Logistics Systems Design: Material Handling Systems
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Logistics Systems Design: Material Handling Systems
Material Handling Systems Overview
13. 14.
Material Handling Systems Material Handling Models
Definition
Classifications
15.
Warehousing Systems
16.
Storage Models
17.
Order Picking Models
Logistics Systems Design
Marc Goetschalckx
21-Jul-03
Material Handling Definition
y Movement y Storage, and y Control
Of materials in a process
Logistics Systems Design
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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
Marc Goetschalckx
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Logistics Systems Design: Material Handling Systems
21-Jul-03
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
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
Marc Goetschalckx
21-Jul-03
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
21-Jul-03
Material Handling Systems Overview
Classification of Material Handling
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
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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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
Marc Goetschalckx
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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
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Logistics Systems Design
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Logistics Systems Design: Material Handling Systems
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Classification of Material Handling
Categories of Methods
n
by Material
o
by Method by Equipment
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
21-Jul-03
Manual Handling Equipment: Wheelbarrow
21-Jul-03
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
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
Marc Goetschalckx
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Logistics Systems Design: Material Handling Systems
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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
21-Jul-03
Conveyors Characteristics
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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
Asynchronous y Automated electrified monorail (AEM)
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Logistics Systems Design
Marc Goetschalckx
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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
21-Jul-03
Belt Conveyor in Electronics Assembly
21-Jul-03
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
13·9
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
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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
21-Jul-03
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
21-Jul-03
Bridge Crane for Aircraft Engine Transport
21-Jul-03
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
21-Jul-03
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
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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
21-Jul-03
Logistics Systems Design
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.
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
21-Jul-03
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
21-Jul-03
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
21-Jul-03
AGVS and Gantry Cranes for Intermodal Containers
21-Jul-03
Logistics Systems Design
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.
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
21-Jul-03
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
Copyright © 1994-2003, Marc Goetschalckx, All rights reserved.
Marc Goetschalckx
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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
21-Jul-03
Order Picking From Bin Shelving
21-Jul-03
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
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Logistics Systems Design
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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
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Logistics Systems Design
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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
21-Jul-03
Unit Load System Example
21-Jul-03
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
21-Jul-03
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
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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
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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
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Logistics Systems Design
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Logistics Systems Design: Material Handling Systems
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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
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Logistics Systems Design
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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
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Logistics Systems Design
Marc Goetschalckx
Robotic Machine Part Loading
Marc Goetschalckx
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Logistics Systems Design
Marc Goetschalckx
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Logistics Systems Design: Material Handling Systems
21-Jul-03
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
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Marc Goetschalckx
Logistics Systems Design
Marc Goetschalckx
Robotic Spray Painting in Automotive Assembly
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Logistics Systems Design
Marc Goetschalckx
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