Wednesday, August 2, 2023

Material Handling Equipment for Industrial Engineering - A List, Sources and References

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.

    Chip removal system
    Cutting fluid or other liquids removal systems

Walking Beams
Ball Tables
Powered Round Tables
Jib Cranes
Vacuum or Magnetic Lifts
Robots



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.



Bulk Material Handling: Practical Guidance for Mechanical Engineers

Michael Rivkin Ph.D.
Partridge Publishing Singapore, 15-Sept-2018 - Technology & Engineering - 304 pages

Tens of thousands of mechanical engineers are engaged in the design, building, upgrading, and optimization of various material handling facilities. The peculiarity of material handling is that there are numerous technical solutions to any problem. The engineer’s personal selection of the optimal solution is as critical as the technical component. Michael Rivkin, Ph.D., draws on his decades of experience in design, construction, upgrading, optimization, troubleshooting, and maintenance throughout the world, to highlight topics such as: • physical principles of various material handling systems; • considerations in selecting technically efficient and environmentally friendly equipment; • best practices in upgrading and optimizing existing bulk material handling facilities; • strategies to select proper equipment in the early phases of a new project. Filled with graphs, charts, and case studies, the book also includes bulleted summaries to help mechanical engineers without a special background in material handling find optimal solutions to everyday problems.



Manufacturing Facilities Design and Material Handling

Matthew P. Stephens, Fred E. Meyers
Purdue University Press, 2013 - Factories - 504 pages

Designed for junior- and senior-level courses in Plant and Facilities Planning and Manufacturing Systems and Procedures, this textbook is also 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 fifth edition of this successful book, previously published by Prentice Hall, numerous updates and corrections have been made. 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. This replaces the 4th Edition by Prentice Hall (ISBN# 978-0135001059).





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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