Modern Material Handling and Storage Systems
Material handling is the movement, storage, protection & control of
material throughout the manufacturing & distribution process including their
consumption & disposal.
Material handling needs to be:
Safe
Efficient
Low cost
On time
Accurate
MH Equipment
Transport
Storage
Unitizing equipment
Identification & tracking System
Transport
Industrial track
AGV
Monorails
Conveyors (belt/roller)
Cranes
Storage
RM/WIP/FG
Bulk on the floor
Rack structural frames
Shelving & bins standard width, depth & height
Drawer for tools/hard ware
AS/RS
Unitizing
Containers to hold items (Pallet)
Equipment used to load & package the containers (Palletizer)
Identification & Tracking
Keeping trade of the material being moved/stored
Affix label on carton
o Bar codes
Consideration for MH system design
1.
Material characteristics
2.
Physical state solid/liquid
Size
Weight
Shape square, round
Condition hot, cold, sticky
Risk of damage fragile
Safety risk explosive, flammable, toxic
Flow rate/Routing/Scheduling
Flow rate
Large quantity dedicated handling system
Small quantity, different types need to share
Routing
Distance pickup & drop off locations
Different flow patterns
Scheduling
Timing of each individual delivery
Maintain performance & efficiency
Must be responsive for timely pick-up & delivery
Quantity
Conveyor
Conveyors
AGV trains
Hand trucks
Powered Truck
Unit load AGV
Distance
3.
Plant layout
For new facility, design of MH system should be considered part of layout
design.
Fixed-position
Large object
Cranes, powered trucks
Process
Flexible to deal with variation
Hand trucks, Fork lift trucks to move WIPs
Recently AGV
Product
Identical parts with high quantity
Fixed route, mechanized, large flow rates
Conveyor, trucks to deliver
Automated Guided Vehicle (AGV)
Battery powered driverless vehicles with programming capabilities for
destination, path, selection & positioning.
Can move in complicated & changing paths
Handle wide variety of material & loads
Provide high degree of flexibility
Can perform loading/unloading operations
Interaction with machines
Communicate with factory computer control system
Components to an AGVS
Vehicle
Guided path
Control unit
Computer interface
Types of Vehicles
1.
AGV Towing Vehicle
2.
For heavy loads (4000 to 25000 kg) over long distance
No intermediate pickup or drop-off
AGV Unit Load Carrier
3.
Move unit loads from one station to other
Equipped with decks powered roller, moving belt,
mechanized lift platforms
AGV Pallet Truck
4.
Lift, maneuver & transport pallets
Along pre-determined routes Automatic / Manual
AGV Fork Truck
5.
Automatic pick up & drop off of loads at different levels
From floor to stands
AGV Light Load Transporter
6.
Handle small light parts over moderate distance
Distribute parts bet storage & Work stations
AGV Assembly Line Vehicle
Adaptation of small, light load AGV for assembly process
AGV Guidance Techniques
1.
Wire Guided
o Electric line below floor
o High frequency AC current
o At junction point, different frequency measured by programmed
sensors
o Sensor pickup electromagnetic signal
Disadvantage:
2.
Cannot change line easily
Line Guided
o Fluorescents paint
o Use optical sensor (photo sensor)
o UV light source reflection
Disadvantage:
Paint deteriorated
Need to maintain, repaint
3.
Free-ranging/Self-Guided
Paths are software programmable & therefore are easily alterable.
Combination of dead reckoning & beacons located throughout the plant
Identified by on-board sensors
Dead reckoning capability of a vehicle to follow a given route in absence of
a defined pathway on the floor
Movement along the route is accomplished by the wheel rotation in
sequence of specified steering angles.
Computations performed by vehicles on board computer
Position accuracy decease as the route length increases
Locate of vehicles must be verified periodically with known positions.
Beacons located strategically throughout the plant.
Beacons may be
Bar coded mounted along aisles recognized by laser
Magnetic imbedded in the floor along pathway
Advantages:
Flexibility software based
Cam be extended or changed without major alteration to facility.
Basic Functions of AGV
Guidance Ability to follow pre-determined route
Routing Selection of optimum route to specific destination
Traffic Management Ability to avoid collation & maximizing vehicle
flow.
Load transfer Pick-up / Delivery
System management Method of system control used to dictate
system operation.
Central
Computer
AGV
Vehicle scheduling program
and control software
Regional
Computer
Vehicle routing command
for each zone
Regional
Computer
Local
Computer
Vehicle routing command
for each AGV
Local
Computer
AGV
AGV
AGV
AGV
AGV
Total number of vehicles required in a system
Ld Total average loaded travel distance
Le Total average empty travel distance
Th handling time = Loading + Unloading time
Ft Traffic factor
o blocking & waiting of vehicles in line & at intersections
o if only one vehicles vale is 1.0 normally let 0.85 ~ 1.0
V c AGV velocity/speed
Total time / delivery / vehicle Tv =
No of Deliveries / vehicle / hr. = 60
Ld
Le
+
+ Th
Vc
Vc
Ft
Tv
No of Deliveries / hr
# Vehicles = No of Deliveries / vehicle / hr
Automated storage System
Reduces or eliminate amount of human intervention required to
operate the System.
In less-automated System, human operator is required in each
storage/retrieval transaction
In highly automated system, loads are entered or retrieval under
computer control, with no human participation
Objectives
Increased storage capacity better floor utilization
Improved security, reduced pilferage
Reduced labor cost
Improved safety & customer service
Improved control over inventories
Automated Storage and Retrieval System
A combination of equipment and controls that handle stores & retrieves
material with precision, accuracy and speed under a defined degree of
automation.
Consists of a series of storage aisles that are serviced by one or more
S/R machines
Aisles have storage racks
S/R machines (cranes) are used to deliver & retrieve material to from
racks
Each aisle has one or more input/output stations (P&D)
Types of AS/RS
Unit load AS/RS typically a large system designed to handle unit
loads stored on pallets.
o Computer controlled
o S/R machines are automated & designed to handle the unit load
containers
Mini load AS/RS for small loads contain in bins or drawers
Man-on-board AS/RS individual items to be picked directly at storage
location
Automated item retrieval system also for individual item stored in
lanes rather than bins. Pushed from lanes & drop on conveyor
Deep lane AS/RS another variation of multi-load
o High density up to 10 items per row instead of 1 or 2
Enter from one side deliver other side
Automatic Data Capture
It refers to the technologies that provide direct entry of data into a
computer or other microprocessor-controlled system without using a
keyboard.
Reduced error
Reduced time
Reduced man power
Overview
Encoded data code is a set of symbols or signals representing
alphanumeric characters
o When data are encoded, the characters are translated into
machine-readable code
Machine reader/scanner reads encoded data &
converts to electrical signal
Decoder transforms electrical signal into digital data &
finally back into original alphanumeric character
Bar code is the leading ADC
Six categories of different technology
Optical high contrast graphical symbol
1D&2D bar codes
Magnetic recording tape credit card
Electromagnetic Radio frequency identification
Smart card chip card, IC card
Touch touch screen
Biometric vocal commands voice recognition, finger print, eye scan
Error in ADC
FRR first read rate probability of a successful (correct) reading by
the scanner in its initial attempt
SER substitution error rate probability or frequency with which the
scanner incorrectly reads the encoded character
Bar code Technology
1D Bar Code (Linear)
o
Most widely used automatic identification & data
collection technique
Types
Height modulated varying height
Width modulated varying width of bars & spaces
Width Modulated
Symbol consists of a sequence of wide & narrow colored bass separated by
wide & narrow spaces.
Black & white for high contrast
Bar code readers interpret the code by scanning & decoding the sequence of
bars.
Consist of scanner & decoder
Scanner
Emits a beam of light
Swept past the code
Senses light reflections to distinguish between bars & spaces
Light reflections are sensed by a photo detector
Converts the spaces into electrical signal & bass into absence of signal
Duration of corresponding signal is related to the width of the bars and
spaces
Decoder analyzes the pulse train to interpret corresponding data
Grocery & Retail stores UPC Numeric
Department of Defense Code 39 Alphanumeric
Bar code symbol
Code 39 uses a series of wide & narrow elements (bars & spaces) to
represent alphanumeric & other characters.
Wide element 1
Narrow element 0
Both bars & spaces
9 elements are used for each number or character
Any 3 elements are wide, 9 are narrow either bar or space
2D Bar Code
High area density can store much greater amount of data
Special scanning equipment is required more expensive
Stacked Bar code multiple rows of linear conventional bar codes stacked on
to of each other
Matrix Bar code capability of containing more data than stacked code
o More complicated
o Both horizontally & vertically
Bar code Reader
Manual contact using pens
Automatic non-contact
Manual: memory device capable of storing data acquired during operation
Automatic: light beam on bar code photo detector reads the reflected signal
to interpret the code
Fixed beam stationary mounted
Moving beam highly focused light bean laser is
used . High rotational speed of mirror (around 1440 scans/ sec)
Stationary
Portable
Group Technology & Cellular Manufacturing
Group Technology
GT is a manufacturing philosophy in which similar parts are identified
and grouped together to take advantage.
Similar parts are arranged into part families:
Each family processes similar design & manufacturing characteristics
Similar processing increased efficiency
Arrange production equipment into machine groups/cells
o Facilitate work flow
Cellular Manufacturing
Grouping the production equipment into machine cells where each cell
specializes in the production of a part family.
Application
In plants currently uses traditional batch production
& process layout
For parts those can be grouped into part families
Steps
Identify part families
Rearranging production machines into machine cells
Advantages
Standardization of tooling / fixture
Reduced material hand ling
Team work
Reduced WIP
Reduced manufacturing time
Part Families
Part family is a collection of parts that are similar either because of
geometric shape & size or because similar processing steps are required in
their manufacture.
Similarities are close enough
Grouping parts into families is the toughest job
Visual
Part classification & coding
Production flow analysis (PFA)
Visual
Least sophisticated, least expensive
Performed by looking at parts or photographs
Least accurate
Parts classification & coding
Most time consuming
Similarities are identified
Related in a coding system
Design Attribute geometry, size, material
Manufacturing Attribute sequence of processing steps
Reason to use coding system
Design retrieval search for design
CAPP search for process plan
Machine cell design producing all members of a part family
Features
Design attributes
Manufacturing attributes
Both design & manufacturing attributes
In terms of meaning of symbols
Hierarchical 2nd digit depends on 1st
Chain-type independent meaning
Mixed mode
Opitz system
Introduced by H. Opitz
Intended for machine parts
12345
form code
6789
supplementary code
ABCD
secondary code
Form code and supplementary code are the basic codes.
Form code primary design attributes
External shape
Machined features
Supplementary some other attributes
Dimension, material
Secondary serve own particular need
Identify production and operation type & sequence
Example:
L/d
1.5
Stepped both sides Thread
Through hole
No shape
No pane surface
Auxiliary hole
1
5
1
0
0
Production Flow Analysis (PFA)
PFA is a method for identifying part families & associated machine
groupings. Work parts with identical & similar routings are classified into part
families.
Uses manufacturing data rather than design data
Steps of PFA
-
Data collection part number & operation sequence
Sorting of processing Routes
Parts are arranged into groups according to route
similarity
Arrange parts into packs
PFA chart
Display
Part-machine incidence matrix 1 or 0
Cluster analysis groupings are identified & rearranged into
new pattern.
Rank order clustering
Example:
machin
e
1
2
3
4
5
6
7
28
27
26
25
24
23
Parts
E
F
22
21
20
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Equiv Rank
290
17
81
136
258
65
140
1
7
5
4
2
6
3
machin
e
1
5
7
4
3
6
2
Equiv
Rank
96
1
1
1
Parts
E
F
1
1
1
machine
1
5
7
4
3
6
2
A
1
1
6
8
H
1
1
64
3
D
1
26
25
24
23
22
21
20
1
1
1
1
1
24
4
1
1
1
1
1
1
5
9
24
5
16
6
96
2
Parts
B
F
1
1
1
1
1
1
1
1
1
7
7
Cellular Manufacturing
Grouped parts are produced using GT machine cells rather than traditional
This is an application of GT in which dissimilar machines or
processes have been aggregated into cells, each of which is dedicated
to the production of a part family.
Cell Design
-
Single machine cell
One machine does all operations
Group machine with manual handling
Group machine with semi-integrated handling loading /
unloading is manual
FMS fully integrated
Key Machine
-
More expensive & perform critical operations
Need to utilize full time bottleneck
Others are supporting machines
Used in designing cell
In line
Loop
Rectangular
Layout
Example: Machine sequence in cell
From
To
1
2
5
30
15
45
10
40
50
4
To
10
50
0
45
0
0
0
40
10
135
From
MACHINE
3
0
4
25
30
From/ To
0.6
0.25
From Maximum to Minimum
3
10
50 IN
40
15
30
25
30 OUT
10
20 OUT
Application of GT
Manufacturing
Product Design
Network Communication
A communication network is the backbone of enterprise integration.
Links all the devices together irrespective of their physical location
Through network, we can integrate the whole enterprise, including
suppliers & customers
Sales
Design
MRP
Manufacture
Delivery
To facilitate rapid interdepartmental responses, well-developed
enterprise network is necessary.
An organization can be mapped onto a communication hierarchy that
includes:
-
Enterprise level
Plant level
Cell level
Equipments level
Network requirements is different in terms of
Communication device
Distance
Physical transmission media
Bandwidth
Protocol functions.
To unify the enterprise, 3 types of network technologies are required to
interconnect different levels:
-
Equipment level sub-networks NC machines & Robots
Plant-wide network connect cells & other departments.
Enterprise-wide networks globally link various plants/sites.
NETWORK
Communication network is a collection of equipment & physical media
that interconnects two or more computers.
-
Local Area Network (LAN) interconnect within same building or
organization
Metropolitan Area Network (MAN) covers a large city or
suburb
o Interconnects
area
LANs
within
metropolitan
Wide Area Network (WAN) uses common career facilities over
long distances.
o Uses to connect sites & equipment
Hierarchical structure
Enterprise Level
Computer
Sales / Marketing /Finance/
CAD/CAM (Design)
Plant Level
Computer
Payroll/Cost accounting
CAD/CAM (Manufacture)
Control/
Coordinate
Cell Level
Satellite
Computer
Satellite
Computer
Enterprise Level
Computer
Computer
Computer
Computer
Computer
Computer
Machine
Machine
Machine
Machine
Machine
Machine
Data management Manufacturing planning & control, MRPII, Order
processing
Data automation
Bar-code reader, Scanner
Selection of Network Technology
Number of factors should be considered:
-
Communication medium
Network topology
Medium access control method
Signaling method
Communication medium
-
Physical material that carry electrical signal of encoded data
Transmit data over short/long distances
Open-wire pairs obsolete now a days
Twisted pair cables good for short distance
Co-axial cables LAN -10 Mb/s transfer rate
Fiber-optic system high data transmission
Wireless media High bandwidth, high cost
Network Topology
It describes the relationship between the nodes in communication system.
1.
Star
-
Central computer is located at the center
Each user is connected directly to the host
High data transfer rate
Computer
Computer
Computer
Central
Computer
Computer
Computer
Computer
2.
Ring
-
Each device is connected to two others
Devices are attached to ring cable if one device fails, ring continues
to function
Number of device connected is not limited by number of slots
Computer
Router
Computer
Computer
Router
Router
Router
Router
Router
Computer
Computer
Computer
3.
BUS
-
One of the most commonly used
Devices are connected to cable
Requires less cable than star
All devices need to share cable.
Computer
Computer
Computer
4.
Computer
Computer
Tree
-
Devices are connected to hub that passes the message from one
device to other
Very flexible layout
Network survives if one cable fails.
Computer
Computer
Computer
Computer
Computer
Access Control
Computer
Information / Data access to network
Token passing Token is a special code. Token is passed to the network in a
predetermined sequence
Some machine may get higher priority
A station may transmit only when it receives the token
Manufacturing network uses this method
CSMA/CD Carrier-sense multiple access with collision detection
Developed by Xerox
Any station wants to send signal, listens whether line is busy or not -then send signal if not busy.
If same time collision occurs.
If collision is detected, sender waits for a while before re-transmitting
the signal.
Signaling method
Data are propagated from one point to another by means of signals
-
Signals are electromagnetic representation of transmitted data
Data/signal converters convert data to signals for transmission on the
sending end & back to data at receiving end
Broad band
LAN converts data into signals before transmission, transmit signals, &
the convert the signals into data at receiving end
Many independent messages can be transmitted simultaneously.
Serves as backbone that supports many channels.
Base band
Uses data itself as a signal by impressing the data directly onto the
communication wire
Works well in small network
Only one signal can be transmitted
MAP/TOP
MAP (Manufacturing Automation Protocol)
Developed by GM
Uses BUS network
Broadband transmission
Token passing access method
Suitable for shop floor
TOP (Technical & Office protocol)
Developed by Boeing
Uses CSMA/CD access method
MAP & TOP are compatible the two can be connected through a bridge.
Bridge - Connects two similar or dissimilar LANs to form a large network at
data link layer
Repeater Interconnects segments of an intended network with identical
protocols & speeds at physical layers
Both MAP & TOP follow 7 layers OSI (Open system interconnection) model,
proposed by ISO.
Application
Application
Presentation
Presentation
Session
Session
Transport
Transport
Network
Network
Data Link
Data Link
Physical
Physical
Medium
Physical
Consists of hardware that drives network & circuits.
Deals with mechanical, electrical, functional
characteristics to access physical medium
&
procedural
Data link
Transfer information across physical link
Error control, flow control of functions
Network
Decides which outgoing line will be used to send the message to a
node
Transport
Provides transported transfer of data to & from the session layer
without disruption
Session
Controls communication between applications
managing & terminating virtual connections
applications
by establishing,
bet cooperating
Presentation
Performs certain decoding & conversation operations on data to match
the device & network requirement.
Application
Provides the user interface to the networking system
Written by the user.
