mat handling

7/21/2019 Mat Handling

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ME 486 - AutomationME 486 - Automation


Materials Handling Ed Red


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To review modern technologies for material handling:

- Part handling

- AGVs

- ASRS

- conve!ors

To consider a""lication conditions #st$dent "resentations%

To introd$ce assessment criteria

To test $nderstanding of the material "resented

&'(ectives


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Material handling "rinci"les

Principle 1 - PLANNING PRINCIPLE:All material handling should be the result o adeliberate plan !here the needs" perormance ob#ecti$es" and unctional speciication

o the proposed methods are completel% deined at the outset&

'he plan should be de$eloped in consultationbet!een the planner(s) and all !ho !ill

use and beneit rom the e*uipment to be emplo%ed&

+uccess in planning large-scale material handling pro#ects generall% re*uires a team

approachin$ol$ing suppliers" consultants !hen appropriate" and end user specialists

rom management" engineering" computer and inormation s%stems" inance" and

operations&

'he plan shouldpromote concurrent engineeringo product" process design" process

la%out" and material handling methods as opposed to independent and se*uential

design practices&

'he plan should relect the strategic ob#ecti$es o the organi,ationas !ell as the more

immediate needs&

( rom Groo$er )


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Princi"le - +'AN.AR.I/A'l0NPRINCIPLE:aterial handling methods"

e*uipment" controls" and sot!are should be standardi,ed !ithin the limits o

achie$ing o$erall perormance ob#ecti$es and !ithout sacriicing needed le2ibilit%

modularit%" and throughput&

+tandardi,ation means less $ariet% and customi,ationin the methods and e*uipmentemplo%ed&

+tandardi,ation applies to si,es o containers and other load orming componentsas

!ell as operating procedures and e*uipment&

'he planner should select methods and e*uipment that canperorm a $ariet% o tas3sunder a $ariet% o operating conditionsand in anticipation o changing uture

re*uirements&

+tandardi,ation" le2ibilit%" and modularit% must not be incompatible&

Material handling "rinci"les ( rom Groo$er )


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Principle 4 - 50R6 PRINCIPLE:aterial handling !or3 should be minimi,ed !ithout

sacriicing producti$it% or the le$el o ser$ice re*uired o the operation&

'he measureo material handling !or3 is lo! rate($olume" !eight" or count per unit

o time) multiplied b% distance mo$ed&

Consider each pic3up and set-do!n" or placing material in and out o storage" as

distinct mo$es and components o the distance mo$ed&

+impli%ing processesb% reducing" combining" shortening" or eliminating unnecessar%

mo$es !ill reduce !or3&

5here possible" gra$it%should be used to mo$e materials or to assist in their

mo$ement !hile respecting consideration o saet% and the potential or product

damage&



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Principle 4 - 50R6 PRINCIPLE:aterial handling !or3 should be minimi,ed !ithout

sacriicing producti$it% or the le$el o ser$ice re*uired o the operation&

'he 5or3 Principle applies uni$ersall%" rom mechani,ed material handling in aactor% to o$er-the-road truc3ing&

'he 5or3 Principle is implemented best b% appropriate la%out planning: locating the

production e*uipment into a ph%sical arrangement corresponding to the lo! o !or3&

'his arrangement tends to minimi,e the distances that must be tra$eledb% the

materials being processed&



7/41ME 486 - AutomationME 486 - AutomationME 486 - AutomationME 486 - Automation

Principle 7 - ERG0N0IC PRINCIPLE:8uman capabilities and limitations must be

recogni,ed and respected in the design o material handling tas3s and e*uipment to

ensure sae and eecti$e operations&

Ergonomicsis the science that see3s to adapt !or3 or !or3ing conditions to suit theabilities o the !or3er&

'he material handling !or3place and the e*uipment must be designed so the% are sae

or people&

'he ergonomic principle embraces bothph%sical and mental tas3s&

E*uipment should be selected that eliminates repetiti$e and strenuous manuallabor

and that eecti$el% interacts !ith human operators and users&




Principle 9 - NI' L0A. PRINCIPLE:nit loads shall be appropriatel% si,ed and

conigured in a !a% !hich achie$es the material lo! and in$entor% ob#ecti$es at each

stage in the suppl% chain&

A unit loadis one that can be stored or mo$ed as a single entit% at one time" such as a

pallet" container" or tote" regardless o the number o indi$idual items that ma3e up theload&

Less eort and !or3 are re*uired to collect and mo$e man% indi$idual items as a

singleloadthan to mo$e man% items one at a time&

Large unit loads are common in both pre- and post-manuacturing in the orm o ra!materials and inished goods&

+maller unit loadsare consistent !ith manuacturing strategies that embrace operating

ob#ecti$es such as le2ibilit%" continuous lo! and #ust-in-time deli$er%&+maller unit

loads (as e! as one item) %ield less in-process in$entor% and shorter item throughput

times&




Princi"le; - +PACE 'ILI/A'I0N PRINCIPLE:Eecti$e and eicient use must be

made o all a$ailable space&

+pace in material handling is three-dimensionaland thereore is counted as cubicspace&

In storage areas" the ob#ecti$e o ma2imi,ing storage densit% must be balanced against

accessibilit% and selecti$it%&

5hen transporting loads !ithin a acilit%" the use o o$erhead spaceshould be

considered as an option& se o o$erhead material handling s%stems sa$es $aluable

loor space or producti$e purposes&




Princi"le< - +=+'E PRINCIPLE:aterial mo$ement and storage acti$ities should be

ull% integrated to orm a coordinated" operational s%stem that spans recei$ing"

inspection" storage" production" assembl%" pac3aging" uniti,ing" order selection"

shipping" transportation" and the handling o returns&

+%stems integration should encompass the entire suppl% chain" including re$erse

logistics& It should include suppliers" manuacturers" distributors" and customers&

In$entor% le$els should be minimi,edat all stages o production and distribution !hile

respecting considerations o process $ariabilit% and customer ser$ice&

Inormation lo! and ph%sical material lo! should be integrated and treated as

concurrent acti$ities&

ethods should be pro$ided or easil% identi%ing materials and products" or

determining their location and status !ithin acilities and !ithin the suppl% chain" and

or controlling their mo$ement&




Princi"le> - A'0A'I0N PRINCIPLE:aterial handling operations should bemechani,ed and?or automated !here easible to impro$e operational eicienc%"

increase responsi$eness" impro$e consistenc% and predictabilit%" decrease operating

costs" and eliminate repetiti$e or potentiall% unsae manual labor&

In an% pro#ect in !hich automation is being considered"pre-e2isting processes and

methods should be simpliiedand?or re-engineered beore an% eorts to installmechani,ed or automated s%stems& +uch anal%sis ma% lead to elimination o

unnecessar% steps in the method& I the method can be suicientl% simpliied" it ma%

not be necessar% to automate the process&

Items that are e2pected to be handled automaticall% must ha$e standard shapes and?or

eaturesthat permit mechani,ed and?or automated handling&

Interace issuesare critical to successul automation" including e*uipment-to-

e*uipment" e*uipment-to-load" e*uipment-to-operator" and in-control communications&

Computeri,ed material handling s%stemsshould be considered !here appropriate or

eecti$e integration o material lo! and inormation management&




Principle @ - ENIR0NEN'AL PRINCIPLE:En$ironmental impact and energ%

consumption should be considered as criteria !hen designing or selecting alternati$e

e*uipment and material handling s%stems&

En$ironmental consciousnessstems rom a desire not to !aste natural resources and to

predict and eliminate the possible negati$e eects o our dail% actions on the

en$ironment&

Containers" pallets" and other productsused to orm and protect unit loads should be

designed or reusabilit% !hen possible and?or biodegradabilit% ater disposal&

aterials speciied as ha,ardous ha$e special needs!ith regard to spill protection"

combustibilit%" and other ris3s&




Principle 1B - LIE C=CLE C0+' PRINCIPLE:A thorough economic anal%sis should

account or the entire lie c%cle o all material handling e*uipment and resulting s%stems&

Lie c%cle costsinclude all cash lo!s that occur bet!een the time the irst dollar is spent

to plan a ne! material handling method or piece o e*uipment until that method and?ore*uipment is totall% replaced&

Lie c%cle costs include capital in$estment" installation" setup and e*uipment

programming" training" s%stem testing and acceptance" operating (labor" utilities" etc&)"

maintenance and repair" reuse $alue" and ultimate disposal&

Aplan or pre$enti$e and predicti$e maintenanceshould be prepared or the e*uipment"

and the estimated cost o maintenance and spare parts should be included in the economic

anal%sis&




Principle 1B - LIE C=CLE C0+' PRINCIPLE:A thorough economic anal%sis should

account or the entire lie c%cle o all material handling e*uipment and resulting s%stems&

A long-range plan or replacement o the e*uipment!hen it becomes obsolete should be

prepared&

Although measurable cost is a primar% actor" it is certainl% not the onl% actor in

selecting among alternati$es& 0ther actors o a strategic nature to the organi,ation and

that orm thebasis or competition in the mar3et placeshould be considered and

*uantiied !hene$er possible&




A$tomated G$ided Vehicle #AGV%

Definition- An AGV is an inde"endentl! o"erated vehicle

that moves material along defined "aths 'etween defined

deliver! "oints or stations) T!"icall! the "aths are defined

'! either $sing wires em'edded in the floor or reflecting

"aint stri"s on the floor)

Some of the more advanced

technologies $se lasertriang$lation or inertial g$idance

s!stems on-'oard the vehicles*

with distri'$ted cali'ration

stations for "osition $"dating)



AGV classification

+riverless trains- AG is a to!ing $ehicle used to to! one or more trailers

orming a train bet!een stations&

Pallet tr$c,s - sed to mo$e palleti,ed loads along predetermined routes&

'%picall%" personnel !ill steer the AG to the pallet" ac*uire the pallet" then

steer it to the guide-path !here the automated guidance s%stem !ill then

mo$e it to its destination& In a sense" it can be thought o as an automated

or3lit&

nit load carriers - o$e unit loads rom rom one station to another

station& A $nit loadis a collection o items that is deli$ered repetiti$el% as a

unit&



AGV a""lications

+riverless train o"erations- o$ement o large material *uantit% o$er large distances

(bet!een buildings" !arehouses)&

Storagedistri'$tion s!stems- ses unit load carriers and pallet truc3s to transer material

bet!een stations" sometimes interacing !ith other automated s%stems such as an A+?R+

(Automated +torage and Retrie$al +%stem)& 5or3s !ell in assembl% operations !here theunit loads (or 3its) can be transerred rom a central storage area to assembl% sites&

Assem'l! line o"erations- AGDs become part o the assembl% operation b% transerring

material along an assembl% line (such as mo$ing an engine bloc3 bet!een operational

stations)

.le/i'le man$fact$ring s!stems #.MS%- AGDs are used to transer parts" materials andtooling bet!een the + process stations&

Miscellaneo$s a""lications- Non-manuacturing applications include the handling o

sensiti$e !aste" transportation o material at hospitals" mail transportation&



AGV g$idance and control

Guidance and control functions:

ehicle guidance - on-board control s%stem to mo$e the $ehicle along pre-deined paths b%

a eedbac3 loop bet!een the control s%stem and the guide !ire (or paint)& ore modern

s%stems use inertial guidance to mo$e the AG bet!een calibration stations& In situations

!here the guide !ire or paint is discontinuous" the control s%stem uses dead rec3oning to

transition these points&

'raic control - collision a$oidance bet!een multiple AGDs& 'he control s%stem is

designed !ith bloc3ing algorithms that use a combination o on-board $ehicle sensing

and ,one control&

+%stems management- programming interaces and algorithms or mo$ing AGDs bet!een

stations" and or scheduling the mo$ement o multiple AGDs&



AGV material handling anal!sis

Terms:

$c- AG a$erage speed(c con$e%or" carrier" cart" etc&)

$e- AG empt% speed

'h- load handling time

Ld- destination distance

Le- empt% mo$e distance

'- traic actor (F 1)

Eh- handling s%stem eicienc%

A - proportion o time $ehicle is operational

A'- a$ailable time in min?hr?$eh

E - !or3er eicienc%

Rd$- rate o deli$eries per $ehicle

nc- number o carriers re*uired

R- speciied lo! rate o s%stem (del?hr)

'c- deli$er% c%cle time (min?del)

'L- time to load at load station (min)

'- time to unload at load station (min)

5L - !or3load (total !or3 in min per hour)



AGV material handling anal!sis

Equations:

del cycle time 'c '

L '

L

d? $

c L

e? $

e (min)

available time A' ;B A 'E (min?hr?$eh)

rate of del per vehicle Rd$

A' ? 'c

(num del?hr?$eh)

work by handling system per hr 5L R'

c(min?hr)

num of vehicles for workload nc 5L?A' R

? R

d$(num o $eh or !or3 load)


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AGV 0$estions

5ho are ma#or $endors o AGDsK

.escribe their components (po!er source" transmission s%stem"

communication s%stem" etc&)K

5hat are t%pical costsK

5hat t%pe o interaces do the% ha$eK 8o! are the% programmedK 8o! ast do the% mo$eK

5hat are load to !eight ratiosK

nusual maintenance re*uirementsK

8o! do the% a$oid collisionsK

8o! are the% scheduledK


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ME 486 - AutomationME 486 - AutomationME 486 - AutomationME 486 - Automation

A$tomated Storage and Retrieval S!stem

#ASRS%

+efinition- An A+?R+ is a

combination o e*uipment and

controls !hich handles" stores"

and retrie$es materials !ith

precision" accurac%" and speed

under a deined degree o

automation& (aterials 8andling Institute)


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ASRS classification

nit load ASRS- Large automated s%stem designed to use +?R machines to

mo$e unit loads on pallets into and out o storage rac3s&

Mini-load ASRS- +maller automated s%stem designed to mo$e smaller

loads into and out o storage bins or dra!ers&

Man-on-'oard ASRS- ses personnel to pic3 items rom rac3s or bins"

reducing transaction time&

A$tomated item retrieval s!stem- Items to be mo$ed are stored in single

ile lanes" rather than in bins or dra!ers&


25/41


ASRS a""lications

nit load storage and handling- 5arehousing or inished

goods?products&

&rder "ic,ing- sed to store and retrie$e materials in less than ull unit

load *uantities" such as man-on-board or mini-load applications&

3or,-in-"rocess- +upport #ust-in-time production acti$ities" buer storage"

and as integral part o assembl% s%stems&


26/41


ASRS control

'he +?R is a large Cartesian t%pe robot that integrates

modern control technolog%" I?0" and sensors

(compartment identiication) to mo$e bet!een storage

compartments& A+?R+ control is integrated !ith modern

material management sot!are or real-time in$entor%control" storage transactions" and material deli$er%&


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ASRS material handling anal!sisTerms:

C capacit% per aisle

2 - !idth o unit load

% - length o unit load (in hori,ontal direction)

, - height o unit load (in $ertical direction)

n,- number o $ertical compartments

n%- number o hori,ontal compartments

- s%stem utili,ation per hr

5 - !idth o A+?R+ rac3

8 - height o A+?R+ rac3

L - length o A+?R+ rac3

$,- $ertical speed (m?min" t?min)$

%- hori,ontal speed (m?min" t?min)

t,- $ertical tra$el time (min)

t%- hori,ontal tra$el time (min)

'cs- single command c%cle time (min?c%cle)

'cd- dual command c%cle time (min?c%cle)

'pd pic3up and deposit time (min)

Rcs- num o single commands per hrRcd- num o dual commands per hr

Rc- total c%cle rate in c%cles?hr

Rt- num transactions per?hr


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ASRS material handling anal!sis

Equations:

AS/RS dimensions 5 4 (2 a) a ; inL n%(% b) b > in

8 n,(, c) c 1B in

capacity per aisle C n%

n,

single command cycle 'cs a2 ML?$

%" 8?$

, '

pd Ouniform racks,

random storage

dual command cycle 'cd

a2 M1&9 L?$%" 1&9 8?$

, 7 '

pd

utilization ;B Rcs 'cs Rcd 'cd

hourly cycle rate Rc R

cs R

cd

num transactions per hr Rt R

cs R

cd


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ASRS e/am"le #from te/t%

Given a 1 aisle ASRS la!o$t* each aisle contains 42 hori5ontal rac,s and 67 vertical rac,s)

nit load dimensions are / 8 17 in* ! 8 19 in* and 5 8 4 in) The SR machine has a hori5ontal

s"eed of 722 ftmin and vertical s"eed of ;< ftmin) =t ta,es 72 s for a P>+ o"eration) .ind

a% ?$m of $nit loads that can 'e stored

'% Total dimensions of ASRS

c% Single and d$al command c!cle times

d% Thro$gh"$t "er aisle ass$ming $tili5ation 8 @2 and n$m of single command

c!cles e0$als the n$m of d$al command c!cles

Sol$tion:

Total ca"acit! 8 1B 8 #1% 7 n! n58 #1%#7%#42% #67% 8


30/41


ASRS e/am"le #cont%

Solution:

Single command c!cle time 8 Tcs8 Ma/F792722*14;


31/41


ASRS 0$estions

1& 5ho are ma#or $endors o A+?R+K

& .escribe their components (po!er source" transmission s%stem"

communication s%stem" etc&)K

4& 5hat are t%pical costsK

7& 5hat t%pe o interaces do the% ha$eK 8o! are the% programmedK

9& 8o! ast do the% mo$eK

;& 5hat are load capabilitiesK

& 5hat t%pe o +?R control is usedK PI.K@& 5ho are primar% usersK


32/41


Bonve!ors

+efinition - A con$e%or is a

mechani,ed de$ice to mo$e

materials in relati$el% large

*uantities bet!een speciic

locations o$er a i2ed path&


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Bonve!ors

Roller conve!ors- +eries o tube rollers perpendicular to motion direction" !hich can bepo!ered or use gra$it% or motion&

S,ate-wheel conve!ors- +imilar to rollers but use s3ate !heels parallel to motion direction&

elt conve!ors- .ri$es mo$e lat or belts shaped into a trough&

Skate

wheel

Belt


34/41


Bonve!ors

Bhain conve!ors- ses loops o chain

that are t%picall% mo$ed b% sproc3ets asdri$en b% motors&

&verhead trolle! conve!ors- Items are

mo$ed in discrete loads b% hoo3s or

bas3ets suspended rom o$erhead rails&

Trolley


35/41


Bonve!ors

=n-floor towline conve!ors- +imilar to

o$erhead trolle% but carts are pulled b%

hoo3 to in-loor con$e%or&

Bart on trac, conve!ors- Items are

mo$ed b% a cart attached to a rails%stem" !hich uses a rotating tube to

mo$e the cart along the rail&

Towline


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Bonve!or material handling

Terms:

$c carrier a$erage speed

(c con$e%or" carrier" cart" etc&)

sc material spacing on con$e%or

'L loading time (min)

' unloading time (min)

R material lo! rate (parts?min)

Ld distance bet!een load and unload

Ledistance o return loop (empt%)

L length o con$e%or loop

'd deli$er% time

np number o parts per carrier

nc number o carriers

RL loading rate (parts?min)

R unloading rate (parts?min)

'c total c%cle time (min)

Np total number o parts in s%stem

Note: I one part per carrier" then part lo! rate

is carrier lo! rate&


37/41


Bonve!or handling anal!sis

Equations single direction:

time from load to unload 'd L

d?$

c (min)

Odeli$er% time deli$er% distance di$ided b% carrier speed

material flow rate (np

!" R

RL

$c

?sc

1? 'L

(num carriers?min)

Os%stem lo! rate loading rate lo! rate o carriers on con$e%or

material flow rate (np# !" R

n

p$

c?s

c 1? '

L(num parts per min)

Os%stem lo! rate loading rate o parts lo! rate o parts on con$e%or

unloading constraint ' '

L(min)

Ounloading time must be less than loading time or else pile up carriers


38/41



Equations continuous loop:

time to complete loop 'c L

?$

c (min)

Oull loop carrier time loop distance di$ided b% carrier speed

time in delivery 'd

Ld

?$c

(min)

Odeli$er% time deli$er% distance di$ided b% carrier speed

number of carriers nc L

?s

c

Onum o carriers loop distance di$ided b% carrier spacing

total parts in system Np n

pn

cL

d? L

Oparts in s%stem num o parts per carrier times num carriers !ith parts

material flow rate R n

p$

c?s

c (num carriers per min)

Omaterial lo! rate num parts per carrier times carrier lo! rate


39/41



Equations recirculating:

Speed rule $ operating conveyor speed must fall within a certain range

from load/unload rates R n

p$

c?s

c a2MR

L" R

Olo! rate o parts on con$e%or must e2ceed the ma2 load or unload part rate to maintain part spacing

from time to load/unload carriers $c?s

c inM1?'

L"1?'

Olo! rate o carriers on con$e%or must e2ceed the ma2 load or unload carrier rate to maintain part spacing

%apacity constraint $conveyor capability (np vc/sc" must e&ceed desired/specifiedflow rate R

f

conveyor speed and carrier parts np

$c?s

c R

'niformity principle $loads should be distributed uniformly over the conveyor


40/41


Bonve!or 0$estions

1& 5ho are ma#or $endors o con$e%orsK

& .escribe their components (po!er source" transmission s%stem" I?0

subs%stem" etc&)K4& 5hat are t%pical costsK

7& 8o! are the% programmed and controlledK

9& 8o! ast do the% mo$eK

;& 5hat are load capabilitiesK

& 5ho are primar% usersK


41/41

Material handling

What have we learned?

mat handling

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