🏭intro to industrial engineering review
6.3 Material Handling Systems and Equipment
Last Updated on July 30, 2024
Material handling systems are the backbone of efficient industrial operations. They encompass a variety of equipment types, from conveyors and forklifts to automated guided vehicles and robots, each designed to move materials effectively through production and storage processes.
Selecting the right material handling system involves considering product characteristics, operational needs, and economic factors. Efficient system design optimizes layout and flow, while automation can boost productivity and safety. These elements are crucial for streamlining facility operations and improving overall efficiency.
Material Handling Equipment Types
Transport and Positioning Equipment
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- Material handling equipment categorized into four main types transport, positioning, unit load formation, and storage equipment
- Conveyors use continuous systems for transporting bulk materials or unit loads over fixed paths (belt conveyors, roller conveyors, pneumatic conveyors)
- Cranes enable vertical and horizontal movement of heavy loads (overhead cranes, gantry cranes, jib cranes)
- Forklifts lift, carry, and stack palletized loads with versatility (counterbalanced forklifts, reach trucks, order pickers)
- Automated Guided Vehicles (AGVs) travel along predefined paths as computer-controlled, wheel-based load carriers (tow vehicles, unit load carriers, fork trucks)
Specialized and Auxiliary Equipment
- Industrial robots perform programmable material handling tasks (palletizing, pick-and-place operations, machine tending)
- Auxiliary equipment facilitates load unitization and transfer between handling equipment (dock levelers, pallets, containers)
- Automated storage and retrieval systems (AS/RS) integrate storage with material handling for efficient inventory management
- Sortation systems automatically divert items to specific destinations based on predefined criteria (tilt-tray sorters, cross-belt sorters)
- Vertical lift modules (VLMs) provide high-density storage and retrieval in a compact footprint
Factors for System Selection
Product and Operational Considerations
- Product characteristics impact equipment and method choices (size, shape, weight, fragility)
- Throughput requirements determine needed capacity and speed (units per hour or day)
- Flexibility requirements influence system choice (handling various products, adapting to changing production volumes)
- Environmental factors affect equipment selection and design (temperature, humidity, presence of hazardous materials)
- Ergonomics and safety considerations minimize worker strain and accident risks (lifting aids, ergonomic workstations)
Economic and Facility Factors
- Initial investment costs, operational expenses, and expected return on investment (ROI) guide financial decisions
- Facility layout and space constraints influence equipment type and size utilization
- Integration capabilities with existing systems affect decision-making process
- Potential for future expansion considered in system selection
- Total cost of ownership (TCO) evaluated, including maintenance, energy consumption, and training costs
Efficient System Design
Layout and Flow Optimization
- Systematic Layout Planning (SLP) designs material handling systems with facility layouts
- Material flow analysis techniques identify inefficiencies and optimize movement patterns (From-To charts, Spaghetti diagrams)
- Unit load design principle maximizes handling efficiency by determining optimal load size and configuration
- Integration of material handling equipment with storage systems creates seamless material flow (AS/RS)
- Cross-docking and staging areas in facility layout enable efficient material transfer and reduced handling
Design Tools and Principles
- Simulation modeling and analysis tools evaluate design alternatives and predict system performance
- Lean manufacturing principles guide system design to minimize waste and inventory (Just-In-Time delivery, kanban systems)
- Warehouse management systems (WMS) and material handling control systems coordinate and optimize material flow
- Value Stream Mapping (VSM) identifies opportunities for improvement in the overall material handling process
- Modular design approaches allow for system flexibility and scalability as needs change
Automation Impact on Operations
Productivity and Safety Enhancements
- Automation increases labor productivity by reducing manual handling and increasing throughput rates
- Safety improvements reduce injury risks from heavy lifting, repetitive motions, and equipment interactions
- Automated systems operate continuously, potentially increasing overall equipment effectiveness (OEE)
- Data collection and analysis capabilities provide opportunities for continuous improvement and real-time decision-making
- Automated guided vehicle (AGV) systems improve efficiency in material transport and reduce human error
Operational Considerations
- Initial capital investment for automated systems typically higher than manual systems, offset by long-term savings
- Flexibility in automated systems varies (adaptability to product changes vs. potential rigidity)
- Workforce retraining often required, shifting job roles from manual labor to system operation and maintenance
- Reliability and uptime of automated systems critical for operational success
- Integration challenges may arise when implementing automated systems with existing manual processes
Key Terms to Review (28)
Inventory Management: Inventory management is the process of overseeing and controlling the flow of goods, materials, and products in a business to ensure optimal stock levels and minimize costs. This involves balancing supply and demand, tracking inventory levels, and implementing strategies for ordering and storage. Effective inventory management plays a crucial role in production efficiency, cost reduction, and customer satisfaction.
Cycle Time: Cycle time refers to the total time it takes to complete one cycle of a process from start to finish. This includes every step in the process, from the initiation of a task to its completion, and is crucial for understanding efficiency and productivity in various systems.
Material flow analysis: Material flow analysis (MFA) is a systematic assessment method used to evaluate the flow of materials within a defined system, focusing on their movement, transformation, and final disposal. By examining the inputs, outputs, and stocks of materials in a process, MFA helps identify inefficiencies and opportunities for improvement in resource utilization. This technique is crucial in understanding how materials are handled and moved throughout production and distribution systems.
Warehouse management systems: Warehouse management systems (WMS) are software solutions designed to optimize and manage warehouse operations efficiently. They facilitate the tracking of inventory levels, orders, and shipments while streamlining processes such as receiving, picking, packing, and shipping. Effective WMS implementation enhances productivity and reduces errors, which are essential components in both material handling and warehouse design.
Total Cost of Ownership: Total Cost of Ownership (TCO) is a financial estimate that helps organizations understand the complete cost of acquiring, operating, and maintaining an asset over its entire lifecycle. This concept goes beyond the initial purchase price, incorporating costs such as maintenance, operation, and disposal, allowing for better decision-making regarding investments. Understanding TCO is crucial when evaluating options in areas such as material handling systems, supply chain design, and resource management to ensure long-term value and efficiency.
Vertical Lift Modules: Vertical lift modules are automated storage and retrieval systems designed to store and manage a variety of items in a vertical configuration. They consist of two parallel columns of trays, which move vertically to deliver items to an access point, allowing for efficient space utilization and improved inventory management. By automating the handling of materials, these systems enhance productivity and reduce the risk of errors associated with manual handling.
Sortation Systems: Sortation systems are automated material handling systems designed to efficiently categorize and distribute items to their designated locations based on specific criteria. These systems utilize various technologies, such as conveyor belts, barcode scanners, and sensors, to identify and separate products, streamlining the logistics process within warehouses and distribution centers.
Cranes: Cranes are mechanical devices used for lifting and moving heavy materials, typically in construction and manufacturing settings. They play a crucial role in material handling systems by enabling the efficient transfer of loads from one location to another, often at great heights or over obstacles. Their design allows for various lifting mechanisms, making them versatile for different applications, including transporting loads across distances and positioning materials accurately.
Value Stream Mapping: Value stream mapping is a visual tool used to analyze and optimize the flow of materials and information required to bring a product or service to the customer. It identifies waste, bottlenecks, and areas for improvement within the process, making it integral to enhancing efficiency and value delivery in both manufacturing and service environments.
Ergonomics: Ergonomics is the science of designing the workplace, products, and systems to fit the users' needs, aiming to improve efficiency and comfort while reducing the risk of injury. This field connects closely with how humans interact with their environments, considering factors like physical capability, cognitive load, and emotional well-being to create optimal working conditions.
Automated guided vehicles: Automated guided vehicles (AGVs) are mobile robots used to transport materials in manufacturing and warehousing environments. They follow predefined paths using various navigation technologies, such as lasers, magnetic strips, or visual markers, making them an essential part of modern material handling systems. By automating transportation tasks, AGVs enhance efficiency, reduce labor costs, and minimize human error in industrial settings.
Equipment utilization rate: Equipment utilization rate is a measure of how effectively a piece of equipment is being used in relation to its total available capacity. It helps organizations assess the efficiency and productivity of their material handling systems by showing how much of the equipment’s potential is being realized in actual operations. A higher utilization rate indicates better performance and can signal optimal scheduling, maintenance practices, and overall workflow management.
ANSI Standards: ANSI standards are a set of guidelines and specifications established by the American National Standards Institute to ensure quality, safety, and efficiency in various industries, including material handling systems and equipment. These standards serve as a benchmark for designing, manufacturing, and operating equipment, facilitating interoperability and promoting best practices. By adhering to ANSI standards, companies can improve workplace safety and optimize operational performance.
Unit loads: Unit loads are standardized packages or assemblies of products that are designed to be handled and transported as a single entity. This concept streamlines material handling processes by reducing the number of individual items that need to be managed, facilitating easier storage, transportation, and inventory control. By utilizing unit loads, organizations can improve efficiency and minimize handling costs within their material handling systems and equipment.
Order picking accuracy: Order picking accuracy refers to the measure of how correctly items are selected from inventory to fulfill customer orders. High order picking accuracy ensures that customers receive the correct products in the right quantities, which is crucial for maintaining satisfaction and operational efficiency.
ISO Certification: ISO certification is a formal recognition that an organization adheres to international standards set by the International Organization for Standardization (ISO). This certification demonstrates a company's commitment to quality management, efficiency, and continuous improvement, which can greatly enhance customer satisfaction and operational effectiveness.
Industrial robots: Industrial robots are programmable machines that can perform a variety of tasks in manufacturing and production processes, often with high precision and efficiency. These robots enhance productivity by automating repetitive or complex tasks, leading to improved consistency, reduced labor costs, and increased safety in industrial settings.
Throughput: Throughput refers to the rate at which a system produces output or completes tasks over a specified period. It is a crucial measure of efficiency in operations, as it helps organizations understand how effectively resources are being utilized to meet demand.
Bulk materials: Bulk materials refer to large quantities of granular or particulate substances that are typically transported and handled in bulk form rather than in individual packages. This category includes items like grains, coal, ores, chemicals, and many other materials that are stored and moved in large quantities, usually utilizing specialized equipment designed for efficient handling and transportation.
Layout design: Layout design refers to the arrangement of physical elements in a workspace to optimize operations, enhance productivity, and ensure efficient workflow. It involves strategically positioning equipment, workstations, and materials to facilitate smooth movement and minimize waste during production processes. Effective layout design is crucial in material handling systems as it directly impacts the efficiency of operations and the ability to meet production goals.
Push vs. Pull Systems: Push and pull systems are two contrasting approaches to inventory management and production control. In a push system, products are manufactured based on forecasted demand and pushed through the supply chain, while in a pull system, production is driven by actual customer demand, pulling materials through the process only when needed. Understanding these systems is essential in optimizing material handling and ensuring efficiency within operations.
Load Capacity: Load capacity refers to the maximum weight or load that a material handling system or piece of equipment can safely carry or support without compromising its structural integrity or performance. Understanding load capacity is crucial for ensuring safety and efficiency in material handling operations, as it directly influences the selection of appropriate equipment and design of systems to meet operational requirements.
Pallet Jacks: Pallet jacks are essential material handling tools used for lifting and moving pallets within warehouses and distribution centers. They come in manual and electric forms, allowing operators to transport heavy loads with ease, improving efficiency in material handling systems. These devices play a crucial role in logistics, facilitating the safe and quick movement of goods, thereby reducing labor intensity and minimizing the risk of injury.
Automated storage and retrieval systems: Automated storage and retrieval systems (AS/RS) are computer-controlled systems that store and retrieve products or materials automatically, significantly enhancing efficiency in warehouses and distribution centers. These systems utilize various technologies such as robotics, shuttles, and conveyor belts to manage inventory, minimize human labor, and optimize space utilization. By integrating AS/RS into operations, organizations can streamline their material handling processes and improve overall warehouse management.
Gravity flow: Gravity flow refers to the natural movement of materials or products from a higher elevation to a lower elevation solely driven by gravitational forces. This process is commonly utilized in material handling systems, as it reduces the need for mechanical energy and enhances efficiency in transporting goods.
Conveyor systems: Conveyor systems are mechanical devices used to transport materials from one location to another within a facility, enhancing efficiency and productivity in material handling processes. These systems can be found in various industries, facilitating the movement of products, parts, and raw materials along defined paths. They play a critical role in automating operations, reducing manual labor, and minimizing the risk of injury while ensuring smooth workflows in manufacturing, warehousing, and distribution.
Forklifts: Forklifts are powered industrial vehicles equipped with a forked platform at the front, designed for lifting and moving materials over short distances. They play a crucial role in material handling systems by improving efficiency in warehouses, distribution centers, and construction sites, enabling quick loading, unloading, and stacking of goods.
Systematic layout planning: Systematic layout planning is a structured approach to designing the layout of facilities, aiming to optimize space utilization and workflow efficiency. This method involves analyzing various factors such as material flow, employee movement, and equipment placement to create an effective layout that minimizes costs and enhances productivity. The process also incorporates specific models and algorithms that assist in making informed decisions and improving material handling systems.