Production Operations management. Chapter 11. Material Handling

Transcription

1 Production Operations management Chapter 11 Material Handling

2 Material Handling Definition Material handling 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 cost of MH estimates of total manufacturing labor cost in the United States [The Material Handling Industry of America (MHIA)]

3 Material Handling Definition Material handling is defined as the art & science of moving Packing & storing of material in any form. The industry comprises establishments primarily engaged in manufacturing material handling equipment. This definition includes : Aerial work platforms, hydraulic or electric truck or carrier mounted, manufacturing Escalators and parts, manufacturing Automobile wrecker hoists, manufacturing Hoisting and lifting machinery, manufacturing Carts for moving goods (e.g., laundry, grocery), manufacturing

4 Material Handling Definition Industrial trucks, tractors, trailers and stackers and parts, manufacturing Conveyors and conveying equipment, manufacturing Tackle blocks, metal, manufacturing Cranes, industrial, manufacturing Walkways, moving, manufacturing Dollies and hand trucks, manufacturing Wheelbarrows, manufacturing Elevators and parts, manufacturing Winches, manufacturing

5 Scope of Material Handling There are three perspectives about material handling. The traditional point of view:emphasis is on material movement from one Location to another within the confines of individual plant Plant wide concern:focuses on overall flow of material. The system point of view:requires visualization of materials handling problem,the physical distribution activities as a one encompassing system.

6 The Importance of Material Handling Material handling is an important part of factory and industrial processes. It covers the entire spectrum of functions such as waste handling, assembly line management, storage and material transport. A material handling system includes several smaller components that work side by side, to make the everyday business more efficient and cost effective. New advances in technology have revamped the entire material handling system and function. Robotics and automation techniques are increasingly becoming prevalent. If you have an existing business, consider hiring a consultant, to set up your material handling processes.

7 The Importance of Material Handling Such experts derive conclusions regarding overall efficiency of operations, recommend appropriate safety precautions and ensure regulatory acquiescence. Do an adequate study and search for both a material handling expert as also appropriate material handling systems required for your purpose and set up an efficient and effective material handling system for your organization.

8 The Objectives of Material Handling The primary Objective is to reduce unit costs of production Maintain or improve product quality, reduce damage of materials Promote safety and improve working conditions Promote productivity material should flow in a straight line use gravity! It is free power move more material at one time mechanize material handling automate material handling

9 Material Handling Principles 1. Orientation Principle Study the system relationships thoroughly prior to preliminary planning in order to identify existing methods and problems, physical and economic constraints, and to establish future requirements and goals. 2. Planning Principle Establish a plan to include basic requirements, desirable options, and the consideration of contingencies for all material handling and storage activities.

10 Material Handling Principles 3. Systems Principle Integrate those handling and storage activities which are economically viable into a coordinated system of operation including receiving, inspection, storage, production, assembly, packaging, warehousing, shipping and transportation. 4. Unit Load Principle Handle product in as large a unit load as practical. 5. Space Utilization Principle Make effective utilization of all cubic space. 6. Standardization Principle Standardize handling methods and equipment wherever possible.

11 Material Handling Principles 7. Ergonomic Principle Recognize human capabilities and limitations by designing material handling equipment and procedures for effective interaction with the people using the system. 8. Energy Principle Include energy consumption of the material handling systems and material handling procedures when making comparisons or preparing economic justifications. 9. Ecology Principle Minimize adverse effects on the environment when selecting material handling equipment and procedures.

12 Material Handling Principles 10. Mechanization Principle Mechanize the handling process where feasible to increase efficiency and economy in the handling of materials. 11. Flexibility Principle Use methods and equipment which can perform a variety of tasks under a variety of operating conditions. 12. Simplification Principle Simplify handling by eliminating, reducing, or combining unnecessary movements and/or equipment. 13. Gravity Principle Utilize gravity to move material wherever possible, while respecting limitations concerning safety, product damage and loss.

13 Material Handling Principles 14. Safety Principle Provide safe material handling equipment and methods which follow existing safety codes and regulations in addition to accrued experience. 15. Computerization Principle Consider computerization in material handling and storage systems, when circumstances warrant, for improved material and information control. 16. System Flow Principle Integrate data flow with the physical material flow in handling and storage.

14 Material Handling Principles 17. Layout Principle Prepare an operational sequence and equipment layout for all viable system solutions, then select the alternative system which best integrates efficiency and effectiveness. 18. Cost Principle Compare the economic justification of alternate solutions in equipment and methods on the basis of economic effectiveness as measured by expense per unit handled. 19. Maintenance Principle Prepare a plan for preventive maintenance and scheduled repairs on all material handling equipment. 20. Obsolescence Principle

15 Material Handling Costs The costs of material handling arises from two sources The cost of owning & maintaining the equipment. Cost of operating System Every effort should be made to how to reduce the material handling cost.there are three functional ways: 1.Eliminating handling itself,where ever & whenever possible 2.Mechanizing largely by conveyors power driven trucks. 3.Making the necessary handling more efficient

16 Material Handling Costs Unit load - number of items or bulk material arranged so they can be picked up and delivered as one load Large or small? If large, cost/unit handled decreases But, depending upon cost of unitizing, de-unitizing

17 Material Handling Costs space required for material handling material handling carrier payload work-in-process inventory costs storage and return of empty pallets or containers used to hold the unit load smaller unit load may be desired space required for material handling material handling carrier payload work-in-process inventory costs - storage and return of empty pallets or containers used to hold the unit load

18 Factors for consideration in planning Material Flow(Material Material Characteristics) Category Physical state Size Weight Shape Condition Safety risk and risk of damage Measures Solid, liquid, or gas Volume; length, width, height Weight per piece, weight per unit volume Long and flat, round, square, etc. Hot, cold, wet, etc. Explosive, flammable, toxic; fragile, etc.

19 Factors for consideration in planning Material Flow( Plant Layout) Layout Type Fixed position Process Product Characteristics Large product size, low production rate Variation in product and processing, low and medium production rates Limited product variety, high production rate Typical MH Equipment Cranes, hoists, industrial trucks Hand trucks, forklift trucks, AGVs Conveyors for product flow, trucks to deliver components to stations.

20 Material Handling Costs Seven steps to design a unit load Unit load concept applicable? Select the unit load type Identify most remote source of load Determine farthest practicable destination for load Establish unit load size Determine unit load configuration Determine how to build unit load

21 Material Handling Devices Material handling equipment includes: Transport Equipment: industrial trucks, Automated Guided vehicles (AGVs), monorails, conveyors, cranes and hoists. Storage Systems: bulk storage, rack systems, shelving and bins, drawer storage, automated storage systems. Unitizing Equipment: palletizers Identification and Tracking systems

22 Material Handling Devices Conveyors Palletizers Pallet Lifting Devices Trucks Robots AGVs Jibs, Cranes and Hoists Warehouse MHSs

23 Material Handling Devices Conveyors: Accumulation,Belt,Bucket Can,Chain,Chute,Gravity Pneumatic or vacuum Power and free,roller Screw,Skid,Slat Tow line,trolley Wheel

24 Material Handling Devices Trucks Hand truck Fork-lift truck Pallet truck Platform truck Counterbalanced truck Tractor-trailer truck AGV

25 Material Handling Devices Robots: Point-to-point Contouring or continuous path Walkthrough or teach Lead through or teach pendant Hydraulic Servo-controlled

26 Material Handling Methods 1. Inspect materials for slivers, jagged edges, burrs, rough or slippery surfaces. 2. Get a firm grip on the object. 3. Keep fingers away from pinch points, especially when setting down materials. 4. When handling lumber, pipe or other long objects, keep hands away from the ends to prevent them from being pinched. 5. Wipe off greasy, wet, slippery or dirty objects before trying to handle them. 6. Keep hands free of oil and grease.

27 Material Handling Methods Lifting and Carrying Before employees are assigned to jobs requiring heavy and/or frequent lifting, make sure they are physically suited for the job. If a load is thought to be more than one employee can handle, assign two employees to the operation or supply materials handling equipment. Instruct employees in proper ways to lift. Proper Way To Lift Here are six steps to safe lifting: Keep feet apart - one alongside, one behind the object; Keep back straight, nearly vertical; bend at the knees instead of the waist;

28 Material Handling Methods 1. Tuck your chin in; 2. Grip the object with the whole hand; 3. Tuck elbows and arms in; 4. Keep body weight directly over feet When bulky objects are to be handled or when objects are to be carried on the shoulder, employees shall be trained in these techniques for special situations. Handling Barrels and Drums Whenever possible, use a dolly or other mechanical device when moving barrels or drums. If two employees are assigned to up-end a full drum, they should use the following procedures:

29 Material Handling Methods 1. Stand on opposite sides of the drum and face each other; 2. Grasp both chimes (rolled edges at both ends of the barrel) near their high points, lift one end; press down on the other; 3. As the drum is up-ended and brought to balance on the bottom chime, release the grip on the bottom chime and straighten the drum. When two employees are to overturn a full drum, they should use this procedure: 1. Make sure there is enough room. Cramped quarters can result in badly injured hands.

30 Material Handling Methods 1. Both stand near each other, facing the drum. Grip the closest point of the top chime with both hands, resting palms against the side of the drum, push until the drum balances on the lower chime. 2. Step forward a short distance, and each employee releases one hand from the top chime in order to grip the bottom chime. They ease the drum down to a horizontal position until it rests solidly on its side.

31 Plant Location End Of Chapter 11