MATERIAL HANDLING Material handling means providing the right amount of the right material, in the right condition, at the right place, at the right time, in the right position and for the right cost, by using the right method. It is simply picking up, moving, and lying down of materials through manufacture. It applies to the movement of raw materials, parts in process, finished goods, packing materials, and disposal of scraps. It is very important for FMS.

OBJECTIVES OF MATERIAL HANDLING • The primary objective of a material handling system is to reduce the unit cost of production. The other subordinate objectives are: • 1. Reduce manufacturing cycle time • 2. Promote safety and improve working conditions

DESIGN OF MATERIAL HANDLING SYSTEMS A common approach to the design of MH systems (MHS) is to consider MH as a cost to be minimized. 1.Material Characteristics For handling purposes, materials can be classified by the physical characteristics may be solid ,liquid or gases. 2.Flow Rate - What amount of material is required. 3.Routing factors - Include pickup and drop-off locations, move distances, routing variations, and conditions that exist along the routes.

4.Scheduling - Relates to the timing of each individual delivery. 5.Plant layout - Plant layout is an important factor in the design of a material handling system. It uses total area of the facility and areas within specific departments in the plant arrangement of equipment in the layout, locations where materials must be picked up (load stations) and delivered (unload stations).

TYPES OF MATERIAL HANDLING • Manual handling • Automated handling Manual handling Manual handling refers to the use of a worker’s hands to move individual containers by lifting, lowering, filling, emptying, or carrying them.

AUTOMATIC MATERIAL HANDLING Material handling system in which all the works are done by automated machines like AGV,robots without involvement of human efforts.

Equipment Categories • Transport Equipment • Positioning Equipment • Unit Load Formation Equipment • Storage Equipment Transport Equipment. Equipment used to move material from one location to another (e.g., between workplaces, between a loading dock and a storage area, etc.). The major subcategories of transport equipment are conveyors, cranes, and industrial trucks.

Positioning Equipment - Equipment used to handle material at a single location (e.g., to feed and/or manipulate materials so that are in the correct position for subsequent handling, machining, transport, or storage). Unlike transport equipment, positioning equipment is usually used for handling at a single workplace. Unit Load Formation Equipment- Equipment used to restrict materials so that they maintain their integrity when handled a single load during transport and for storage.

Storage Equipment - Equipment used for holding or buffering materials over a period of time. Some storage equipment may include the transport of materials (e.g., the S/R machines of an AS/RS, or storage carousels).

Material Handling transport Equipment • Conveyors • Cranes • Industrial Trucks

Conveyors Conveyors are used: • When material is to be moved frequently between specific points. • To move materials over a fixed path. • When there is a sufficient flow volume to justify the fixed conveyor investment.

Conveyor Types • Flat belt conveyor • Roller conveyor

wheel conveyor screw conveyor

Cranes • Used to move loads over variable (horizontal and vertical) paths within a restricted area • Used when there is insufficient (or intermittent) flow volume such that the use of a conveyor cannot be justified • Provide more flexibility in movement than conveyors • Loads handled are more varied with respect to their shape and weight than those handled by a conveyor • Most cranes utilize hoists for vertical movement, although manipulators can be used if precise positioning of the load is required

TYPE OF CRANES 1. Jib crane 2. Bridge crane 3. Gantry crane 4. Stacker crane

Jib crane Bridge crane

Gantry crane Stacker crane

Industrial Trucks • Used to move materials over variable (horizontal) paths with no restrictions on the area covered (i.e., unrestricted area) • Provide vertical movement if the truck has lifting capabilities • Used when there is insufficient (or intermittent) flow volume such that the use of a conveyor cannot be justified • Provide more flexibility in movement than conveyors and cranes

Type Of Industrial Trucks Hand truck counter balance lift truck

Trolly Pallet Jack

Automated Guided Vehicle An Automated Guided Vehicle is an automated material handling system which moves along predefined or preprogram path along an aisle from one station to another to MH operation. Most AGV are driven by electric motors powered by storage battery. • Good for high labor cost, hazardous, or environmentally sensitive conditions. • AGVs good for low-to-medium volume medium-to-long distance random material flow operations (e.g., transport between work cells in a flexible manufacturing system (FMS) environment)

Types Of AGV • Tow AGV • Unit Load AGV • Light Load AGV • Assembly AGV • Fork Lift AGV

Types Of AGV Tow or rail AGV • Used to pull a train of trailers • Automated version of a tractor trailer • Trailers usually loaded manually or semi automated(early type of AGV, not much used today)

Unit Load AGV • Have decks that can be loaded manually or automatically with help of rollers. • Deck can include conveyor or lift/lower mechanism for automatic loading and unloading. • Load capacity ranges upto250 kg or less.

Light Load AGV • It is use for light load include components, tools etc. • These are generally used for electronic assembly and office environment. • It is used to carry upto 35 kg or less.

Assembly AGV • It is adaptation of light load transporter. • It is used for serial assembly process like car chasis, engine.

Fork Lift AGV • It has ability to pick up and drop off palletized load both at floor level and on stand • It have sensors on fork for pallet interfacing.

How motion is controlled ? • NAVIGATION • Wired Guidance System • Magnetic Guidance System • Laser Guidance System • TRAFIC CONTROL

WIRED GUIDANCE SYSTEM A slot is cut in to the floor and a wire is placed approximately 1 inch below the surface. This slot is cut along the path the AGV is to follow. • This wire is used to transmit a radio signal. A sensor is installed on the bottom of the AGV close to the ground. • The sensor detects the relative position of the radio signal being transmitted from the wire.

MAGNETIC GUIDANCE • Magnetic spots are provided on the path. • The AGV is fitted with the appropriate guide sensor to follow the path of the tape. • One major advantage of tape over wired guidance is that it can be easily removed and relocated if the path needs to change.

LASER GUIDANCE SYSTEM • The navigation is done by mounting reflective tape on walls, poles or fixed machines. • The laser is transmitted and received by the same sensor. • The angle and (sometimes) distance to any reflectors that in line of sight and in range are automatically calculated. • This information is compared to the map of the reflector layout stored in the AGV's memory.

TRAFIC CONTROL • It is based on zone control rule in which only one vehicle allowed in a given zone at a time. • A wireless transmitter transmit a signal in a fixed area each AGV contains a sensing device to receive this signal and transmit back to the transmitter. • If the area is clear the signal is set at “clear” allowing any AGV to enter and pass through the area. • When an AGV is in the area the “stop” signal is sent and all AGV attempting to enter the area stop and wait for their turn. Once the AGV in the zone has moved out beyond the zone the “clear” signal is sent to one of the waiting AGVs.

REFRENCES • "Material Handling and Logistics U.S. Roadmap" (PDF). MHI. January 2014. Retrieved 2015 05 08. • “The Basics of Automated Guided Vehicles” (http://www.agvsystems.com/basics/vehicle.htm). AGV Systems. Savant. 5 March 2006 • Jeong, B.H., Randhawa, S.U., 2001. A multi-attribute dispatching rule for automated guide vehicle systems. International Journal of Production Research 39 (13), 2817–2832. • P.S. Gabbert, D.E. Brown, A knowledgebased approach to material handling system design in manufacturing facilities, in: Proceedings of the 1987 International Industrial Engineering Conference, 1988, pp. 153–157.

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