mhse part 01

TVSM / PED / MSE / MHSE Slide 1

MATERIAL HANDLING SYSTEM

ENGINEERING (MHSE)

(Logistics Engineering)

Course Code : GCE

Thiagarajar College of Engineering

2013-2014


Course Objectives:

1. Understand and map process and material flow.

2. Access the potential failure modes in material storage and handling between

POM/POS to POC.

3. Design material storage and handling system to prevent potential failure

modes.

4. Verify produced part quality is delivered to the point of consumption

5. Apply "OR" (Operation Research) and REBA/RULA tools and techniques in

storage and material handling system design.

6. Develop standardized storage and handling work procedures.


1 - INTRODUCTION TO MATERIAL HANDLING SYSTEM

Need, scope, definitions and terminologies, types, elements, Organization for logistics

management and control. Introduction Types of Material Handling Equipments (AGVs,

Fork lift, prime movers, stackers, lifts etc), selection criteria for MHES Process flow

charting/mapping techniques

2 - DESIGNING OF MATERIAL HANDLING FACILITIES

Design considerations for MHF, selection of materials. Estimation of number of facilities

required; cost estimation and control. Introduction to thermoforming/injection molded

crate design and manufacturing for kitting of the parts.

3 ERGONOMICS IN MATERIAL HANDLING FACILITIES DESIGN

Application of RULA & REBA in MHF design, MHF design considerations for plastic

parts, painted Parts, machined parts, fragile parts, c class parts, inter-plant material

movement, and in-direct areas.

Course Contents:


5 - STORAGE SYSTEM

Creation of modern stores and storage systems: concept of stores, types of stores,

storage facilities, considerations for creation of stores, estimation of docks, truck turn-

around time, truck window time, inventory and types, WIP, material retention point,

model store concept.

6 ANALYSIS OF MATERIAL HANDLING SYSTEMS

Analysis of Vehicle based system- determination of number of vehicles in AGVs and

determination of delivery distance. Conveyor analysis single direction, continuous

loop and re-circulating conveyors

4 - MEASURES OF MATERIAL HANDLING SYSTEM

Reliability, maintainability, serviceability, availability factors, Supply supports, TPM for

MHF, manufacturing consideration: processes, methods and tools, assembly and

dismantling of MHF, system feasibility analysis, system operational requirements,

Supportability analysis, functional analysis, MTBF and MTTR for MHFs, flexibility in

MHFs, traceability of MHFs and MHEs, salvaging of MHFs and MHEs


References:

1. Blanchard and Benjamin S, Logistics Engineering and Management, 6th

International Edition, Prentice Hall Inc, 2004.

2. Christopher M, Logistics and Supply Chain Management - Creating Value

Adding Networks, Prentice Hall, 2005.

3. James M. Apple, Plant Layout and Material Handling John Wiley, 3rd Edition,

1977.

4. Mikel P.Groover, Automation, Production Systems, and Computer-Integrated

Manufacturing, PHI Publishers, 3rd Edition 2008.

5. Prauss L, The Green Multiplier - a Study of Environmental Protection and

Supply Chain, Antonn Rauss Limited, Palgrave Macmillan, 2005.

6. Taylor G.D, Logistics Engineering handbook, CRC Press, 2008.

7. TVSM Material Handling Facilities Design Guidelines and Manuals


What is Logistics ?

The movement of goods through the supply chain

the art and science of obtaining, producing, and distributing material and product in the proper place and in proper quantities


Perspective of Logistics Industry

Global logistics industry is estimated to be worth USD 300 billion

The annual logistics in any country varies between 9% to 20% of their GDP

The annual logistics cost in India is estimated to be 14% of GDP whereas

automotive sector contributes to 7 to 8% of GDP.

Out of the total cost 99% is accounted by the unorganized sector

Ref: Logistics industry

analysis by market

research.com


Carried loads manually

Used animal carts Used animal carts

Used animals

Evolution of Logistics Industry



Ref: Logistics industry analysis by market research.com

TVSM / Operating Plan / Board / 21-Apr-2009Slide no. 12

PD Rollout /PED /Apr-13 Slide 12Inbound Logistics Supplier Training

SUPPLIERS

TVSMArea warehouse

Dealership

Material flowInformation flowCash flow

Inbound Logistics

InhouseLogistics

Outbound Logistics

Custome

Supply Chain Management


PD Rollout /PED /Apr-13 Slide 13Inbound Logistics Supplier Training

Web

SUPPLIERS

TVS-MSCHEDULES

JIT Call

(2Bin/Kanban)

PACKINGMILKRUN

Information flow

Material flow

Point of consumption

2Bin/ Kanban

Stores

WebAdvance

shipping

notification

Barcoded invoice

Assembly line

Weekly release

2Bin/Kanban

Containerisation:Milk run

Frequency: 90% of value daily

Inbound Logistics


PD Rollout /PED /Apr-13 Slide 14

Schedules

Information flow

Material flow

WebOrders -

MOS

Area warehouse Dealership

TVSMPrimary distribution

Secondary distribution

Schedules

Information flow

Material flow

WebOrders -

MOS

Area warehouse Dealership

TVSMPrimary distribution

Secondary distribution

Mfg. Plant

Outbound Logistics Overview

Transporters

Outbound Logistics


Manufacturing Plant Layout

2Bin stores

VU stores

Vehicle

assembly-

Mainline

Vehicle

assembly-

Pre-line

Vehicle

assembly-

Sub assyPainting

stores

Engine

storage

Testing &

BookingKitting area

In-house Logistics


Testing

Warehouse booking

Vehicle unit stores

Vehicle sub assy

Painted parts storage Plastic parts

Painted parts storage Metal parts

Schematic of vehicle assembly with supporting units

Engine assembly

Vehicle main line

Vehicle main line

Vehicle pre-line

Vehicle pre-line

2Bin stores

DP Stores

In-house Logistics


Material Handling System Engineering

In-house Logistics is also Referred as

Material handling System Engineering

Material Handling System Engineering Consists of

Handling Material Handling Facilities

Transfer Material Handling Equipment

Storage Material Storage Systems


Video


What is Material Handling ?


Material Handling System in Home

Kitchen equipment stand Kitchen equipment stand

Cell phone stand


Material Handling System - Definition

Material handling system is the art and science of moving, storing, protecting

and controlling the materials.

Materials handling system is the movement and storage of materials at the

lowest possible cost through the use of proper methods and equipment.

Material handling system is the function of moving the right material to the

right place in the right time, in the right amount, in sequence, and in the right

condition to minimize production cost.

The movement of raw material, semi-finished goods and finished articles

through various stages of production and warehousing.

Material Handling System


- Moving: Transfer of the material at the right time and the right place.

- Storing: Provides a buffer between operations, facilitates the efficient use of people and

machines.

Material handling



Material handling

- Protecting: Includes the packaging, packing against damage and theft.

- Controlling: Physical orientation, sequence and space between material.

Ratio counter Scanner



PD Rollout /PED /Apr-13 Slide 24

3W material handling facilities with modular concept and flexibility to accommodate future models

Chassis trolley

Shock absorber trolley

Wind sheld trolley

Engine trolley

Material Handling Facilities


Storage BinsStorage pallets Flow Rack System

Heavy Duty Racking System

Material Storage Facilities

Lean Lifts Over head Conveyor


Material Transfer Equipment

Hand pallet truck Battery pallet truck Loading/Unloading Conveyor

Stacker Reach Truck Fork Lift


Material Handling accounts for:

25% of all employees,

55% of all factory space,

87% of production time

15-70% of the total cost of a manufactured product

3-5% of all material handled becomes damaged

Totally eliminate

However, handling less is not the answer.

Importance of Material Handling System



Importance of material handling

The primary objective of a material handling system is to reduce the unit cost of

production.

Reduce manufacturing cycle time

Reduce delays, and damage

Promote safety and improve working conditions

Maintain or improve product quality

Improve productivity

Improve the utilization of facilities

Reduce tare weight

Control inventory



The essential requirements of a good materials handling system:

(i) Efficient and safe movement of materials to the desired place.

(ii) Timely movement of the materials when needed.

(iii) Supply of materials at the desired rate.

(iv) Storing of materials utilizing minimum space.

(v) Lowest cost solution to the materials handling activities.

Requirements of Material Handling System


Scope of material handling

Bulk materials as well as unit materials handing. Bulk handling is particularly relevant

in the processing, mining and construction industries.

Scope of Material Handling System


Scope of material handling

Industrial packaging of in-process materials, semi finished or finished goods, primarily

from the point of view of ease and safety of handling, storage and transportation.

Handling of materials for storage or warehousing from raw materials to finished

product stage.

Scope of Material Handling System


Material handling system equation

Why?

What? Where? When? How? Who? Which?

Material

Material handling systems alternatives

MethodsPreferred

systemMoves+ + +

Material Handling System Equation


The What Question

What are the types of material to be moved?

What are their characteristics?

What are the amounts moved and stored?



The Where Question

Where is the material coming from? Where should it come from?

Where is the material delivered? Where should it be delivered?

Where is the material stored? Where should it be stored?

Where can material handling tasks be eliminated, combined or simplified?

Where can you apply mechanization or automation?



The When Question

When is material needed? When should it be moved?

When is it time to mechanize or automate?

When should we conduct a material handling performance audit?



The How Question

How is the material moved or stored? How should material be moved or

stored? What are the alternative ways of moving or storing the material?

How much inventory should be maintained?

How is the material tracked? How should the material be tracked?

How should the problem be analyzed?



The Who Question

Who should be handling material? What are the required skills to perform the

material handling tasks?

Who should be trained to service and maintain the material handling system?

Who should be involved in designing the system?



The Which Question

Which material handling operations are necessary?

Which type of material handling equipment, if any, should be considered?

Which material handling system is cost effective?

Which alternative is preferred?



Characteristic and Classification of materials

Method to be adopted and choice of equipment for a materials handling system

primarily depends on the type of materials to be handled.

Basic classification of material is made on the basis of forms, which are

(i) Gases,

(ii) Liquids,

(iii) Semi liquids,

(iv) Solids.

Characteristic and Classification of Materials


Gases Handling

Gases are generally handled in tight and where required, pressure resisting

containers. However, most common method of handling of large volume of gas is

through pipes by the help of compressor, blower etc. This process is known as

pneumatic conveying.


Natural gas pipelinesLPG gas pipelines


Liquid Handling

Liquids and semi-liquids can be handled in tight or open containers which may be

fitted with facilities like insulation, heating, cooling, agitating etc.

Large quantity of stable liquids/semi-liquids are generally conveyed through pipes

using suitable pumps, which is commonly known as hydraulic conveying.


Oil pipelinesWater pipelines


Solids Handling

Solids form the majority of materials which are handled in industrial situation.

Solids are classified into two main groups:

- Bulk load

- Unit load.


Bulk load Unit load


Bulk load

- Bulk material handling is an engineering field that is centered around the design

of equipment used for the handling of dry materials such as ores, coal, cereals,

wood chips, sand.

- The purpose of a bulk material handling facility may be to transport material from

one to several locations



Unit load

- Picked up and moved between two locations as a single mass.

- These materials are counted by number of pieces like machine parts,

packed boxes, fabricated items.

Example:

1. A single item picked up and moved manually between two locations

2. Two tote pans with identical components picked up moved by a dolly from one

machine to another

3. One pallet load of nonuniform-size cartons with different products picked up and

moved by a lift truck from the packaging area to the shipping dock

4. One full load of products delivered by a truck trailer from a warehouse to a

customer store If the trailer is half full, it is still one unit load.



Advantages:

Standardized handling equipment

Standardized storage equipment

Reduced information and control burden

Efficient space utilization

Disadvantages:

Cost of assembly and disassembly

Cost of container and wrappings

Cost of empty container handling and disposal

Unit load - Advantages & Disadvantages



Classification of unit load

a) Shape of unit loads - Basic geometric forms like rectangular, cylindrical,

pyramidal/conical

b) Position of C.G. (stability) of load.

c) Mass of unit load in 10 steps from 0-2.5 kg to more than 5000 kg.

d) Volume per unit in 10 steps from 0-10 cm3 to more than 10 m3.

e) Type of material in contact with conveying system like metal, wood, paper/cardboard,

textile, rubber / plastics, glass and other materials.

f) Geometrical shape (flat, concave, convex, irregular/uneven, ribbed etc.) and physical

properties (smooth, slippery, rough, hard, elastic etc.) of base surface of unit load.



Classification of unit load

g) Specific physical and chemical properties of unit loads like abrasive, corrosive, dust

emitting, damp, greasy/oily, hot, cold, fragile, having sharp edges, inflammable, explosive,

hygroscopic, sticky, toxic, obnoxious, radioactive etc.

h) Loads sensitive to pressure, shock, vibration, turning/tilting, acceleration/deceleration,

cold, heat, light, radiation, damp etc.



MH

1. Planning

2. Systems

3. Material flow

4. Simplification

5. Gravity

6. Space utilization

7. Unit size

8. Mechanization9. Automation

10. Equipment

selection

11. Standardization

12. Adaptability

13. Dead weight

14. Utilization

15. Maintenance

16. Obsolescence

17. Control

18. Capacity

19. Performance

20. Safety

Material Handling System Principles

MH Principles


1. Planning :

Plan all material handling and storage activities to obtain maximum overall

operating efficiency.

2. System :

Integrate as many handling activities as is practical into a coordinated

system of operations, covering vendor, receiving, storage, production,

inspection, packaging, warehousing, shipping, transportation and customer.

3. Material flow :

Provide an operation sequence and equipment layout optimizing material

flow.



4. Simplification :

Simplify handling by reducing, eliminating or combining unnecessary

movements and/or equipment.

5. Gravity :

Utilize gravity to move material wherever practical.

6. Space utilization :

Make optimum utilization of building cube.



7. Unit size :

Increase the quantity, size or weight of unit loads or

flow rate.

8. Mechanization :

Mechanize handling operations.

9. Automation :

Provide automation to include both production,

handling and storage functions.



10. Equipment selection :

In selecting handling equipment consider all aspects of the material

handled , the movement and the method to be used.

11. Standardization :

Standardize handling methods, as well as types and sizes of handling

equipment.

12. Adaptability :

Use methods and equipment that can best perform a variety of tasks and

applications where special purpose equipment is not justified.



13. Dead weight :

Reduce ratio of dead weight of mobile handling equipment to load carried.

14. Utilization :

Plan for optimum utilization of handling equipment and manpower.

15. Maintenance :

Plan for preventive maintenance and scheduled repairs of all handling

equipment's.



16. Obsolescence :

Replace obsolete handling methods and equipment with more efficient

methods or equipment will improve operations.

17. Control :

Use material handling activities to improve control of production, inventory

and order handling.

18. Capacity :

Use handling equipment to help achieve desired production capacity.

19. Performance :

Determine effectiveness of handling performance in terms of expense per

unit handled.

20. Safety :

Provide suitable methods and equipment for safe handling.



Conditions for improvement

MH

Idle production

equipment due to

material shortage

Material piled

directly on floor

In-plant containers

not standardized

Operators travel

excessively for

materials and

suppliesExcessive

demurrage

Misdirected material

Backtracking of

material

Automatic data

collection system

not used

No pre-kitting of

work

System not capable

of change or

expansion

Conditions for improvements


Organization for MHFS :

Good organization of the materials handling system operation is essential for good

results.

Roles of Material handling operations organization:

To move the right material to the right destination on time.

To minimize production downtime due to materials handling breakdowns.

To minimize costs.

To minimize damage and accidents.

To supervise personnel and training effectively.

To report production, movement and inventory data.

To advise management.

To plan.

Organization for MHFS


Roles of the Material handling organization:

To move the material.

To staff the materials handling system.

To train materials handling personnel.

To supervise the system.

To report on the systems functioning.

To report production, movement and inventory data.

To advise management.

To plan.

Roles of MHS Organization


Roles of the Material handling organization:

These functions closely follow the objectives listed in the previous section.

These functions may differ from company to company owing to the nature of the

industry, union contracts, industry custom or other causes.

However, these functions are necessary in every company, the organizational

location may vary.



To move material

The major function and objective of the materials handling organization is

to deliver the right material to the right destination at the right time. This is

the reason for material handling. Other objectives and functions are

secondary.

To minimize downtime

In todays highly automated mass production, downtime in any part of the

system will shut the whole system down. The resulting loss of production

will be very costly to the company.



To minimize damage and accidents

Not only are accidents to material and personnel expensive, they interrupt

operations and may cause a shutdown. Since materials handling accounts

for a substantial proportion of all industrial accidents, the materials

handling supervisor should strive to keep these to a minimum.

To minimize costs

Materials handling operations should be carried out at minimum cost.



To supervise personnel and training effectively

A major part of the materials handling managers time will be spent

supervising and training workers. Achieving this objective leads to

achieving the major objective of moving the material.



To submit prompt and accurate reports

Prompt and accurate reports are essential to management control and

to efficient operation of the whole production system.



To advise management

The head of the materials handling department should be the person to

advise management on the materials handling function. He should keep

track of new technology that could improve the system.



To plan

Planning requires coordination with the plans and prospects of other

divisions of the company regarding future product lines, product

changes, volume changes, and relocations.



To report on the systems functioning

The system manager reports on the systems functioning in which only

deviations from the planned norms are reported. These include

breakdowns, personnel problems beyond the authority of the system

manager, and recommended replacements and improvements.



Material Handling Equipment


Material Handling Equipments

Material handling equipment is used to increase output, control costs, and

maximize productivity.

WHY ???

- To reduce manual efforts

Material handling equipment's


Types of Material handling equipment's

Types of material equipment's

3. Storage and Retrieval Equipment

Unit Load Storage and Retrieval

Unit Load Storage Equipment

Unit Load Retrieval Equipment

Small Load Storage and Retrieval

4. Automatic Data Collection and Communication Equipment

Automatic Identification and Recognition

Automatic Paperless Communication


Types of Material handling equipment's

Types of material equipment's

1. Containers and Unitizing Equipment

Containers

Unitizers

2. Material Transport Equipment

Conveyors

Industrial Vehicles

Monorails, Hoists, and Cranes


Factors Affecting the selection of Materials Handling Equipment

The selection of materials handling equipment requires the attaining of proper

balance between the production problem, the capabilities of the equipment available, and

the human element involved. The ultimate aim is to arrive at the lowest cost per unit of

material handled.

Selection of Material handling equipment's


Factors affecting the selection of Material Handling Equipment

MH

1. Adaptability

2. Flexibility

3. Load capacity

4. Power5. Speed

6. Space

requirement

7. Supervision

required

8. Ease of

maintenance

9. Environment10. Cost



Equipment factors to be taken into consideration may well include the following:

1. Adaptability: the load carrying and movement characteristics of the equipment should fit the materials handling problem.

2. Flexibility: Where possible the equipment should have flexibility to handle more than one material, referring either to class or size.

3. Load capacity: Equipment selected should have great enough load-carrying characteristics to do the job effectively, yet should not be too large and result in

excessive operating costs.

4. Power: Enough power should be available to do the job.

5. Speed: Rapidity of movement of material, within the limits of the production process or plant safety, should be considered.



Equipment factors to be taken into consideration may well include the following:

6. Space requirements: The space required to install or operate materials handling equipment is an important factor in its selection.

7. Supervision required: As applied to equipment selection, this refers to the degree of automaticity designed into the equipment.

8. Ease of maintenance: Equipment selected should be easily maintained at reasonable cost.

9. Environment: Equipment selected must conform to any environment regulations.

10. Cost: The consideration of the cost of the equipment is an obvious factor in its selection.



Selection method of equipment for Material movements


Manual handlingHand trucks

Powered trucks,Unit load AGV

ConveyorsConveyors,AGV trainHigh

Low

LongShort Move Distance

Quantity of material moved


Unitizers: Palletizer

Palletization is the task of taking cases and stacking them in layers on pallets for

storage and/or transportation.

Manual Palletizing is the most basic and also the most widely used method. Typically, workers remove cases from a conveyor line or an existing pallet load

and stack them onto a pallet.

Semi-Automatic Palletizing is used when case weight is a factor and workers are subject to back strain injuries, often resulting from manual palletizing. With a

semi-automatic system, a conveyor delivers product to an operator who arranges

the cases in layers on a variable height lift table.

Automatic Palletizing provides the fastest, most efficient and most ergonomical method of palletizing.

Automatic palletizerSemi-automatic palletizerManual palletizing

Material handling equipment's Palletizer


Unitizers: Stretchwrapper

Stretch wrapping is the most cost-effective way to keep loads secured on a pallet.

Manual stretch wrapping.

Semi-Automatic stretch wrapping.

Automatic stretch wrapping.

Automatic stretch wrapperSemi-automatic stretch wrapper

Manual stretch wrapping

Material handling equipment's Stretch wrapper


Conveyors A conveyor system is a common piece of mechanical handling equipment that moves

materials from one location to another.

Conveyors are especially useful in applications involving the transportation of heavy or

bulky materials.

Conveyor systems allow quick and efficient transportation for a wide variety of

materials, which make them very popular in the material handling and packaging

industries.

Various conveyor systems,

Chain conveyors

Belt conveyors

Slot conveyors

Roller conveyors

Belt conveyor Roller conveyorChain conveyor Slot conveyor

Material handling equipment's Conveyors


Automated guided vehicles

AGV AGV with load unit

An automated guided vehicle or automatic guided vehicle (AGV) is a mobile robot that

follows markers or wires in the floor, or uses vision or lasers. They are most often

used in industrial applications to move materials around a manufacturing facility or a

warehouse.

AGV with floor marking

Material handling equipment's AGV


Industrial Vehicles

Industrial trucks refer to the different kinds of transportation items and vehicles used

to move materials and products in materials handling. These transportation devices

can include small hand-operated trucks, pallet-jacks, and various kinds of forklifts.

These trucks have a variety of characteristics to make them suitable for different

operations. Some trucks have forks, as in a forklift, or a flat surface with which to lift

items, while some trucks require a separate piece of equipment for loading.

Trucks can also be manual or powered lift and operation can be walk or ride, requiring

a user to manually push them or to ride along on the truck.

Fork lift Stacker Hand pallet truckTractor truck

(Towing truck)

Material handling equipment's Industrial vehicles


Monorails

A monorail is a rail-based transportation system based on a single rail, which acts as

its sole support and its guide way. The term is also used variously to describe the

beam of the system, or the vehicles traveling on such a beam or track.

Types of monorail systems are,

1. Pipe rail system

2. Flat-bar monorail system

3. Structural rail system

Monorail system Monorail system Monorail system

Material handling equipment's Monorails


Hoists

A hoist is a device used for lifting or lowering a load by means of a drum or lift-wheel

around which rope or chain wraps. It may be manually operated, electrically or

pneumatically driven and may use chain, fiber or wire rope as its lifting medium. The

load is attached to the hoist by means of a lifting hook.

Its various types are,

1. Chain hand hoists

- Lever operated hoists

- Portable hand chain hoists

- Differential hoists

- Screw or Worm geared hoists

- Spur geared hoists

2. Powered hoists

- Electric hoists

- Pneumatic hoists

Chain hand hoists

Electric hoist Pneumatic hoist

Material handling equipment's Hoists


Cranes

Cranes are a combination of separate hoisting mechanisms with a frame for lifting or a

combination of lifting and moving loads which can be truly suspended on or secured to

them.

Generally it will be used in a factory, for repair and maintenance work and for

intermittent lifting jobs.

An important advantage of a crane equipped with a rotating boom is the high degree

of flexibility provided in picking up and placing loads.

The cranes are classified as,

- Revolving or rotary cranes

- Trackless cranes

- Mobile cranes

- Bridge cranes

- Floating cranes

- Helicopter cranes

Rotary crane Mobile crane Bridge crane

Material handling equipment's Cranes


Storage and Retrieval

Storage and retrieval system provide the combined

function of handling and storage the material. Function can

be done by automated or semi-automated.

Examples are unit load automated storage and retrieval

systems (AS/RS) which store and retrieve whole pallets,

mini load systems with storage drawers, micro load

systems with storages totes and carousels with extractors.

In hi-rack system, storage and retrieval will be done by

manual with the help of handling equipment's.

Material handling equipment's Storage


Containers: Tote pans

A tote pan or crate is a large shipping container, often made of plastic, steel and

wood, typically used to transport large, heavy or awkward items.

Plain crates

Perforated crates

Plain crates with lid

Foldable crates

Material Storage Systems


Containers: Pallets

A pallet is a flat transport structure that supports goods in a stable fashion while

being lifted by a forklift, pallet jack, front loader, work saver or other jacking

device.

A pallet is the structural foundation of a unit load which allows handling and

storage efficiencies. Its also called as a skid.

Plastic pallets Wooden pallets

Steel pallets



Storage and Retrieval

Hi-rack systems (Using hand stacker) Drive-in-rack systems

Unit load AS/RS system

Person-aboard AS/RS system

Vertical Carousel Systems



New generation material handling system

The new-generation material handling system are highly automated system based on

latest technologies, provided with flexibility capable of changing its own structure or

function in response to changes from manufacturing systems, and autonomous

functions to enhance system reliability. Such system is defined as MMHS -

Metamorphic Material Handling System.




MMHS project perform research and development activities focusing on the following four

Points,

1. Life cycle optimization

2. Environmentally conscious manufacturing

3. User-friendliness

4. Contribution to global industry productivity.



Subjects and objectives of MMHS



Subjects and objectives of MMHS project conceived from this viewpoint were as follows.,

1. Responsive: Responsive to changes that may take place in manufacturing

technology and environment, type of product or material to be handled, work

schedule and load.

2. Flexible: Capable of transforming itself and altering its function to meet any

change in handling requirements.

3. Autonomous: Able to make decisions on its own (to enhance system availability).

4. Highly automatic: Incorporated with next-generation automation technology.

5. Multi-functional: Having such functions as assembling, packaging and disassembling,

besides transporting.



6. Modularized: Composed of various modules, each with a distinct function; e.g.

planning module, basic module, tool-setting module, communication module, capable

of associating or dissociating one another to organize themselves into a configuration

as required.

7. Multi-level: Designed into multi-level sub-systems so as to be capable of cooperating

other independent material-handling equipment including AGVs and mobile robots.

8. Compatible: Capable of adapting itself to other existing material-handling systems.



Material Flow Analysis


Material flow

- Material flow is defined as an organized movement of materials (raw

materials, basic and auxiliary materials, semi products, tools, and finished

products, packages and waste) in the production process or circulation.

- Material flow draws the routes, outputs, travel distances, times and

costs.

Material flow diagram

Material flow


Web

SUPPLIERS

TVS-MSCHEDULES

JIT Call

(2Bin/Kanban)

PACKINGMILKRUN

Information flow

Material flow

Point of consumption

2Bin/ Kanban

Stores

WebAdvance

shipping

notification

Barcoded invoice

Assembly line

Weekly release

2Bin/Kanban

Containerisation:Milk run

Frequency: 90% of value daily

Material flow


Material flow in one module

Material flow in warehouse

Material flow


Material flow

This movement is expressed by following parameters :

Frequency - number of transportations per time unit,

Intensity - the amount transported per time unit,

Length - the distance the material pass from the starting point to the end point,

Performance - the product of the intensity and length of material flow,

Direction - from - to,

Manipulation factor - the number of manipulation operations carried out.

Material flow parameters


The quantifiable parameters are,

Quantity of material [Q] - which can be expressed in units of mass or volume in

case of the bulk materials or in manipulation units in case of materials in pieces.

Path [s] - which is expressed in length of track or route of material movement in

the area between the source (supplier) and consumer (customer).

Time [t] - is expressed by the duration of any work activity (operation process) or

term when to start an activity or finish (time of submission the vehicle for loading,

delivery time inventory).

Retention Points -

Material flow parameters


Retention:

The point which is holding the inventory before/after process and

re-handling in the material flow, it is called as retention point.

Material receipt

Storage Painting

Vehicle testing

Vehicle assembly

Sub assembly

2 4

34

13

5

Material retention


Material flow benefits,

A controlled material flow would result the following,

Lower overhead costs

Minimization of machinery usage

Increased accuracy in monitoring materials flow

Smoother processing of materials

Increased profits

Reduced waste

A culture of continuous improvement

Material flow Benefits


Material flow analysis

Objectives :

Define system of material flows and stocks

Reduce no. of retention

Reduce system complexity while maintaining basis for decision-making

Assess relevant flows and stocks quantitatively, checking mass balance,

sensitivities, and uncertainties

Present system results in reproducible, understandable, transparent

fashion

Use results as a basis for managing resources, the environment, and

wastes

Material flow analysis (MFA) is a systematic assessment of the flows and

stocks of materials within a system defined in space and time.



Material flow analysis techniques

A complete material flow analysis comprises seven steps.

1. Define the objective of the material flow analysis and the parameters to

be monitored

2. Define the balance scope

3. Define the balance period

4. Identify and define process steps

5. Draw the flowchart: material flows qualitative approach

6. Draw up balances: material flows quantitative approach

7. Interpret the results and draw conclusions.

7 Steps of Material flow analysis


No. of nodes

Human work factor

Output

Handling units

Transportation

machines

Space and size of the

area

No. of operations on

components of materialsParameters of material flows b/w objects

No. of components and types of materials

Technical solution of

warehouses

Types of

warehouses

Time

Level of flow control

Track or path

Nature of materials Storage concept


Factors affecting Material flow analysis


The following types of charts can be used for the graphical representation

of a material flow analysis:

1. Flow charts:- A flowchart is a graphic representation of how a process works, showing the

sequence of steps.

- It includes multiple steps, how the process "flows" through from start to finish.

- It is used to describe process that are to be improved.



Case study - Flow analysis for crank case

Material Flow Analysis Case study


2. Pie charts & Histograms:

- A bar graph of a frequency distribution in which the widths of the bars are

proportional to the classes into which the variable has been divided and the heights of the bars are proportional to the class frequencies.

Pie chart Histogram chart



3. Timetravel diagrams:

Time travel diagram


4. Sankey diagram:

- Sankey diagrams are a specific type of flow diagram, in which the

width of the arrows is shown proportionally to the flow quantity.

- They are typically used to visualize energy or material or cost transfers between processes.

Sankey diagram


Material Handling Safety


Safety

- Safety is the state of being "safe" , the condition of being protected against

physical, emotional, occupational, or other types or consequences of failure,

damage, accidents, or any other event which could be considered non-

desirable.

- Safety can also be defined to be the control of recognized hazards to achieve

an acceptable level of risk

Safety


Industrial Safety

- In a factory, handling and storing of materials provide a continuous flow

of parts and assemblies through the workplace and ensure that materials

are available when needed.

- Unfortunately, the improper handling and storing of materials often result

in costly injuries.

Industrial safety


Mechanical Hazards

Mechanical Hazards

Hazard Risk

Rotating shafts, pullies, sprockets and gears Entanglement

Hard surfaces moving together Crushing

Scissor or shear action Severing

Sharp edge moving or stationary Cutting or puncturing

Cable or hose connections Slips, trips and falls (e.g. oil leaks)


Non-Mechanical Hazards

Non-Mechanical Hazards

Hazard Risk

Dust Mist (vapours or fumes)

Explosive or flammable atmospheres Noise

Heat (radiated or conducted) Ignition sources (flame or spark)

High intensity light (laser, ultra-violet) Molten materials

Heavy metals (lead, cadmium, mercury) Chemicals

Steam Pressurised fluids and gases

Ionising radiation (x-rays, microwaves) Electrical


Health and Safety Hazards

Health and Safety Hazards:

Physical hazards; lighting.

Ergonomic hazards; force (lifting and pushing/pulling) and posture (bending,

reaching and twisting).

Energy hazards; gravity (falling objects).

Materials handling hazards; lifting, pushing/pulling and hazardous substances.

Work practice hazards; following established safe work


Safe Work Procedure:

1. Wear appropriate personal protective equipment.

2. Warm up your muscles (do some light stretching) for a few minutes

before you start lifting.

Safe work procedures


3. Know the approximate weight of the item before you attempt to lift it.

Use a mechanical lifting device (e.g. dolly, hand truck, cart, etc.) to move a

heavy or bulky load wherever possible.

4. Do not attempt to lift a load that is too heavy or too bulky for you. Ask

for assistance.



5. Lifting guidelines:

i. Look and plan ahead. Make sure your path is free of obstructions,

debris and slip and fall hazards such as grease, oil, water, etc.

ii. Ensure that you can lift the load without over-exertion.

iii. Ensure that the load is free to move.

iv. Check that you can get a good grip of the load.

v. Stand over the object.

vi. Place your feet so you are balanced.

vii. Bend your knees (not beyond 90 degrees) and keep your back

comfortably upright.

viii. Grip the object with your two whole hands (not just the fingers) so

you can hold it securely. Avoid grasping the ends of long items.

ix. Tighten your abdominal muscles.

x. Tuck your chin into your chest.



5. Lifting guidelines:

xi. Lift by straightening your legs. Use your legs to lift.

xii. Lift smoothly without jerking.

xiii. Hold the load close to your body.

xiv. Move your feet if you must turn while lifting. Do not twist your body.

xv. When walking with a load, short steps are best. Keep the load at a

reasonable height. Watch where you are going. Watch for tripping

hazards.



6. Lowering guidelines (putting a load down):

i. Take a wide stance with one foot in front of the other.

ii. Keep the load close to your body.

iii. Keep your back straight. Do not bend over when setting a load down

iv. Bend your hips and knees.

v. Set the load down. Keep the load tilted so you do not squat your

fingers. Avoid a jerky release.

vi. Stand up smoothly, easing your muscles.



Thank you

mhse part 01

Documents

material handling systemneed

design material storage

material flow

material handling john

material retention point

storage facilities

mhes tvsm ped mse mhse

handling work procedures