2. storage systems, and
3. automatic identification and data capture.
In addition, there are several material handling devices, including:
 industrial robots ,
 pallet shuttles in NC machining centers ,
 conveyors in manual assembly lines,
 transfer mechanisms in automated transfer lines, and
 parts feeding devices in automated assembly .
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 LOAD CONTAINER

wooden pallet, pallet box tote box

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 Features and Applications of Five Categories of Material
Handling Equipment

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 Nonpowered Industrial Truck

Two wheel hand truck Four wheel dolly Hand-operated low-lift pallet truck.

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 POWERED TRUCKS

Three principal types

of powered trucks:
(a) walkie truck,
(b) forklift truck, and
(c) towing tractor.

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 AUTOMATED GUIDED VEHICLE (AGV)

(a) driverless automated guided train,

(b) AGV pallet truck, and
(c) unit load carrier.

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 AGV – HOW IT WORKS

Operation of the
on-board sensor
system that uses
two coils to track
the magnetic field
in the guide wire.

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 VEHICLE MANAGEMENT

For the AGVS to operate efficiently, the vehicles must be well managed. Delivery tasks must be
allocated to vehicles to minimize waiting times at load/unload stations. Traffic congestion in the
guide-path network must be minimized.
Two aspects of vehicle management are considered here:
(1) traffic control: to minimize interference between vehicles and to prevent collisions:
• on-board vehicle sensing and
• zone control
(2) vehicle dispatching: vehicles must be dispatched in a timely and efficient manner to the
points in the system where they are needed
• on-board control panels,
• remote call stations, and
• central computer control

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 AGV ANALYSIS

The total cycle time per delivery per vehicle is given by :

Tc = TL + Ld/vc + Tu + Le/vc

Where: Tc = delivery cycle time, min/del; TL = time to load at load station, min; Ld = distance the vehicle travels
between load and unload station, m (ft); vc = carrier velocity, m/min (ft/min); TU = time to unload at unload
station, min; and Le = distance the vehicle travels empty until the start of the next delivery cycle, m (ft).

EXAMPLE - Determining Number of Vehicles in an AGVS

Consider the AGVS layout in Figure below. Vehicles travel counterclockwise around the loop to deliver loads from the
load station to the unload station. Loading time at the load station = 0.75 min, and unloading time at the unload
station = 0.50 min. The following performance parameters are given: vehicle speed = 50 m>min, availability = 0.95,
and traffic factor = 0.90. Operator efficiency does not apply, so Ew = 1.0. Determine (a) travel distances loaded and
empty, (b) ideal delivery cycle time, and (c) number of vehicles required to satisfy the delivery demand if a total of
40 deliveries per hour must be completed by the AGVS.

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 SOLUTION

Unld (a) Ignoring effects of slightly shorter distances around the

Man
AGV Guide Path curves at corners of the loop, the values of Ld and Le are
readily determined from the layout to be 110 m and 80
m, respectively.
20 m (b) Ideal cycle time per delivery per vehicle is
= 0.75 + 110/50 + 0.50 + 80/50
= 5.05 min.
55 m

40 m
(c) To determine the number of vehicles required to make
40 deliveries/hr, compute the workload of the AGVS and
20 m the available time per hour per vehicle,
Work Load = WL = 40 x 5.05 = 202 min/hr
Available Time = AT = 60 x 0.95 x 0.90 x 1.0
= 51.3 min/hr per vehicle
Direction of vehicle Number of vehicle required =
Load movement
Man
nc = 202/51.3 = 3.94 vehicles ~ 4 vehicles

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 CONVEYOR

Types of Conveyors:
(a) Roller conveyor,
(b) skate-wheel conveyor,
(c) belt (flat) conveyor
(support frame not
shown),
(d) in-floor towline conveyor,
and
(e) overhead trolley conveyor.

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 Conveyor Analysis (1)

Single direction powered conveyor

Ld Td = Ld / Vc Where: Td = delivery time, min
Ld = length between load and

UNLOAD
unload station, m
LOAD

Vc = conveyor velocity , m/min

Vc

The flow rate of materials on the conveyor is determined by the rate of loading at the load station. The loading
rate is limited by the reciprocal of the time required to load the materials.

Rf = RL = Vc / Sc < 1/TL Where: Rf = material flow rate = parts/min

RL = Loading rate = parts/min
Sc = center-to-center spacing of material on conveyor, m/part
TL = loading time, min/part

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 Conveyor Analysis (2)

Continous Loop Conveyor Consider a continuous loop conveyor such as an overhead trolley in
which the pathway is formed by an endless chain moving in a track loop,
delivery loop and carriers are suspended from the track and pulled by the chain. The
conveyor moves parts in the carriers between a load station and an

UNLOAD
unload station. The complete loop is divided into two sections: a delivery
LOAD

Vc (forward) loop in which the carriers are loaded and a return loop in
Vc which the carriers travel empty. The length of the delivery loop is Ld, and
the length of the return loop is Le. Total length of the conveyor is
therefore L = Ld + Le. The total time required to travel the complete loop
return loop is
Tc = L/Vc
Where:
Tc = total cycle time, min; and vc = speed of the conveyor chain, m/min .

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
Each carrier is capable of holding parts on the delivery loop, and it holds no parts on the return trip. Since only those carriers on the
forward loop contain parts, the maximum number of parts in the system at any one time is given by
Total parts in the system = npncLd /L

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 Conveyor Analysis – Circulating Conveyor

Two problems complicating the operation of a recirculating conveyor system: (1) the possibility that no empty carriers
are immediately available at the loading station when needed and (2) the possibility that no loaded carriers are
immediately available at the unloading station when needed.
Kwo Three Rules in designing such a conveyor system:
1. Speed Rule. Then the conveyor speed must satisfy the relationship  (np.vc / sc) > Max (RL, RU)
where RL = required loading rate, pc/min; and RU = the corresponding unloading rate.
The upper speed limit is determined by the physical capabilities of the mate- rial handlers who perform the loading
and unloading tasks  vc/sc < Min(1/TL, 1/TU)
2. Capacity Constraint. The flow rate capacity of the conveyor system must be at least equal to the flow rate
requirement to accommodate reserve stock and allow for the time elapsed between loading and unloading due to
delivery distance …..  np.vc > Rf …….  Rf must be interpreted as a system specification required of the
recirculating conveyor
3. Uniformity Principle. This principle states that parts (loads) should be uniformly distributed throughout the length
of the conveyor, so that there will be no sections of the conveyor in which every carrier is full while other sections
are virtually empty.

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 HOIST

A hoist with a mechanical advantage of

4.0:
(a) sketch of the hoist and
(b) diagram to illustrate mechanical
advantage.

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 CRANE

(a) bridge crane, (b) gantry crane (a half gantry crane is shown), and (c) jib crane.

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STORAGE SYSTEM
The Function Of A Material Storage System is to store materials for a period of time
and to permit access to those materials when required. Some production plants
and storage facilities use manual methods for storing and retrieving materials.
More effective approaches and automated methods are available to improve the
efficiency of the storage function.
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 Types of Materials Typically Stored in a Factory
NO TYPE
1 Raw materials
2 Purchased parts
3 Work-in-process
4 Finished product
5 Rework and scrap
6 Refuse
7 Tooling and supplies
8 Spare parts
9 Office supplies
10 Plant records
MESDIN KORNALIS SIMARMATA
DESCRIPTION
Raw stock to be processed (e.g., bar stock, sheet metal, plastic molding compound)
Parts from vendors to be processed or assembled (e.g., castings, purchased components)
Partially completed parts between processing operations and parts awaiting assembly
Completed product ready for shipment
Parts that do not meet specifications, either to be reworked or scrapped
Chips, swarf, oils, other waste products left over after processing; these materials must be
disposed of sometimes using special precautions
Cutting tools, jigs, fixtures, molds, dies, welding wire and other tools used in production; supplies
such as helmets and gloves
Parts needed for maintenance and repair of factory equipment
Paper, paper forms, writing instruments, and other items
Records on product, production, equipment, personnel, etc.
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 Bulk Storage
(a) Bulk storage using pallet trucks
and powered forklifts
Used for the storage of stock in an open
floor area, generally in unit loads on
pallets or similar containers. Unit loads
may be stacked on top of each other to
achieve higher storage densities.
(b) Rack systems that use pallet
trucks and powered forklifts
Rack systems provide bulk storage
facilities with adequate support to aid
safe stacking, by means of various
methods, such as : pallet racks—
consisting of a frame to support unit
loads stacked one over the other.

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 Pallet Rack System

Pallet loads placed on racks in

multi-rack structure
(a) Low cost
(b) Good stroge density
(c) Good accessibility

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 Drawer Storage

• Contents easily visible

• Good accessibility
• Relatively high cost

Small items (tools, repair parts,

etc.)

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 AUTOMATED STORAGE SYSTEM

1. Automated Storage/Retrieval System (AS/RS) – Fix

Aisle AS/RS
Rack system with mechanized or automated crane to
store/retrieve loads

2. Carousel Storage System

Oval conveyor system with bins to contain individual items

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 DIFFERENCES

Feature Fixed-Aisle AS/RS Carousel Storage System

Storage structure Rack system to support pallets or Baskets suspended from overhead
shelf system to support tote bins conveyor trolleys

Motions Linear motions of S/R machine Revolution of conveyor trolleys around

oval track

Storage/retrieval S/R machine travels to compartments Conveyor revolves to bring baskets to

operation in rack structure load/unload station

Replication of storage Multiple aisles, each consisting of rack Multiple carousels, each consisting of
capacity structure and S/R machine oval track and storage bins

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 AS/RS Analysis – Aisle AS/RS
Kapasitas  Cap = ny.nz
ny = jumlah rak mendatar
nz = jumlah rak vertical
Bila: W = lebar Aisle
L = panjang Aisle
H = tinggi Aisle
Maka W = 3(x + a)
L = ny(y + b)
H = nz( z = c)
x,y, z adalah ukuran load, sedangkan
a,b,c adalah allowances
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 AS/RS THROUGHPUT TIME
H = height of the rack structure, m (ft); vz = velocity
of the S/R machine in the vertical direction of the
AS/RS, m/min (ft/min); and Tpd =
pickup@and@deposit time, min.

2) Dual Command Cycle

For a dual-command cycle, the S/R machine is
assumed to travel to the center of the rack structure
to deposit a load, and then it travels to 3/4 the
1) Single Command Cycle length and height of the AS/RS to retrieve a load 
The load to be entered or retrieved is assumed to be located (b)
at the center of the rack structure  (a). Thus, the S/R
machine must travel half the length and half the height of Tds = Max {1.5L/vy, 1.5H/vz} + Tpd
the AS/RS, and it must return the same distance.
3) Utilization of the system:
Tcs = Max { L/vy, H/vz} + Tpd 60 U = Rcs Tcs + Rcd Tcd
Rcs = number of single-command cycles performed
Tcs = cycle time of a single-command cycle, min/cycle; L = per hour, and Rcd = number of dual-command cycles
length of the AS/RS rack structure, m (ft); vy = velocity of the per hour. Then Total transaction, Rt
S/R machine along the length of the AS/RS, m/min (ft/min); Rt = Rcs + 2 Rcd
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 PROBLEM -1

Consider the AS/RS, in which an S/R machine is used for each aisle. The
length of the storage aisle = 280 ft and its height = 46 ft. Suppose
horizontal and vertical speeds of the S/R machine are 200 ft/min and 75
ft/min, respectively. The S/R machine requires 20 sec to accomplish a
P&D operation.
Determine …..
a) the single-command and dual-command cycle times per aisle and
b) throughput per aisle under the assumptions that storage system
utilization = 90% and the number of single-command and dual-
command cycles are equal.

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 PROBLEM - 2

An AS/RS is used for work-in-process storage in a manufacturing facility.

The AS/RS has five aisles, each aisle being 120 ft long and 40 ft high.
The horizontal and vertical speeds of the S/R machine are 400 ft/min
and 50 ft/min, respectively. The S/R machine requires 12 sec to
accomplish a pick and deposit operation. The number of single
command cycles equals the number of dual command cycles. If the
requirement is that the AS/RS must have a throughput rate of 200 S/R
transactions per hour during periods of peak activity, will the AS/RS
satisfy this requirement? If so, what is the utilization of the AS/RS
during peak hours.

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 CAROUSEL STORAGE SYSTEM
HORIZONTAL CARAUSEL STORAGE SYSTEM
• A carousel storage system is one with a series of bins or
baskets suspended from an overhead chain conveyor that
revolves around a long oval rail system.

• Carousels are classified as horizontal or vertical, with the

former being more common in practice.

• Horizontal carousels consist of a welded steel framework

for the oval rail system, which can be either mounted
overhead (a top-driven unit), or from below (a bottom-
driven unit). In the top-driven structure, a motorised
pulley system drives the overhead trolley system,
attached to which are suspended bins.

• In the bottom-driven structure, the pulley drive system is

mounted at the base of the frame, and the trolley system
rides on a rail in the base. Carousel

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 Carousel Systems Analysis
• Mean travel distance between the
• Keliling dari Carausel = C load/unload station and a bin randomly
C = 2(L-W) + πW located in the carousel is C/4. Thus, the
• Total number of bins S/R cycle time is given by:
Ttot = nc.nb 𝐶
Tc = + Tpd
4𝑣𝑐
nb = number of bins that may hang in
a column, one below another, vc = carousel velocity
from each carrier Tpd = average time required to pick or
nc = number of carriers supported by deposit items each cycle
the rail
• The number of transactions accomplished
• If sc is the centre-to-centre per hour is the same as the number of
spacing from one carrier to the cycles and is given by the following:
next carrier 60
sn . nc = C Rt = Rc =
𝑇𝑐

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SEKIAN DAN TERIMA KASIH
GET READY FOR MIDTEST

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