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Chapter 2Chapter 2

Material HandlingMaterial Handling

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IntroductionIntroduction Definition – the movement, storage, protection and

control of material (MHIA). The purpose is to handle safely, efficiently, at low

cost, on time, accurately, and without damage to the material.

Advantages – safer operating condition, lower cost, better utilization and better performance of material handling systems.

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ExamplesExamples

Movement – industrial trucks and robots. Storage – rack, drawer, bins. Protection – wooden pallet, pallet box, tote box. Control – bar codes, magnetic stripes, radio

frequency tags.

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Position of MHPosition of MH

Automation and control technologies in the production system

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Equipments of MHEquipments of MHCategories of the equipment includes:

1. Transport.

2. Storage.

3. Unitizing.

4. Identification.

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TransportTransportUsed to move material inside a factory.1. Industrial trucks – non-powered and powered.2. Automated guided vehicles – battery-powered and

automatically steered.3. Rail guided vehicle – self-propelled and

independently operating.4. Conveyors – move material over fixed paths in

large quantities.5. Cranes and hoists – horizontal travel and vertical

lifting for heavy loads. Manually or powered operating.

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Industrial TrucksIndustrial Trucks The non-powered types are often referred as

hand trucks because they are pushed or pulled by human workers

Quantities of material moved and distances are relatively low

Classified as either two-wheel or multiple-wheel

Examples of non-powered industrial are shown in Figure 1

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F our w heel dolly

Two-wheel truck

Four wheel

dolly

Hand-operated low-lift pallet truck

Figure 1

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Powered truck are self-propelled to relieve the worker of manually having to move the truck

Three common types are used in factories and warehouse are walkie trucks, fork lift truck and towing tractor

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Walkie truck

Fork lift

truck

Towing tractor

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Automated Guided Vehicle Automated Guided Vehicle SystemsSystems An automated guided vehicle system (AGVS)

is a material handling system that uses independently operated, self-propelled vehicles guided along defined pathways

The pathways for AGVS is unobtrusive An AGVS is appropriate where different

materials are moved from various load points to various unload points

Suitable for automating material handling in batch production and mixed production

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Three types of AGV : (a) driveless automated guided train, (b) AGV pallet truck, (c) Unit load carrier

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Monorails and other rail Monorails and other rail guided vehiclesguided vehicles

Monorail is the motorized vehicles that are guided by a fixed rail system

Are typically suspended overhead from the ceiling

Rail guided vehicles pick up electrical power from an electrified rail

Electrified overhead monorails are used to move large components and subassemblies in its manufacturing operations

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Conveyor SystemConveyor System Conveyors are used material must be moved

in relatively large quantities between specific locations over a fixed path

The fixed path is implemented by a track system, which may be in-the-floor, above-the-floor or overhead

Divide into two categories : (1) powered(2) non-powered

Examples of powered conveyors are shown in Figure 3 and Figure 4

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Roller conveyor

Belt (flat)conveyorSkate wheel

conveyor

Figure 3

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Overhead trolley conveyor

Cart-on-track conveyor

In-floor towline conveyor

Figure 4

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Cranes and HoistCranes and Hoist Cranes are used for horizontal movement of

materials in a facility, and hoists are used for vertical lifting.

A hoist is a mechanical device that can be used to raise and lower loads

Cranes include a variety of material handling equipment designed for lifting and moving heavy loads using one or more overhead beams for support

Types of cranes : bridge cranes, gantry cranes and jib cranes

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Jib crane with hoist

(a) Bridge crane (b) Gantry crane

A hoist

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StorageStorage To store materials for a period of time. To permit access when required. Storage performance is measured according to the

capacity, density, accessibility and throughput. There are bulk storage, rack systems, bins, drawer

storage and automated storage systems.

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High density bulk storage provides low accessibility and bulk storage with loads arranged to form rows and blocks for improved accessibility

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Pallet rack system for storage of unit loads on pallet

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Drawer storage

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A unit load autom ated s torage/retr ieval s ys tem

24A horizontal storage carousel

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UnitizingUnitizing Containers used to hold individual items for

protection. Equipment used to load and package the containers. Examples: wooden pallet, pallet box and tote box.

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IdentificationIdentification To collect the data in material handling

automatically. There are three basic components: encoder data,

machine reader and decoder. Examples of technologies: bar codes, magnetic

stripes, radio frequency tags and machine vision.

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Stationary moving beam bar code scanner located along a moving conveyor

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Material Handling SystemMaterial Handling SystemThere are some considerations before design the system as follows:

1. Material characteristics.

2. Flow rate, routing, and scheduling.

3. Plan layout.

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Principle of MHPrinciple of MH The purpose is to be applicable in the analysis,

design and operation of MH system.1. Planning2. Standard3. Work4. Ergonomic5. Unit load6. Space utilization7 System8. Automation9. Environment 10. Life cycle cost

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AUTOMATIC DATA AUTOMATIC DATA CAPTURECAPTURE

Automatic data capture (ADC) also known as automatic identification and data capture (AIDC).

Refers to the technologies that provide direct entry of data into a computer or other microprocessor controlled system without using a keyboard.

Used to collect data in material handling and manufacturing applications

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Material handling : shipping and receiving, storage, sortation

and order picking Manufacturing :

Monitoring the status of order processing, work-in-process and worker attendance.

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Component of ADCConsists of three component :Encoded data A code is a set of symbols or signals

representing alphanumeric characters When data are encoded, the characters

are translated into a machine-readable code

A label or tag containing the encoded data is attached to the item that is to be later identified

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Machine reader or scanner This device reads the encoded data,

converting them to alternative form, usually an electrical analog signal

Decoder This component transforms the electrical

signal into digital data and finally back into original alphanumeric characters

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Categories of ADC Can be divided into six :Optical Use high-contrast graphical symbols that

can be interpreted by an optical scanner Include bar codes, optical character

recognition and machine visionMagnetic Encode data magnetically, similar to

recording tape Include magnetic stripe and magnetic ink

character recognition

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Electromagnetic : Radio frequencySmart card Refers to small plastic cards (the size of credit

card) imbedded with microchips capable of containing large amounts of information

Touch techniques : Touch screen and button memoryBiometric To identify humans or interpret vocal commands

of human Include voice recognition, fingerprint analysis

and retinal eye scans

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Most widely used in industry :1. Bar codes2. Radio frequency 3. Magnetic stripe4. Optical character recognition5. Machine vision