Material Handling Systems. Logistics Systems Design: Material Handling Systems. Overview. Material Handling Definition. Material Handling Is Expensive

Logistics Systems Design: Material Handling Systems 21-Jul-03 21-Jul-03 Logistics Systems Design: Material Handling Systems Material Handling Syst...
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Logistics Systems Design: Material Handling Systems

21-Jul-03

21-Jul-03

Logistics Systems Design: Material Handling Systems

Material Handling Systems Overview

13. 14.

Material Handling Systems Material Handling Models

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Definition

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Classifications

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Warehousing Systems

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Storage Models

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Order Picking Models

Logistics Systems Design

Marc Goetschalckx

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Material Handling Definition

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y Movement y Storage, and y Control

” ”

Of materials in a process

Logistics Systems Design

Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.

Marc Goetschalckx

Marc Goetschalckx

Material Handling Is Expensive

Material handling is concerned with the

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Logistics Systems Design

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10 % to 80 % of product cost Physical distribution costs 25 % of product cost More than 90 % of flow time in job shop production systems

Logistics Systems Design

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Logistics Systems Design: Material Handling Systems

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Material Handling in Early Automotive Assembly

Traditional Versus Modern View ”

Traditional y Not value adding, only cost adding y Minimize as much as possible y Support automation

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Modern y Provides space and time utility y Maximize flexibility y Support integration

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Logistics Systems Design

Marc Goetschalckx

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o p q r

n

Why ? What ? When and where ? How ? By whom ?

o p q

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Logistics Systems Design

Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.

Marc Goetschalckx

Nine Rights of Material Handling

Stages in M.H.S. Design n

Logistics Systems Design

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Uses the right METHOD To provide the right AMOUNT Of the right MATERIAL To the right PLACE

r s t u v

Logistics Systems Design

At the right TIME In the right SEQUENCE In the right POSITION In the right CONDITION At the right COST Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Material Handling Systems Overview

Classification of Material Handling

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Definition

n

”

Classifications

o p

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Logistics Systems Design

Marc Goetschalckx

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Categories of Materials ” ” ” ” ” ” ” 21-Jul-03

Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.

Logistics Systems Design

Marc Goetschalckx

Unit Load Definition

Gasses Liquids Bulk materials Discrete (unit) loads Documents & money Livestock People Logistics Systems Design

by Material by Method by Equipment

A collection of materials so arranged and restrained that it can be handled, stored, and controlled as a single entity

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Logistics Systems Design

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Logistics Systems Design: Material Handling Systems

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Unit Load Advantages ” ” ” ”

Unit Load Disadvantages

Standardized handling equipment Standardized storage equipment Reduced information & control burden Efficient macro space utilization

” ” ” ”

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Logistics Systems Design

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” ” ”

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Logistics Systems Design

Marc Goetschalckx

Unit Load Example: Ocean Going Intermodal Container

Unit Load Examples ”

Cost of assembly and disassembly Cost of container and wrappings Cost of empty container handling & disposal Inefficient micro space utilization

Pallet Drum Truck Ocean going intermodal container

Logistics Systems Design

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Marc Goetschalckx

21-Jul-03

Logistics Systems Design

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Logistics Systems Design: Material Handling Systems

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Classification of Material Handling

Categories of Methods

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by Material

”

o

by Method by Equipment

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p

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”

Logistics Systems Design

Marc Goetschalckx

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Labor And Control Providers Capability Labor

Logistics Systems Design

Marc Goetschalckx

Method Characteristics Flexibility

Control

Manual

Type Manual Human Mechanized Machine Automated Machine

Manual Mechanized Automated

Human Human Machine

Mechanized & Soft Automated Hard Automation Project

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Logistics Systems Design

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Marc Goetschalckx

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Job Shop

Logistics Systems Design

Flow Shop

Capacity

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Logistics Systems Design: Material Handling Systems

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Characteristics of Material Handling Methods Characteristic Weight Volume Speed Frequency Capacity Flexibility Acquisition cost Operating cost

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Manual Handling Illustration: Postman and Farmer

Type Manual Low Low Low Low Low High Low High

Mechanized High High Medium Medium Medium Medium Medium Medium

Logistics Systems Design

Automated High High High High High Low High Low

Marc Goetschalckx

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Manual Handling Equipment: Wheelbarrow

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Logistics Systems Design

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Logistics Systems Design

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Mechanized Handling Illustration: Forklift Truck

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Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Automated Illustration: Deep Lane Storage Detail

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Logistics Systems Design

Classification of Material Handling

Marc Goetschalckx

n

by Material

o

by Method

p

by Equipment

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CICMHE-MHIA Taxonomy of Material Handling Equipment

Logistics Systems Design

Equipment Categories n o p q r

www.mhia.org/et/mhe_tax.htm 21-Jul-03

Logistics Systems Design

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Marc Goetschalckx

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Conveyors Cranes and hoists Industrial trucks Containers and supports Storage equipment

s t u v

Logistics Systems Design

Auxiliary equipment Storage/retrieval systems Robots Pipelines

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Pipeline Systems ” ” ” ” ” ” 21-Jul-03

Pipeline Characteristics

Liquids, gasses, slurries, documents High fixed cost, very low operational cost, high volume Slow transportation speed but continuous movement Dependable and low time variance Larger diameters are more efficient Water, waste, documents Logistics Systems Design

Marc Goetschalckx

” ” ” ” ” ”

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Conveyors Characteristics ” ” ” ” ” ”

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Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.

Marc Goetschalckx

Logistics Systems Design

Marc Goetschalckx

Conveyor Examples

Continuous movement Fixed paths Very limited access area Very high hardware cost Very high volume Asynchronous versus synchronous

Logistics Systems Design

Continuous movement Fixed paths - ceiling suspended Very limited access area Very high hardware cost Very high volume Synchronous or asynchronous with containers

”

Synchronous y Belt y Roller y Power and free

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Asynchronous y Automated electrified monorail (AEM)

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Logistics Systems Design

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Logistics Systems Design: Material Handling Systems

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Bulk Belt Conveyor in Gold Mining Leach Removal

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Logistics Systems Design

Marc Goetschalckx

Bulk Belt Conveyor in Wood Chip Removal

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Belt Conveyor in Electronics Assembly

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Logistics Systems Design

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Marc Goetschalckx

Logistics Systems Design

Marc Goetschalckx

Belt Conveyor With Diverter Bar in Electronics Assembly

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Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Belt Conveyor in A-Frame Order Picking System

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Logistics Systems Design

Marc Goetschalckx

Conveyor Network in Electronics Manufacturing

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Roller Conveyor With Diverter in Electronics Manufacturing

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Logistics Systems Design

Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.

Marc Goetschalckx

Logistics Systems Design

Marc Goetschalckx

Roller Conveyor in Order Picking

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Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Power and Free Buffer in Automotive Assembly

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Logistics Systems Design

Power and Free in Automotive Engine Assembly

Marc Goetschalckx

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Power and Free in Automotive Final Assembly

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Logistics Systems Design

Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.

Marc Goetschalckx

Logistics Systems Design

Marc Goetschalckx

Automated Electrified Conveyor in Typewriter Manufacturing

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Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Cranes and Hoists Characteristics ” ” ” ” ”

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Bridge Crane Illustration

Overhead devices with vertical movement Intermittent movement Limited access area Medium hardware costs Medium volume

Logistics Systems Design

Marc Goetschalckx

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Bridge Crane for Aircraft Engine Transport

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Logistics Systems Design

Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.

Logistics Systems Design

Marc Goetschalckx

Moveable Bulk Crane Illustration

Marc Goetschalckx

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Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Gantry Cranes Unloading a Container Ship

Mobile Harbor Crane

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Logistics Systems Design

Marc Goetschalckx

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Gantry Crane Example

Logistics Systems Design

Cranes and Hoists Access Areas ”

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Logistics Systems Design

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Marc Goetschalckx

Marc Goetschalckx

21-Jul-03

Circular jib access area

”

Logistics Systems Design

Rectangular bridge crane access area

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Industrial Trucks Characteristics ” ” ” ” ” ”

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Industrial Trucks Illustration: Counterbalanced Lift Truck

Moving vehicles on wheels Intermitted movement Variable paths Very wide access area Low hardware cost Low volume

Logistics Systems Design

Marc Goetschalckx

21-Jul-03

Pallet Jack and Tractor

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Logistics Systems Design

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Logistics Systems Design

Marc Goetschalckx

Tractor Trailer Example

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Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Straddle and Counterbalanced Forklift Trucks

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Logistics Systems Design

Marc Goetschalckx

Block Stacking Operation With Counterbalanced Truck

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Order Picking Truck

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Logistics Systems Design

Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.

Logistics Systems Design

Marc Goetschalckx

Stacker Cranes Example

Marc Goetschalckx

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Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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AGV With Collision Bumpers

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Logistics Systems Design

Marc Goetschalckx

AGVS With Load Station

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AGV Load Station

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Logistics Systems Design

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Logistics Systems Design

Marc Goetschalckx

AGVS to ASRS Interface

Marc Goetschalckx

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Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Multiload AGV in Semiconductor Manufacturing

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Logistics Systems Design

Marc Goetschalckx

Multiload AGV Interfacing With Clean Room

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AGVS and Gantry Cranes for Intermodal Containers

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Logistics Systems Design

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Marc Goetschalckx

Logistics Systems Design

Marc Goetschalckx

Stacker Cranes for Intermodal Containers

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Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Containers Characteristics ”

Container Examples

To maintain a unit load

” ” ”

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Logistics Systems Design

Marc Goetschalckx

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Storage Equipment Characteristics ”

Pallet Tote box Intermodal container

Logistics Systems Design

Marc Goetschalckx

Storage Equipment Examples

To hold materials

”

Person-to-part y y y y

”

Block stacking Pallet rack Gravity flow rack Bin shelving

Part-to-person y Carousels y Miniload

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Logistics Systems Design

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Marc Goetschalckx

21-Jul-03

Logistics Systems Design

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Logistics Systems Design: Material Handling Systems

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Block Stacking Storage of Household Appliances

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Logistics Systems Design

Bin Shelving

Marc Goetschalckx

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Order Picking From Bin Shelving

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Logistics Systems Design

Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.

Logistics Systems Design

Marc Goetschalckx

Pallet Rack

Marc Goetschalckx

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Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Shelves With Quantity Displays (Pick-to-light)

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Logistics Systems Design

Marc Goetschalckx

Small Parts Carousel Example

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Auxiliary Equipment Types ” ” ” ” ” ” ” ” 21-Jul-03

Logistics Systems Design

Marc Goetschalckx

Pallet Positioners

Bar code readers Stretch wrappers Palletizers Lift tables Measuring frames Air film handling equipment Radio frequency terminals .. Logistics Systems Design

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Marc Goetschalckx

21-Jul-03

Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Voice Communications for Hands-free Order Picking

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Logistics Systems Design

Marc Goetschalckx

Radio Frequency Communications Terminals

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Storage & Retrieval Characteristics ”

21-Jul-03

Logistics Systems Design

Marc Goetschalckx

Unit Load AS/RS Illustration

Combined handling and storage

Logistics Systems Design

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Marc Goetschalckx

21-Jul-03

Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Unit Load Storage System With Multiple Aisles

Storage & Retrieval Types ”

Part-to-person y y y y y y

”

Unit load AS/RS Miniload (storage drawer) Microload (tote stacker) Carousel with extractor V and A frame order picking Deep lane storage

Person-to-part y Person-aboard

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Logistics Systems Design

Marc Goetschalckx

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Unit Load System Example

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Logistics Systems Design

Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.

Marc Goetschalckx

Logistics Systems Design

Marc Goetschalckx

Unit Load ASRS for Paper Rolls

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Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Unit Load ASRS for Thread Coils

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Logistics Systems Design

Marc Goetschalckx

Miniload Example

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Deep Lane Storage System Detail

21-Jul-03

Logistics Systems Design

Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.

Marc Goetschalckx

Logistics Systems Design

Marc Goetschalckx

Deep Lane Storage System

21-Jul-03

Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Unit Load, Deep Lane, Storage Retrieval System Detail

Deep Lane Storage Example

Activ System Detail (Retrotech) 21-Jul-03

Logistics Systems Design

Marc Goetschalckx

21-Jul-03

Unit Load, Deep Lane, Automated Staging Warehouse

Logistics Systems Design

Marc Goetschalckx

A-Frame Automatic Order Picking Example Detail

Activ System (Retrotech) 21-Jul-03

Logistics Systems Design

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Marc Goetschalckx

21-Jul-03

Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

21-Jul-03

Person-aboard Example: Inside the Aisle View

Person-aboard Example

21-Jul-03

Logistics Systems Design

Marc Goetschalckx

21-Jul-03

Robot Characteristics ” ” ”

21-Jul-03

Logistics Systems Design

Marc Goetschalckx

Robot Degrees of Freedom

Programmable Anthropomorphic (gripper) General purpose (multifunctional)

Logistics Systems Design

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Marc Goetschalckx

21-Jul-03

Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

21-Jul-03

Six Degree of Freedom Robot Example

Japanese Robot Classification n o p q r s

Manual manipulator Fixed sequence robot Variable sequence robot Play back robot Numerically controlled robot Intelligent robot

Fanuc 710i 21-Jul-03

Logistics Systems Design

Marc Goetschalckx

21-Jul-03

Robot Application Areas ”

21-Jul-03

Marc Goetschalckx

Robotic Processes

3 D areas

”

y Dull y Dirty y Dangerous ”

Logistics Systems Design

” ”

Spot and arc welding Pick and place Paint spraying

70 % automotive industry

Logistics Systems Design

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Marc Goetschalckx

21-Jul-03

Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Welding Robot Example

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Logistics Systems Design

Pick and Place Robot Example

Marc Goetschalckx

21-Jul-03

Robotic Assembly

21-Jul-03

Logistics Systems Design

Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.

Logistics Systems Design

Marc Goetschalckx

Robotic Machine Part Loading

Marc Goetschalckx

21-Jul-03

Logistics Systems Design

Marc Goetschalckx

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Logistics Systems Design: Material Handling Systems

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Pick and Place Palletizing Robot Example

Motoman K3crpic

Motoman 21-Jul-03

Pick and Place Clean Room Robot

Logistics Systems Design

Marc Goetschalckx

21-Jul-03

Robotic Part Unloading With Vacuum

21-Jul-03

Logistics Systems Design

Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.

Marc Goetschalckx

Logistics Systems Design

Marc Goetschalckx

Robotic Spray Painting in Automotive Assembly

21-Jul-03

Logistics Systems Design

Marc Goetschalckx

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