For improving any operation in a process, industrial engineers need to have a good knowledge of alternatives at element level. Industrial engineering has to be carried out at element level, operation level, process level, facilities level and system level. System level productivity improvement is achieved by IE at the minute level to the macro level.
Manufacturing Facilities Design & Material Handling, International Edition.
Prentice Hall
Author: Matthew P. Stephens / Fred E. Meyers
Chapter 11 Material Handling Equipment
Material handling equipment are grouped into four general categories.
Fixed-path or point-to-point equipment. (Rail, conveyor)
Fixed-area material handling system (Jib crane)
Variable-path variable-area equipment. (All manual carts)
Auxiliary tools and equipment (pallets, skids, automatic data collection systems, and containers).
Equipments are listed under the following sections.
1. Receiving and shipping
2. Stores
3. Fabrication
4. Assembly and paint
5. Packout
6. Warehousing
Receiving and Shipping
Receiving and Shipping Docks 252
Shipping Docks - Types
Flush docks
Drive-in docks
Drive-through docks
Finger docks
The four types represent over 90 percent of all docks used for trucks or railcars.
Dock Equipment 256
Dock Door
An awning or porch over the rear of the trailer
Air curtains and plastic curtains
Extra lighting is often needed inside trailers, so portable lighting
Moving Equipment 256
Hand Carts
Literally hundreds of different hand carts are available today. A few of the most
versatile and popular pieces of equipment follow:
1. Two-wheel hand truck
2. Pallet hand jack or pallet truck-hydraulic lift (also called just hand jacks)
3. Four-wheel hand carts
4. Pallets
See for currently available carts
https://www.globalindustrial.com/t/carts-trucks
https://www.globalindustrial.com/t/material-handling
Fork Trucks
Fork truck attachments
Attachments are available for moving paper rolls, carpet rolls, drums, trash, or many other parts and containers. . A boat marina uses extended forks to put motor boats into a storage rack. Oil, paint, scrap, and parts can be dumped by using a special dumping attachment.
Multipurpose Equipment
In an attempt to standardize material handling equipment, diversified multipurpose equipment must be given special consideration.
A universal lift system. In the receiving and shipping areas, as well as in storage and warehousing, this material handling system can assist in loading and unloading trucks, and in lifting pallets, boxes, and other containers. It is capable of reaching high and hard-to-reach places, lifting or lowering loads well below the ground level, and performing a variety of other activities. The same equipment can also be quite useful on the factory floor. It can simplify the handling of dies and molds, handle large coils, and uncoil sheet metals.
Bridge cranes
Double gantry crane
Telescopic Conveyor 261
Telescopic conveyors have several sections of conveyor that extend as needed.
Weight Scale 263
Weight scales are valuable and useful receiving and shipping tools and they are built into the material handling system.
Systems Required on Receiving and Shipping Docks 263
Information and Coding Systems
1. Part numbering systems that allow for identification of inventory
2. Purchase order system authorizing the receiving of material. POs are received by stores and on their authority they receive material from suppliers.
3. Customer order system authorizing the shipment of material. (The sales orders to sent to stores/shipping by sales department)
4. Bill of lading authorizing a trucking company to move material and to bill for their services.
Stores
“Stores” is the term used to describe the room where raw materials and supplies are held until they are needed by the operations department.
Storage Units 264
Storage units can include the following:
1. Shelves store small parts. A typical shelving unit resembles a bookshelf with six 1 3 1 3 3-foot shelves one over the other.
2. Racks (pallet racks) are used to store palletized material on pallet racks. A typical pallet rack is 9 feet wide with five tiers for a height of 22 feet. With two pallets per tier, five tiers high equals 10 pallets per pallet rack.
3. Double deep pallet racks allow for stacking 20 pallets in a rack instead of 10 pallets. The density of storage is much better, and utilization of the building cube is improved.
4. Portable racks are racks that fit over a pallet load of soft material. Another pallet is then set on top of this portable rack. Heights can be much higher without the danger of a stack falling over.
5. Mezzanines can be built over shelving areas to use the space over the shelves. Slow-moving stock can be placed on the mezzanines.
6. Rolling shelves can function with one aisle in maybe 10 rows of shelves. Thus 9 aisles space is saved. The shelves are on wheels and tracks and can be moved to open up an aisle where no aisle exists now. Rolling shelves are popular in maintenance stores (especially insurance spares) where daily issues are less.
7. Drawer storage units are another popular maintenance storage unit. Many small parts can be stored in a small area. One drawer may have 32 to 64 storage locations, and a 6-foot drawer unit could hold nearly 1,000 different parts.
Stores Mobile Equipment 267
Narrow aisle reach trucks are one of the better choices for maneuvering in storage
areas. Narrow aisle trucks can turn in narrow aisles, and the operator stands up.
Types of narrow aisle trucks:
1. Reach truck
2. Straddle truck.
3. Side shifting lift trucks
Others
4. Maintenance carts.
5. Dollies and casters.
6. Maintenance tool crib.
7. Carousel storage and retrieval systems.
Systems Required for the Stores Department 269
Locator System
Every location must have an address and the warehouse person must know how to reach any address without taking time to think.
Kitting System
Fabrication
The fabrication department is the department that produces parts for the assembly and/or packout lines (direct despatch to customer). This fabrication starts with raw materials and ends with finished parts.
Fabrication department has many shops like machine shop, foundry, forge shop, heat treatment shop and paint shop etc.
The material handling facilities include containers, workstation handling devices, and mobile equipment.
Shop Containers 273
Shop containers are used to move parts in unit loads (see Figure 11–24). Large
sheets of steel or coils of steel are chopped into smaller parts. These parts are collected in bins or boxes made of cardboard, plastic, or steel and moved to the second operation (see Figure 11–25). Shop containers are often stacked on pallets moved to the next machine and placed on the next machine
Tubs and Baskets 274
Tubs and baskets are larger shop containers. Regular-sized tubs and baskets are 4 feet 3 4 feet 3 42 inches high. Parts on the bottom are often difficult (and time consuming) to retrieve. For this reason, several special tubs and baskets generally are available.
Drop Bottom Tubs
Drop Side Tubs or Baskets
Tilt Stands
V Stands
Scissor Lifts or Hydraulic Lifts
Dump Hoppers
Workstation Material Handling Devices 278
Counterbalances
Manipulators and Lifting Devices 278
Vibratory Feeders
Waste Disposal - special material handling equipment
Dump hoppers can be used for waste disposal. Trash compactors reduce waste removal costs, and paper bailers will turn trash costs into profits. Waste disposal is an area where material handling equipment can greatly improve performance and reduce costs.
Mobile Fabrication Equipment 285
Slides and Chutes
Skate Wheel and Roller Conveyors (Nonpowered)
Lift Conveyors
Adjustable Angle Conveyors
Magnetic Conveyors
Auger or Screw Conveyors
Vibratory Conveyors
Assembly and Paint
Assembly operations also will use the equipment used in fabrication shops. Counterbalances , vibratory feeders, tilt stands, dump hoppers, shop containers, and tubs and baskets all are used in assembly. When speaking of assembly material handling equipment, conveyors are emphasized. There are many different conveyors. Some of the popular conveyors are:
Belt Conveyors 293
Powered Roller Conveyors 293
Car-Type Conveyors 294
Slat Conveyors 294
Tow Conveyors 295
Overhead Trolley Conveyors 296
Power and Free Conveyors 298
Packout
Box Formers 299
Automatic Taping, Gluing, and Stapling 299
Palletizers 301
Pick and Place Robots 301
Banding 301
Stretch Wrap 306
Warehousing
Picking Carts 306
Gravity Flow Bins 306
Tractor-Trailer Picking Carts 306
Clamp Trucks 306
Rotary Conveyor Bins 310
Vertical Warehouse and Picking Cars 310
Packing Station 312
Shipping Containers 312
Bulk Material Handling
- Bulk Material Conveyors 316
- Troughed Belt Conveyors
- Screw Conveyors
- Vacuum Delivery Systems
- Pumps and Tanks
- Conveyor Systems
Computer-Integrated Material Handling Systems 318
Automated storage and retrieval system (ASRS).
ASRS will automatically put away the product or parts, or take out the product, move it to where required, and adjust the inventory level at both ends of the move ASRS systems are typically in very tall (60 feet and over) and very large areas. The ASRS is made up of (1) racks, (2) shuttle cars, (3) bridge cranes, (4) computer control center, and (5) conveyor systems.
Cross-Docking and Flow-Through 31
Cross-docking is used in distribution centers. Cross-docking facilitates product mixing and sorting operations on the dock itself. Different Materials come in trucks and these materials are unloaded and mixed as required by say retail shops and loaded on the trucks that go to retailers. So no storing of the material takes place in cross docking.
Articles on Material Handling - Narayana Rao K.V.S.S.
Material Handling and Transport System - Principles for Design and Options
https://nraoiekc.blogspot.com/2012/01/material-handling.html
News - Information for Material Handling and Transport Operation Industrial Engineering Analysis
https://nraoiekc.blogspot.com/2020/07/news-information-for-material-handling.html
Automated Material Handling - Transport - Bibliography
https://nraoiekc.blogspot.com/2020/12/automated-material-handling-transport.html
Material Handling Illustrations - Video Collection
https://nraoiekc.blogspot.com/2015/07/material-handling-youtube-video.html
Books
Robotic Systems: Concepts, Methodologies, Tools, and Applications: Concepts, Methodologies, Tools, and Applications
Management Association, Information Resources
IGI Global, 03-Jan-2020 - Technology & Engineering - 2075 pages
https://books.google.co.in/books?id=f6TDDwAAQBAJ
Manufacturing Facilities Design & Material Handling: Sixth Edition
Matthew P. Stephens
Purdue University Press, 15-May-2019 - Technology & Engineering - 524 pages
Designed for junior- and senior-level courses in plant and facilities planning and manufacturing systems and procedures, this textbook also is suitable for graduate-level and two-year college courses. The book takes a practical, hands-on, project-oriented approach to exploring the techniques and procedures for developing an efficient facility layout. It also introduces state-of-the-art tools including computer simulation. Access to Layout-iQ workspace planning software is included for purchasers of the book. Theoretical concepts are clearly explained and then rapidly applied to a practical setting through a detailed case study at the end of the volume. The book systematically leads students through the collection, analysis, and development of information to produce a quality functional plant layout for a lean manufacturing environment. All aspects of facility design, from receiving to shipping, are covered. In the sixth edition of this successful book, numerous updates have been made, and a chapter on engineering cost estimating and analysis has been added. Also, rather than including brief case-in-point examples at the end of each chapter, a single, detailed case study is provided that better exposes students to the multiple considerations that need to be taken into account when improving efficiency in a real manufacturing facility. The textbook has enjoyed substantial international adoptions and has been translated into Spanish and Chinese.
Conveyors: Application, Selection, and Integration
Patrick M McGuire
CRC Press, 05-Aug-2009 - Business & Economics - 210 pages
Put simply, this is probably the first book in 40 years to comprehensively discuss conveyors, a topic that seems mundane until the need arises to move material from point A to point B without manual intervention. Conveyors: Application, Selection, and Integration gives industrial designers, engineers, and operations managers key information
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