Example for ACC

Group Technology

2
4
 Group Technology (GT) Defined

“A manufacturing philosophy in which similar parts are

identified and grouped together to take advantage of their
similarities in design and production”

 In each part family, processing steps are similar.

 The improvement is typically achieved by organizing the production

facilities into manufacturing cells that specialize in production of certain part
families.

6
 Overview of Group Technology

 Parts in the medium production quantity range are usually

made in batches.

 Disadvantages of batch production:

 Downtime for changeovers

 High inventory carrying costs

 GT minimizes these disadvantages by recognizing that

although the parts are different, there are groups of parts
that possess similarities.

7
 When to Use GT and Cellular Manufacturing

1. The plant currently uses traditional batch production and

a process type layout

2. The parts can be grouped into part families

9
 Problems in Implementing GT

1. Identifying the part families

2. Rearranging production machines into GT cells

10
 Part Family

“A collection of parts that possess similarities in geometric

shape and size, or in the processing steps used in their
manufacture”
 Part families are a central feature of group technology.
There are always differences among parts in a family.
 But the similarities are close enough that the parts can be
grouped into the same family.

11
Part Family

12
 Part Families

 Two parts that are identical in shape and size but quite
different in manufacturing:
 (a) 1,000,000 units/yr, tolerance = 0.010 inch, 1015 CR
steel, nickel plate;
 (b) 100/yr, tolerance = 0.001 inch, 18-8 stainless steel

13
 Part Families

Ten parts are different in

 size, shape, and
material, but quite similar
in terms of manufacturing
All parts are machined
 from cylindrical stock by
turning; some parts
require drilling and/or
milling
Traditional Process Layout
 Cellular Layout Based on GT

 Each cell
specializes in
producing
one or a
limited
number of
part families
17
18
• Reading Assignment

• Line lay out, functional layout comparison –

advantage and disadvantages.
• Follow link below:-

• https://keydifferences.com/difference-
between-product-and-process-layout.html
19
 Ways to Identify Part Families

1. Visual inspection

2. Parts classification and coding

3. Production flow analysis

 Features of Parts Classification and
Coding Systems

 Most classification and coding systems are based on one

of the following:
 Part design attributes
 Part manufacturing attributes
 Both design and manufacturing attributes
 Part Design Attributes

 Major dimensions
 Basic external shape
 Basic internal shape
 Length/diameter ratio
 Material type
 Part function
 Tolerances
 Surface finish
 Part Manufacturing Attributes

 Major process
 Operation sequence
 Batch size
 Annual production
 Machine tools
 Cutting tools
 Material type
 Coding Scheme Structures

1. Hierarchical structure (monocode)

 Interpretation of each successive digit depends on
the value of the preceding digit
2. Chain-type structure (polycode)
 Interpretation of each symbol is always the same
 No dependence on previous digits
3. Mixed-code structure
 Combination of hierarchical and chain-type
structures
26
https://www.accountingtools.com/articles/what-is-manufacturing-
throughput-time.html
27
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29
30
31
32
33
34
35
36
37
38
Unidirectional work flow

39
40
41
42
43
44
45
46
47
Opitz Classification and
Coding System

48
49
 Opitz Classification and Coding System
• It is intended for machined parts and uses the following digits sequence
• Form Code 12345 for design attributes
• Supplementary Code 6789 for manufacturing attributes
• Secondary Code ABCD for production operation type &
sequence
Digits (1-5) for Rotational parts in the Opitz System
• Given the rotational part design below, determine the form code in the
Optiz parts classification and coding system.

52
Solution

• Length-to-diameter ratio: L/D = 1.5 Digit 1 = 1

• External shape: both ends stepped with screw thread on one end Digit 2 = 5
• Internal shape: part contains a through hole Digit 3 = 1
• Plane surface machining: none Digit 4 = 0
• Auxiliary holes, gear teeth, etc.: none Digit 5 = 0

The form code in the Optiz system is 15100

54
 Production Flow Analysis (PFA)

“Method for identifying part families and associated machine

groupings based on production route sheets rather than part
design data”

 Workparts with identical or similar route sheets are

classified into part families.

Advantages of using route sheet data
 Parts with different geometries may nevertheless require the same
or similar processing
 Parts with nearly the same geometries may nevertheless
require different processing
 Steps in Production Flow Analysis

1. Data collection – operation sequence and machine routing for

each part (number)

2. Sortation of process routings – parts with same sequences and

routings are arranged into “packs”

3. PFA chart – each pack is displayed on a PFA chart

 Also called a part-machine incidence matrix

4. Cluster analysis – purpose is to collect packs with similar routings

into groups
 Each machine group = a machine cell
Production Flow Analysis (PFA)
King’s Algorithm

59
1. Formulate the Incidence Matrix.
2. Calculate the total (binary) weight of each column.
3. Sort the columns into rank order.
4. Calculate the total (binary) weight of each row.
5. Sort them in Ascending order.
6. If all rows are in rank order STOP,
Else repeat steps 2 to 5.

60
 Incidence Matrix
• Rows represent Machining (index = i)
• Columns represent Components (index = j)
• Cell Entries are: (Mij)
– 1 (or mark) - if the component requires the operation
– 0 (or blank) - if the component does NOT require the operation

A-112 A-115
Saw01 1
Lathe01
Lathe02 1
Drill01 1
Mill02 1
Mill05
Grind05 1
2/18/2020 IENG 471 Facilities Planning 61
 King’s Algorithm – Step 1
• Calculate the total (binary) weight of each column j:
Wj =  2i Mij
i

A1 A2 A3 A4 A5 A6 A7 A8 A9 A0 2i i
S01 1 1 1 1 1 1 2 1
L01 1 4 2
L02 1 1 1 1 1 8 3
D01 1 1 16 4
M02 1 32 5
M05 1 1 1 64 6
G05 1 128 7
G06 1 256 8

Wj
138

336
48

10

10

64

64

10

10
6

Rank 5 3 2 1 2 4 4 2 2 6
2/18/2020 IENG 471 Facilities Planning 62
 King’s Algorithm – Step 2
• Sort the columns into rank order, then go to Step 3:
A4 A3 A5 A8 A9 A2 A6 A7 A1 A0

S01 1 1 1 1 1 1
L01 1
L02 1 1 1 1 1
D01 1 1
M02 1
M05 1 1 1
G05 1
G06 1

Wj
138

336
10

10

10

10

48

64

64
6

Rank 1 2 2 2 2 3 4 4 5 6
2/18/2020 IENG 471 Facilities Planning 63
 King’s Algorithm – Step 3
• Calculate the total (binary) weight of each row i:
Wi =  2j Mij
j

A4 A3 A5 A8 A9 A2 A6 A7 A1 A0 Wi Rank
S01 1 1 1 1 1 1 574 4
L01 1 2 1
L02 1 1 1 1 1 602 5
D01 1 1 1088 7
M02 1 64 2
M05 1 1 1 1408 8
G05 1 512 3
G06 1 1024 6

1024
2j
128

256

512
16

32

64
2

j 1 2 3 4 5 6 7 8 9 10
2/18/2020 IENG 471 Facilities Planning 64
 King’s Algorithm – Step 4
• If all rows are in rank order STOP; otherwise, sort the rows into rank order,
and then go to Step 1:

A4 A3 A5 A8 A9 A2 A6 A7 A1 A0 Wi Rank
L01 1 2 1
M02 1 64 2
G05 1 512 3
S01 1 1 1 1 1 1 574 4
L02 1 1 1 1 1 602 5
G06 1 1024 6
D01 1 1 1088 7
M05 1 1 1 1408 8

2/18/2020 IENG 471 Facilities Planning 65

 King’s Algorithm – Step 1 (2nd time)
• Calculate the total (binary) weight of each column j:
Wj =  2i Mij
i

A4 A3 A5 A8 A9 A2 A6 A7 A1 A0 2i i
L01 1 2 1
M02 1 4 2
G05 1 8 3
S01 1 1 1 1 1 1 16 4
L02 1 1 1 1 1 32 5
G06 1 64 6
D01 1 1 128 7
M05 1 1 1 256 8

Wj
132

256

256

448
18

48

48

48

48

56

Rank 1 2 2 2 2 4 5 5 3 6
2/18/2020 IENG 471 Facilities Planning 66
 King’s Algorithm – Step 2 (2nd time)
• Sort the columns into rank order, then go to Step 3:

A4 A3 A5 A8 A9 A1 A2 A6 A7 A0
L01 1
M02 1
G05 1
S01 1 1 1 1 1 1
L02 1 1 1 1 1
G06 1
D01 1 1
M05 1 1 1

Wj
132

256

256

448
18

48

48

48

48

56

Rank 1 2 2 2 2 3 4 5 5 6
2/18/2020 IENG 471 Facilities Planning 67
 King’s Algorithm – Step 3 (2nd time)
• Calculate the total (binary) weight of each row i:
Wi =  2j Mij
j

A4 A3 A5 A8 A9 A1 A2 A6 A7 A0 Wi Rank
L01 1 2 1
M02 1 128 5
G05 1 64 2
S01 1 1 1 1 1 1 126 4
L02 1 1 1 1 1 124 3
G06 1 1024 6
D01 1 1 1152 7
M05 1 1 1 1792 8

1024
2j
128

256

512
16

32

64
2

j 1 2 3 4 5 6 7 8 9 10
2/18/2020 IENG 471 Facilities Planning 68
 King’s Algorithm – Step 4 (2nd time)
• If all rows are in rank order STOP; otherwise, sort the rows into rank order,
and then go to Step 1:

A4 A3 A5 A8 A9 A1 A2 A6 A7 A0 Wi Rank
L01 1 2 1
G05 1 64 2
L02 1 1 1 1 1 124 3
S01 1 1 1 1 1 1 126 4
M02 1 128 5
G06 1 1024 6
D01 1 1 1152 7
M05 1 1 1 1792 8

2/18/2020 IENG 471 Facilities Planning 69

 King’s Algorithm – Step 1 (3rd time)
• Calculate the total (binary) weight of each column j:
Wj =  2i Mij
i

A4 A3 A5 A8 A9 A1 A2 A6 A7 A0 2i i
L01 1 2 1
G05 1 4 2
L02 1 1 1 1 1 8 3
S01 1 1 1 1 1 1 16 4
M02 1 32 5
G06 1 64 6
D01 1 1 128 7
M05 1 1 1 256 8

Wj
160

256

256

510
18

24

24

24

24

26

Rank 1 2 2 2 2 3 4 5 5 6
2/18/2020 IENG 471 Facilities Planning 70
 King’s Algorithm – Step 2 (3rd time)
• Sort the columns into rank order, then go to Step 3:
NO CHANGE IN SORTED ORDER!
A4 A3 A5 A8 A9 A1 A2 A6 A7 A0
L01 1
G05 1
L02 1 1 1 1 1
S01 1 1 1 1 1 1
M02 1
G06 1
D01 1 1
M05 1 1 1

Wj
160

256

256

510
18

24

24

24

24

26

Rank 1 2 2 2 2 3 4 5 5 6
2/18/2020 IENG 471 Facilities Planning 71
 King’s Algorithm – Step 3 (3rd time)
• Calculate the total (binary) weight of each row i:
Wi =  2j Mij
j

A4 A3 A5 A8 A9 A1 A2 A6 A7 A0 Wi Rank
L01 1 2 1
G05 1 64 2
L02 1 1 1 1 1 124 3
S01 1 1 1 1 1 1 126 4
M02 1 128 5
G06 1 1024 6
D01 1 1 1152 7
M05 1 1 1 1792 8

1024
2j
128

256

512
16

32

64
2

j 1 2 3 4 5 6 7 8 9 10
2/18/2020 IENG 471 Facilities Planning 72
 King’s Algorithm – Step 4 (3rd time)
• If all rows are in rank order STOP; otherwise, sort the rows into rank order, and
then go to Step 1:
SINCE THE ROWS WERE IN RANK ORDER, WE STOP!

A4 A3 A5 A8 A9 A1 A2 A6 A7 A0 Wi Rank
L01 1 2 1
G05 1 64 2
L02 1 1 1 1 1 124 3
S01 1 1 1 1 1 1 126 4
M02 1 128 5
G06 1 1024 6
D01 1 1 1152 7
M05 1 1 1 1792 8

2/18/2020 IENG 471 Facilities Planning 73

 Partitioning
• Ideally, the cells form mutually exclusive blocks (as below). These blocks define
the Families:
– Family A consists of Components A1, A3, A4, A5, A8, and A9; which can be
machined in a cell performing Operations G05, L01, L02, and S01
– Family B consists of Components A0, A2, A6, and A7; which can be
machined in a cell performing Operations D01, G06, M02, and M05

A4 A3 A5 A8 A9 A1 A2 A6 A7 A0
L01 1
G05 1
L02 1 1 1 1 1
S01 1 1 1 1 1 1
M02 1
G06 1
D01 1 1
M05 1 1 1
2/18/2020 IENG 471 Facilities Planning 74
 Machine Cell Designs

1. Single machine
2. Multiple machines with manual handling
 Often organized into U-shaped layout
3. Multiple machines with semi-integrated handling
4. Automated cell – automated processing and integrated
handling
 Flexible manufacturing cell
 Flexible manufacturing system
 Machine Cell with Manual Handling

U-shaped machine cell with manual part handling between machines

 Cell with Semi-Integrated Handling

In-line layout using mechanized work handling between machines

 Cell with Semi-Integrated Handling

• Loop layout allows variations in part routing between machines.

• Rectangular layout also allows variations in part routing and allows
return of work carriers if they are used.
Four Types of Part Moves in
Mixed Model Production System
Flexible Manufacturing
System(FMS)
 Introduction

• "FMS consists of a group of processing work stations

interconnected by means of an automated material
handling and storage system and controlled by integrated
computer control system.“

81
 Basic Components of FMS
1. Workstations
2. Automated Material Handling and Storage system
3. Computer Control System
4. Human Labour

Example, example 2

82
 Types of FMS – Based on Number of
Machines
• Flexible manufacturing systems can be distinguished according to the
number of machines in the system. The following are typical categories:

 Single machine cell

 Flexible manufacturing cell
 Flexible manufacturing system
• A single machine cell consists of one CNC machining center combined with a
parts storage system for unattended operation.
• Completed parts are periodically unloaded from the parts storage unit, and
raw workparts are loaded into it
• A flexible manufacturing cell consists of two or three processing workstations
(typically CNC machining centers) plus a part handling system.
• The part handling system is connected to a load/unload station.
• A flexible manufacturing system has four or more processing workstations
connected mechanically by a common part handling system and electronically
by a distributed computer system.
Some of the distinguishing characteristics of the three categories of flexible
manufacturing cells and systems are summarized in figure below
Flexibility Criteria Applied to the Three Types of Manufacturing Cells and Systems
 FMS Layouts
1. Progressive or Line type: The machines and handling system are arranged in a
line. It is most appropriate for a system in which the part progress from one
workstation to the next in a well-defined sequence with no back flow. The
operation of this type of system is very similar to transfer type. Work always flows
in unidirectional path.
2. Loop Type: Here the parts usually move in one direction around the
loop, with the capability to stop and be transferred to any station. The loading
and unloading station are typically located at one end of the loop.

91
 FMS Layouts

3. Ladder Type: The loading and unloading station is typically located at the same end. The
sequence to the operation/transfer of parts from one machine tool to another is in the form
of ladder steps.
 FMS Layouts
4. Open Field Type: The loading and unloading station is typically located at the same end. The
parts will go through all the substations, such as CNC machines, coordinate measuring
machines and wash station by the help of AGV’s from one substation to another.
 FMS Layouts
5. Robot Centred Type: Robot centred cell is a relatively new form of flexible system in which
one or more robots are used as the material handling systems. Industrial robots can be
equipped with grippers that make them well suited for handling of rotational parts.
 Benefits of FMS
• Higher machine utilization than a conventional machine shop due to
better work handling, off-line setups, and improved scheduling

• Lower manufacturing lead times

• Greater flexibility in production scheduling

 Quantitative analysis of FMS

Bottleneck Model

 Technique used in starting state of FMS analysis

 Rough estimates of system parameters:

production rate, capacity, and utilization

 Overestimates system performance

 Terminology and Symbols
1. Part mix: The mix of the various part or product styles produced by
the system is defined by "Pj' where Pj is the fraction of the total
system output that is of style j.

The values of Pj must sum to unity.

2. Workstations and servers:

In the terminology of the bottleneck model, each workstation may have

more than one server, which simply means that it is possible to have
two or more machines capable of performing the same operations.

Let Si = the number of servers at workstation i,

Where i = 1,2. .. n
3.Process routing :

tijk = processing time for a part/product in a given server, not

including waiting time,
where
i = station i
j = part/product j
k = particular operation in process routing sequence of
operations

99
4.Work handling system: material handling system is considered
a special workstation and designate it as station n + 1; then
sn+1 = number of carriers (servers) in handling system
(conveyors, carts, AGV’s, etc.)

5.Transport time:
tn+1 = mean transport time required to move a part from
one workstation to the next station in the process
routing

100
6. Operation frequency :

fijk : The operation frequency for operation k in process plan j at

station i
FMS Operational Parameters:

1. The average workload for a given station is defined as the mean total time spent
at the station per part. It is calculated as follows

WLijk = σ𝑖 σ𝑘 𝑡𝑖𝑗𝑘 𝑓𝑖𝑗𝑘 𝑝𝑗

2. Workload of handling system is WLn+1 = nt tn+1

Average number of transports (nt) is the mean number of operations

in the process routing minus 1:
nt = i j k fijkpj – 1

Bottleneck station is identified by finding the maximum

valve of the ratio of WLi / Si
Example – determine nt
Simple system has machining station and load/unload station.
If system processes single part, determine nt.
One part (j = 1) so
p1 = 1.0 Unload
Load
fi1k = 1.0
3 routing operations: load part at 1-, route to station 2 for machining, return
to station 1 for unloading
Then
nt = 1(1.0) + 1(1.0) + 1(1.0) - 1 = 2
“load” “machine at 2” “unload”
System Performance Measures

1. Work load of The FMS maximum production rate of all parts can be
determined as the ratio of s* to W L* . Let us refer to it as the
maximum production rate because it is limited by the capacity of the
bottleneck station.

𝑆∗
R p* =
𝑊𝐿∗

104
2. The utilization of each workstation is the proportion of time that the servers at the
station are working and not idle. This can be computed as follows:

𝑊𝐿𝑖
Ui= (Rp*)
𝑆𝑖

3. To obtain the Overall FMS utilization, one simply computes the average value for all
stations. including the transport system. This can he calculated as follow,

σ𝑛𝑖=1 𝑆𝑖𝑈𝑖
ഥ=
𝑈
σ𝑛𝑖=1 𝑆𝑖
4. Finally, the number of busy servers at each station is of interest. All of the servers at
the bottleneck station are busy at the maximum production rate, but the servers at
the other stations are idle some of the time. The values can be calculated as follows:

BSi = WLi (Rp*)

1. WLijk = σ𝒊 σ𝒌 𝒕𝒊𝒋𝒌 𝒇𝒊𝒋𝒌 𝒑𝒋 σ𝒏𝒊=𝟏 𝑺𝒊𝑼𝒊

𝟒. 𝑼 =
σ𝒏𝒊=𝟏 𝑺𝒊
𝑺∗
2. Rp* =
𝑾𝑳∗
𝑾𝑳𝒊 5. BSi = WLi (Rp*)
3. Ui= (Rp*)
𝑺𝒊
Example 1 :
A flexible machining system consists of a load/unload station and two
machining workstations . Station 1 is the load/unload station. Station 2
performs milling operations and consists of two servers (two identical CNC
milling machines). Station 3 has one server that performs drilling (one CNC drill
press). The stations are connected by a part handling system that has four
work carriers. The mean transport time is 3.0 min. The FMS produces two
parts A and B. The part mix fractions and process routings for the two parts are
presented in the table. The operation frequency fijk = 1.0 for all operations.
Determine:
(a) maximum production rate of the FMS,
(b) corresponding production rates of each product,
(c) utilization of each station, and
(d) number of busy servers at each station.
Part Part Mix Operation Station Process Time (tijk)
Description
(j) (Pj) (k) (i) min.
1 Load 1 4
2 Mill 2 30
A 0.4
3 Drill 3 10
4 Unload 1 2
1 Load 1 4
2 Mill 2 40
B 0.6
3 Drill 3 15
4 Unload 1 2
 ( a) Maximum production rate of FMS

Wkt, WLijk = σ𝒊 σ𝒌 𝒕𝒊𝒋𝒌 𝒇𝒊𝒋𝒌 𝒑𝒋

• WL1 = (4+2) (0.4) (1) + (4+2) (0.6) (1) = 6 min

• WL2 = (30) (0.4) (1) + (40) (0.6) (1) = 36 min
• WL3 = (10) (0.4) (1) + (15) (0.6) (1) = 13 min
• nt = 3, Station routing is 1 2 3 1
– Average of transport= (4x0.4)+ (4x.6)-1=3
• WL4 = 3 (3) = 9 min (3(3x.4x1)+(3(3x.6x1))
• The bottleneck station is identified by finding the largest WLi /Si ratio.
• For station 1, WL1/S1 = 6/1 = 6 min
• For station 2, WL2/S2 = 36/2 = 18 min
• For station 3, WL3/S3 = 13/1 = 13 min
• For station 4, WL4/S4 = 9/4 = 2.25 min (part handling system)

The maximum ratio occurs at station 2, so it is the bottleneck station that

determines the maximum production rate of all parts made by the system.
𝑺∗
Rp* =
𝑾𝑳∗

= 2/36 = 0.05555 pc/min = 3.333 pc/hr

109
(b) To determine production rate of each product ,
multiply RP* by its respective part mix fraction
• RPA* = 3.333 (0.4) = 1.333 pc/hr
• RPB* = 3.333 (0.6) = 2.00 pc/hr

(C) The utilization of each station is given by Ui= 𝑾𝑳

𝑺𝒊
𝒊
(Rp*)
• U1= (6/1) (0.05555) = 0.333 ( 33.3 %)
• U2= (36/2) (0.05555) = 1.0 ( 100%)
• U3= (13/1) (0.05555) = 0.722( 72.2 %)
• U4= (9/4) (0.05555) = 0.125( 12.5 %)

110
(d) Mean number of busy server at each station
is determined by BSi = WLi (Rp*)

• BS1 = 6 (0.05555) = 0.333

• BS2 = 36 (0.05555) = 2
• BS3 = 13 (0.05555) = 0.722
• BS4 = 9 (0.05555) = 0.5

111
Example 2 :
An FMS consists of four stations. Station 1 is a load/unload station with one
server. Station 2 performs milling operations with three servers (three identical
CNC milling machines). Station 3 performs drilling operations with two servers
(two identical CNC drill presses). Station 4 is an inspection station with one
server that performs inspections on a sampling of the parts. The stations are
connected by a part handling system that has two work carriers and whose
mean transport time = 3.5 min. The FMS produces four parts. A, B, C, and D.
The part mix fractions and process routings for the four parts are presented in
the table . Determine:
(a) maximum production rate of the FMS,
(b) Corresponding production rate of each part,
(c) utilization of each station in the system, and
(d) the overall FMS utilization.
Part Part Mix Operation Descriptio Station Process Time Frequency
(j) (Pj) (k) n (i) (tijk) min. Fijk
1 Load 1 4 1.0
2 Mill 2 20 1.0
A 0.1 3 Drill 3 15 1.0
4 Inspect 4 12 0.5
5 Unload 1 2 1.0
1 Load 1 4 1.0
2 Drill 3 16 1.0
3 Mill 2 25 1.0
B 0.2
4 Drill 3 14 1.0
5 Inspect 4 15 0.2
6 Unload 1 2 1.0
Part Part Mix Operation Descriptio Station Process Time Frequency
(j) (Pj) (k) n (i) (tijk) min. Fijk
1 Load 1 4 1.0
2 Drill 3 23 1.0
C 0.3
3 Inspect 4 8 0.5
4 Unload 1 2 1.0
1 Load 1 4 1.0
2 Mill 2 30 1.0
D 0.4
3 Inspect 4 12 0.333
4 Unload 1 2 1.0
 MATERIAL TRANSPORT SYSTEMS

Material handling is defined by the Material Handling Industry of America as "the

movement, storage, protection and control of materials throughout the manufacturing
and distribution process including their consumption and disposal"
Material Transport Equipment: Material transport includes equipment that is used to
move materials inside a factory, warehouse. or other facility.

1. Industrial trucks:

a) Two wheel hand truck, b) four wheel dolly, c)hand operated low lift pallet truck
a) Walkie truck, b) forklift truck, c) towing tractor
2. Automated guided vehicles (AGVs):

a) Driverless automated guided train b)AGV pallet truck, c) unit load carrier
3. Monorails and other rail guided vehicles:

Cart on track conveyor

4. Conveyors:

a) Roller conveyor, b) skate wheel conveyor, c) belt, d) in-floor towline, e) overhead trolley
5. Cranes and hoists:
Material Handling Features Typical Applications
Equipment
Industrial trucks, Low cost Moving light loads in a factory
manual Low rate of deliveries/hr
Industrial trucks, Medium cost Movement of pallet loads and
powered pelletized containers in a factory
or warehouse
Automated guided High cost Moving pallet loads in factory
vehicle systems Battery-powered vehicles or warehouse
Flexible routing Moving work-in-process along
Non obstructive pathways variable routes in low
and medium production
Monorails and High cost Moving single assemblies, products,
other rail guided vehicles Flexible routing or pallet loads along variable
Vehicles On-the-floor or overhead types routes in factory or warehouse
Moving large quantities of items over
fixed routes in a factory
or warehouse
Conveyors, Great variety of equipment Moving products along a manual
powered In-floor, on-the-floor, or overhead assembly line
Mechanical power to move loads Sortation of items in a distribution
resides in pathway center
Cranes and hoists Lift capacities ranging up to more Moving large, heavy items
than 100 tons in factories, mills, warehouses, etc.
12
1
 Analysis of Material Transport Systems

We assume that,
• The vehicle operates at a constant velocity throughout its operation
• Ignore effects of acceleration, deceleration, and other speed differences that might
depend on whether the vehicle is traveling loaded or empty or other reasons.
The time for a typical delivery cycle in the operation of a vehicle-based transport
system consists of;
(1) Loading at the pickup station.
(2) Travel time to the drop-off station,
(3) Unloading at the drop-off station,
(4) Empty travel time of the vehicle between deliveries.

The total cycle time per delivery per vehicle is given by,
Where,
Tc = Delivery cycle time (min/del),
TL = Time to load at load station (min),
𝐿𝑑 𝐿𝑒 Ld = Distance the vehicle travels between load and
𝑇𝐶 = 𝑇𝐿 + + 𝑇𝑈 + unload station (m)
𝑉𝑐 𝑉𝑒
Vc = carrier velocity (m/min)
Tu = Time to unload at unload station (min)
Le = Distance the vehicle travels empty until the
(1) start of the next delivery cycle (m).
The available time per hour per vehicle as 60 min adjusted by A, Tf and E. That is,

Available Time (AT) = 60 AFtEw

Where, AT = available time (min/hr per vehicle), A = availability, Ft = traffic factor,

and Ew = worker efficiency.
The rate of deliveries per vehicle is given by:

𝐴𝑇
𝑅𝑑𝑣 =
𝑇𝑐

Where, Rdv = Hourly delivery rate per vehicle (del/hr per vehicle), Tc = delivery cycle
time computed by Eq. (1) (min/del),and AT = the available time in 1 hr with
adjustments for time losses (min/hr).
Workload is defined as the total amount of work, expressed in terms of time, that
must be accomplished by the material transport system in 1 hr.
This can be expressed as follows:

WL = Rf Tc

Where, WL = workload (min/hr),Rf = specified flow rate of total deliveries per hour for
the system (del/hr), and Tc = delivery cycle time (min/del).
Now the number of vehicles required to accomplish this workload can be written as,

𝑾𝑳 𝑹𝒇
𝒏𝒄 = =
𝑨𝑻 𝑹𝒅𝒗
Determining Number of Vehicles in an AGVs required,

Given the AGVS layout shown in Figure. Vehicles travel counter clockwise 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. It is desired to determine how many vehicles are required to satisfy demand
for this layout if a total of 40 del/hr must be completed by the AGVs. The following
performance parameters are given: vehicle velocity= 50m/min, availability = 0.95,
traffic factor = 0.90,and operator efficiency does not apply, so E = 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.
a) 110m and 80m
b) Tc= 0.75+110/50+0.5+80/50= 5.05min.
c) nc= WL/AT= 3.94 vehicles.

WL= 40(5.05)=202min/hr
AT= 60(0.95)(0.9)(1)=51.3 min/hr per vehicle
 AUTOMATED STORAGE AND RETRIEVAL SYSTEMS

An automated storage and retrieval system (ASRS) can be

defined as a storage system that performs storage and
retrieval operations with speed and accuracy under a defined
degree of automation.
Reasons that justify the installation of automated storage systems for work-in-process
include:

• Buffer storage in production

• Support of just-in-time delivery
• Kitting of parts for assembly
• Compatible with automatic identification systems
• Computer control and tracking of materials
• Support of factory wide automation.
Components and Operating Features of an AS/RS. Virtually all of the automated
storage/retrieval systems described above consist of the following components:
(1) Storage structure,
(2) S/R machine,
(3) Storage modules (e.g., pallets for unit loads),
(4) One or more pickup-and-deposit stations.

In addition, a control system is required to operate the AS/RS.

AS/RS COMPONENTS AND TERMINOLOGY
 AS/RS COMPONENTS AND TERMINOLOGY
1. Storage Space : It is the three-dimensional space in the storage racks used to store
a single load unit of material.

2. Storage Racks : This structural entity comprises storage locations, bays and rows.

3. Bay : It is the height of the storage rack from floor to the ceiling.

4. Row : It is a series of bays placed side by side.

5. Aisle : It is the spacing between two rows for the machine operations of AS/RS.

6. Aisle Unit : It encompasses aisle space and racks adjacent to an aisle.

7. Storage Structure : It is the rack framework, made of fabricated steel that

supports the loads contained in the AS/RS and is used to store inventory items.
8. Storage/Retrieval Machine : It is used to move items in and out of inventory. An
S/R machine is capable of both horizontal and vertical movement. A rail system
along the floor guides the machine and a parallel rail at the top of the storage
structure is used to maintain its alignment.

9. Storage Modules : These are the unit load containers used to hold the inventory
items. These include pallets, steel wire baskets and containers, pans and special
drawers. These modules are generally made to a standard base size capable of
being stored in the structure and moved by the S/R machines.

10. Pickup and Deposit (P/D) Stations: P/D stations are where inventory are
transferred into and out of the AS/RS. They are generally located at the end of the
aisles to facilitate easy access by the S/R machines from the external material-
handling system. The location and number of P/D stations depends upon the
origination point of incoming loads and the destination of output loads.
 DESIGN AND ENGINEERING ANALYSIS OF AN ASRS

1. Capacity per aisle:

The total storage capacity of one storage aisle depends on how many storage
compartments are arranged horizontally and vertically in the aisle. This can be
expressed as follows

capacity per aisle  2n y nz

Where ny = number of load compartments along the length of the aisle, and
nz = number of load compartments that make up the height of the aisle.
The constant 2 accounts for the fact that loads are contained on both sides of the aisle
 DESIGN AND ENGINEERING ANALYSIS OF AN ASRS

2. Calculating Individual Storage Space Dimensions

Let l, b and h be the length, width and height of the unit load. The length (L), width (W)
and height (H) of the rack structure of the AS/RS aisle are related to the unit load
dimensions and number of compartments as follows :
W  u( x + l )
L  n y ( y + b)
H  n z ( z + h)
W, L, and H are the width, length and height of one rack of the AS/RS rack structure (mm).
l, b, and h are the dimensions of the unit load (mm). “U” is storage depth in number of unit
loads.
x, y, and z are allowances designed into each storage compartment to provide clearance for the
unit load (mm)
Example 1:
In each aisle of an AS/RS, there are 70 storage compartments in the length
direction and 10 storage compartments vertically. The dimensions of the unit load
in inches (in) are 50 (length), 45 (width) and 50 (height) respectively. The
allowances designed for each storage compartment are : x = 8 inch, y = 7 inch and
z = 10 inch. Storage depth u in the number of unit load is 3. Determine the
capacity per aisle and the dimensions of the single storage system.

Solution
(a) Capacity per aisle = 2 ny nz
= 2 * 70 * 10 = 1400 unit loads

(b)
L = ny (l + y) = 70 (50 + 7) = 3990 in
W = u (b + X) = 3 (45 + 8) = 159 in
H = nz (h + z) = 10 (50 + 10) = 600 in
3. Estimation of AS/RS Throughput and the Number of S/R Machines

System throughput is defined as hourly rate of S/R transactions (number of loads

stored and number of loads retrieved) that an automated storage system can perform.

The number of S/R machines can be determined as follows :

System Throughput
Number of S/R machines =
S/R machine capacity in cycles per hour
AS/RS cycle time

min/cycle

min/cycle

L= length, H= height, Tpd= pickup and deposit time

142
System throughput depends on the relative numbers of single and
dual command cycles performed by the cycle. Rcs= no of single
command cycles performed per hour, Rcd= dual. Amount of time
spend in performing single and dual command cycles each hour
U system utilization during the hour.

Total hourly cycle rate : RC= Rcs+Rcd, cycles/hour

Total number of transactions performed per hr= Rt= Rcs+2Rcd

143
4. Estimating the Size Parameters of the Storage and Retrieval System

Number of Rows and the Number of Bays in a System

S/R machines are used for one or more aisles. Each aisle has two rows.

Therefore, the number of rows in case of one S/R

machine per aisle is :

Number of rows in the system = 2 x Number of S/R machines in the system.

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑡𝑜𝑟𝑎𝑔𝑒 𝑠𝑝𝑎𝑐𝑒 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑

𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑩𝒂𝒚𝒔 =
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑜𝑤𝑠 𝑝𝑒𝑟 𝑆𝑅 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 ∗ 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑆𝑅 𝑚𝑎𝑐ℎ𝑖𝑛𝑒𝑠
∗ 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑡𝑜𝑟𝑎𝑔𝑒𝑠𝑝𝑎𝑐𝑒𝑠 𝑝𝑒𝑟 𝑠𝑦𝑠𝑡𝑒𝑚 ℎ𝑒𝑖𝑔ℎ𝑡

𝑆𝑦𝑠𝑡𝑒𝑚 ℎ𝑒𝑖𝑔ℎ𝑡 𝑑𝑒𝑠𝑖𝑟𝑒𝑑

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑡𝑜𝑟𝑎𝑔𝑒𝑠𝑝𝑎𝑐𝑒𝑠 𝑝𝑒𝑟 𝑠𝑦𝑠𝑡𝑒𝑚 ℎ𝑒𝑖𝑔ℎ𝑡 =
𝑆𝑡𝑜𝑟𝑎𝑔𝑒 𝑠𝑝𝑎𝑐𝑒 ℎ𝑒𝑖𝑔ℎ𝑡
5. Estimation of Bay Width, System Width, Rack Length, System Length, Bay Depth
and Aisle Unit

Bay width = Load width + Required Clearance + Centre-to-centre rack support width

Rack length = bay width * number of bays

System length = rack length + clearance for S/R machine run-out + P/D area

Bay depth = width of the individual storage space + bay side support allowance

Aisle unit = Aisle width + (2 × Bay depth)

System width = Aisle unit × Desired number of aisle

146
Example 1:
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.
148
W  u( x + l )
L  ( y + b)
H  ( z + h)
System Throughput
Number of S/R machines =
S/R machine capacity in cycles per hour

Number of rows in the system = 2 x Number of S/R machines in the system.

𝑆𝑦𝑠𝑡𝑒𝑚 ℎ𝑒𝑖𝑔ℎ𝑡 𝑑𝑒𝑠𝑖𝑟𝑒𝑑

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑡𝑜𝑟𝑎𝑔𝑒𝑠𝑝𝑎𝑐𝑒𝑠 𝑝𝑒𝑟 𝑠𝑦𝑠𝑡𝑒𝑚 ℎ𝑒𝑖𝑔ℎ𝑡 =
𝑆𝑡𝑜𝑟𝑎𝑔𝑒 𝑠𝑝𝑎𝑐𝑒 ℎ𝑒𝑖𝑔ℎ𝑡
 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑡𝑜𝑟𝑎𝑔𝑒 𝑠𝑝𝑎𝑐𝑒 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑩𝒂𝒚𝒔 =
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑜𝑤𝑠 𝑝𝑒𝑟 𝑆𝑅 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 ∗ 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑆𝑅 𝑚𝑎𝑐ℎ𝑖𝑛𝑒𝑠
∗ 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑡𝑜𝑟𝑎𝑔𝑒𝑠𝑝𝑎𝑐𝑒𝑠 𝑝𝑒𝑟 𝑠𝑦𝑠𝑡𝑒𝑚 ℎ𝑒𝑖𝑔ℎ𝑡

Bay width = Load width + Required Clearance + Centre-to-centre rack support width

Rack length = bay width * number of bays

System length = rack length + clearance for S/R machine run-out + P/D area

Bay depth = width of the individual storage space + bay side support allowance

Aisle unit = Aisle width + (2 × Bay depth)

System width = Aisle unit × Desired number of aisle