Material Handling and Storage. Dr. Viboon Sangveraphunsiri. ME Control & Automation Lab, Chulalongkorn University

Transcription

1 Material Handling and Storage Dr. Viboon Sangveraphunsiri

2 Material Handling in the Production System

3 Material Transport Equipment Industrial Trucks Automated Guided Vehicles (AGVs) Monorails and other rail guided vehicles Conveyors Cranes and hoists

4 Industrial Truck

5 Automatic Guided Vehicle

6 Automatic Guided Vehicle

7 Conveyor

8 Crane & hoist and Monorail

9 a) Bulk storage b) Rack systems c) Shelving and bins d) Drawer storage Storage Systems e) Automated storage systems

10 Unitizing Equipment Containers used to hold individual items during handling Equipment used to load and package the containers

11 Standard Pallet Sizes Commonly Used in Factories and Warehouses Depth = x Dimension 800 mm (32 in) 900 mm (36 in) 1000 mm (40 in) 1060 mm (42 in) 1200 mm (48 in) Width = y dimension 1000 mm (40 in) 1200 mm (48 in) 1200 mm (48 in) 1060 mm (42 in) 1200 mm (48 in)

12 Material Handling in FMS

13 Material Characteristics Characteristics of Materials in Material Handling Category Physical state Size Weight Shape Condition Risk of damage Safety risk Measures or Descriptors Solid, liquid, or gas Volume; length, width, height Weight per piece, weight per unit volume Long and flat, round, square, etc Hot, cold, wet, dirty, sticky Fragile, brittle, sturdy Explosive, flammable, toxic, corrosive, etc.

14 General types of material transport equipment as a function of material quantity and distance moved Quantities of material moved High Conveyors Conveyors AGV trains Low Manual handling Hand trucks Powered trucks Unit load AGV Short Long Move distance

15 Types of Material Handling Equipment Associated with Three Layout Types Layout Type Fixed-position Process Characteristics Large product size, low production rate Variations in product and processing, low and medium production rates Typical Material Handling Equipment Cranes, hoists, industrial trucks Hand trucks, forklift trucks, automated guided vehicle systems Product Limited product variety, high production rate Conveyors for product flow, trucks to deliver components to stations

16 Unit Load Principle A Unit Load Principle is simply the mass that is to be moved or otherwise handled at one time. The unit load may consist of only one part, it may consist of a container loaded with multiple parts, or it may consist of a pallet loaded with multiple containers of parts. Benefit 1) Multiple items can be handled simultaneously 2) The required number of trips is reduced 3) Loading and unloading times are reduced 4) Product damage is decreased (So, lower cost and higher operating efficiency)

17 10 Principles of Material Handling Principle 1. Planning Principle All material handling should be the result of a deliberate plan where the needs performance objectives, and functional specification of the proposed methods are completely defined at the outset.

18 10 Principles of Material Handling Principle 2. Standardization principle Material handling methods, equipment, controls, and software should be standardized within the limits of achieving overall performance objectives and without sacrificing needed flexibility, modularity, and thoughput.

19 10 Principles of Material Handling Principle 3. Work Principle Material handling work should be minimized without sacrificing productivity or the level of service required of the operation

20 10 Principles of Material Handling Principle 4. Ergonomic Principle Human capabilities an delimitations must be recognized and respected in the design of material handling tasks and equipment to ensure safe and effective operations

21 10 Principles of Material Handling Principle 5. Unit Load Principle Unit loads shall be appropriately sized and configured in a way which achieves the material flow and inventory objectives at each stage in the supply chain

22 10 Principles of Material Handling Principle 6. Space Utilization Principle Effective and efficient use must be made of all available space

23 10 Principles of Material Handling Principle 7. System Principle Material movement and storage activities should be fully integrated to form a coordinated, operational system that spans receiving, inspection, storage, production, assembly, packaging, unitizing, order selection, shipping, transportation, and the handling of returns.

24 10 Principles of Material Handling Principle 8. Automation Principle Material handling operations should be mechanized and/or automated where feasible to improve operational efficiency, increase responsiveness, improve consistency and predictability, decrease operating costs, and eliminate repetitive o potentially unsafe manual labor

25 10 Principles of Material Handling Principle 9. Environmental Principle Environmental impact and energy consumption should be considered as criteria when designing or selecting alternative equipment and material handling systems

26 10 Principles of Material Handling Principle 10. Life Cycle Cost Principle A thorough economic analysis should account for the entire life cycle of all material handling equipment and resulting systems

27 Material Transport System Dr. Viboon Sangveraphunsiri

28 Five Categories of Material Handling Equipment Material Handling Equipment Industrial Trucks, manual Industrial trucks, powered Automated guided vehicle systems Monorails and other rail guided vehicles Conveyors, powered Cranes and hoists Low Cost High cost Battery-powered vehicles Flexible routing High cost Flexible routing Features Low rate of deliveries/hr Medium cost Non-obstructive pathways On-the-floor or overhead types Great variety of equipment In-floor, on-the-floor, or overhead Mechanical power to move loads resides in pathway Lift capacities ranging up to more than 100 tons Typical Applications Moving light loads in a factory Movement of pallet loads and palletized containers in a factory or warehouse Moving single assemblies, products, or pallet loads along variable routes in factory or warehouse Moving large quantities or items over fixed routes in a factory or warehouse Moving single assemblies, products, or pallet loads along variable routes in factory or warehouse Moving large quantities of items over fixed routes in a factory or warehouse Moving products along a manual assembly line Sortation of items in a distribution center Moving large, heavy items in factories, mills, warehouses, etc.

29 Non-powered : Hand trucks Industrial Trucks Hand operated Low-lift pallet truck Powered : Walkie truck, fork lift truck, and towing tractor

30 Automated Guided Vehicle Systems Driverless Automated Guided Train AGV pallet truck, Unit Load Carrier

31 Driverless Automated Guided

32 Palletizer AGVS PALLETIZER AGVS Corecon s line of REL and RHL Series Pallet Carrier s can be equipped with our newly designed rotating fork and grab unit, which is ideal for palletizing and box handling operations. A customers product boxes can be picked up directly from a floor, workstation, or conveyor with the AGV s grab unit. ROTATING FORKS Once the pallet is fully loaded then the forks on the AGV are rotated back 90 degrees to their normal fork truck position. BOX CLAMP FORKS To accomplish this the AGV s forks rotate 90 degrees so they are vertical and travel inward to act as a box clamp and grab. The boxes are then taken automatically to a pallet to stack them three layers high. PALLET CARRIER The AGV then acts as a pallet truck and picks up the finished pallets and takes them to their final destination. Each grab is custom engineered to provide the best possible solution for all your pallet and box handling requirements.

33 Unit Load Material Transport Warehouse to Production Load Capacity 5,000 lbs Vehicle Type: Dual Load Conveyor Food and Beverage Load Capacity 3,000 lbs Vehicle Type: Unit Load with Variable Height Conveyor

34 AGV Benefits Horizontal transportation solutions in both stand-alone and integrated systems Cost effective solution in multiple pick-up/delivery point applications Easy to adjust to changing production requirements Capable of handling any load from standard pallets to paper reels, totes, and car bodies Extremely safe mode of industrial transport Provide fully accessible floor areas to pedestrians and other traffic

35 AGV Features Control software package can stand alone or communicate with any host system Stationary control system based on Windows NT Battery powered and automatic charging ensures continuous, reliable operation Precise positioning, securing immediate, damage-free handling Virtually immune to single point failure - if one vehicle is inoperative - remainder of fleet continues Wire or laser guidance Vehicles equipped with diverse handling devices

36 AGV Advantages Over Manual Forktrucks Reduce labor and associated costs One AGV operating three shifts a day can replace the salary of three manual forklift operators saving your company a substantial amount of money in material handling expenses. Increased dependability and productivity AGV's can operate 24 hours a day, 7 days a week without taking a break or days off. This reduces replacement labor costs. Less product handling damage AGV's have controlled vehicle motion with a repetitive stopping accuracy or plus or minus 3/8". This along with accurate load positioning to heights reduces pallet and product damage caused by manual forklift handling. Increase safety Because the process of material handling requires no human interaction, personnel injuries are reduced. Accidents are also reduced because the vehicle's always act according to preprogrammed instructions, along paths and through aisle-ways. This reduces downtown from collisions and reduces damage to the facility and equipment. Corecon AGV's are equipped with safety devices to prevent collisions and verify product movement. Flexibility Unlike fixed material handling solutions, such as overhead conveyors, the path that an AGV takes can be reprogrammed easily at any time to facilitate changes in your plant layout.

37 Consumer Goods Manufacturing Paper Products Load Capacity 5,000 lbs Vehicle Type: Fork Mail Processing Load Capacity 2,000 lbs Vehicle Type: Laser Guided Fork Lift and Tow

38 Warehousing & Distribution Warehousing & Distribution Load Capacity 3,800 lbs Vehicle Type: Fork Lift, Dual Load

39 Special Vehicle Project Type: Textile Manufacturing Vehicle Type: Cloth and Yarn Handling Automotive Assembly Number of Vehicles: 20 for Trim Assembly 20 for Chassis Assembly Vehicle Type: Custom Design Project Type: Tractor Assembly Load Capacity : 7,200 lbs Vehicle Type: Custom

40 The Automated Warehouse Very Narrow Aisle AGVs in the warehouse Forklift Vehicle picks up outgoing load

41 Vehicle Guidance Technology Imbedded Guide Wires and Plaint Strips ME Control & Automation Lab, ME CAD/CAM Center, CHULA

42 Line Tracking (Paint Stripes)

43 Control Components

44 Battery Charge Examples Manual Change Out Stand Floor Charge Plate AGV Interfaced with Auto- Charge Stand Collectors Auto-Charge When running only 1 or 2 shifts of factory operations, an auto-charge option is available. When the AGV is not required on an off shift, the AGV s are sent to a specified autocharge area in the plant where the batteries can be automatically charged. Each AGV interfaces with a autocharge station which includes a battery charger and a set of charge collector shoes mounted to the stand. Upon entering the station, battery charge rails mounted on the AGV come into contact with the stand s collector shoes and automatic charging begins. Floor mounted chargers are also commonly used on our DSC and DSL series AGV s

45 Vehicle Management and Safety Traffic Control On-board vehicle sensing Zone control Vehicle Dispatching On-board control panel Remote call stations Central computer control Safety

46 Monorails and Other Rail Guided Vehicles

47 Conveyor Systems Roller and Skate Wheel Conveyors Belt Conveyors Conveyors Driven by Chains and Cables

48 Cranes and Hoists Crane Bridge crane Gantry crane

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51 Bridge Crane & Gantry Crane Bridge Crane Gantry Crane

52 Analysis of Material Handling Systems Charting Techniques in Material Handling Analysis of Vehicle-Based Systems Conveyor Analysis

53 Charting Techniques in Material Handling From-To Chart From-To Chart shows flow rates, loads/hr (value before the slash mark) and travel distances, m (value after the slash mark) between Stations in a layout. To From 1 0 9/50 5/120 6/ / /85 3/ /

54 Flow Diagram Showing Material Deliveries between Load/Unload Stations 1 6/ /50 9/80 5/120 3/ /85 4 2/85

55 Analysis of Vehicle Based System Delivery Cycle Loading at the pickup station (T L, min) Travel time to the drop-off station (L d /v c ) Unloading at the drop-off station (T U, min) Empty travel time of the vehicle between deliveries (L e /v e ) T c = T L + L d /v c + T U + L e /v e T c = delivery cycle time (min) T L = time to load at load station (min) L d = distance the vehicle travels between load and unload station (m, ft) v c = carrier velocity (m/min, ft/min) T U = time to unload at unload station (min) L e = distance the vehicle travels empty until the start of the next delivery cycle (m, ft)