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Facilities Planning and Design Course code: 1704031511 Spring 2017-2018

Facilities Planning and Design Course code: 1704031511 Spring 2017-2018 Required Text: Tompkins et al., (2003). Facilities Planning, 3rd or later Edition, John Wiley and Sons Inc. Students are encouraged to refer to the text book, and to take notes during the lectures.

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Facilities Planning and Design Course code: 1704031511 Spring 2017-2018

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  1. Facilities Planning and DesignCourse code: 1704031511 • Spring 2017-2018 • Required Text: Tompkins et al., (2003). Facilities Planning, 3rd or later Edition, John Wiley and Sons Inc. • Students are encouraged to refer to the text book, and to take notes during the lectures.

  2. Chapter 5 - Material Handling Major Topics: • Scope and definition of Material Handling. • Material Handling Principles • Unitloaddesign • Designingmaterial handlingsystems • Material handlingequipment

  3. Scope and definition of Material Handling • Definitions: • Material handling is the combination of art and science of moving, storing, protecting and controlling the material. • Material handling means providing the right amount of the right material, in the right condition, at the right place, in the right position, in the right sequence, in the right time, for the right cost by the right method(s). • Scope of Material Handling • Conventional view: movement of material from one location to another within the same facility • Contemporary view: overall movement of materials in a factory or warehouse through an integrated material handling plan • Goals of material handling: • Reduce unit costs of production • Maintain or improve product quality, reduce damages, and provide for protection of materials • Promote safety and improve working conditions • Promote productivity • Promote increased use of facilities • Control inventory

  4. Material Handling system equation

  5. WHAT WHEN HOW WHERE O- Operation T- Transportation S-Storage I-Inspection

  6. Material Handling Principles The Ten Principles of Material Handling adopted by the College-Industry Council on Material Handling Education (CIC-MHE) are: Planning Principle Standardization Principle Work Principle Ergonomic Principle Unit load principle Space Utilization Principle System Principle Automation Principle Environmental Principle Life Cycle Cost Principle For a detailed explanation, see the provided attachment. Chances for improvements are explored using material handling audit sheet (checklist).

  7. Material Handling Principles Material Handling audit sheet (checklist)

  8. Unit Load Design • Unit load is the amount of material that can be moved as a single mass between two locations • Primary advantage of using unit loads is the capability of handling more items at a time and reducing the number of trips, handling cost, loading and unloading times, and product damage. • The Optimal Unit Load is the quantity where the system idle time, WIP and transportation cost are minimized • Size (volume and weight) of the unit load has major impact on the specification and operation of the material handling • Through a sequence of moves in a given facility, it might be more economic to handle different types of unit loads, than a single type of unit load • Next two examples show how the unit load size affects the completion time of a given job, and the number of trips needed to complete a job.

  9. Effect of unit load size on job completion times

  10. Effect of unit load size on number of trips 5.21 The routing for a given component is given by: A-F-E-D-C-B-A-F Required: moving 2000 pcs from A to F Unit load size at A, F, E is 50 pcs Unit load size at D is 100 pcs How many trips do we need to move all the produced quantity? Vehicle is able to move one unit load Number of trips = 13 There are 13 trips for every 100 loads. Since we have 2000 pieces, then the total number of trip is 2000/100 * 13 = 260 trips Number of trips = 11 There are 11 trips for every 100 loads. Since we have 2000 pieces, then the total number of trip is 2000/100 * 11 = 220 trips

  11. Designing material handling systems Moving of the unit load: Lifting under the mass Inserting the lifting element into the body of the unit load Squeezing the load between two lifting surfaces Suspending the load

  12. Classification of Material Handling Systems: • Mechanized • Semi-automated • Automated • Information-directed Designing material handling systems Categories of Material Handling equipment: I. Containers and unitizing equipment II. Material transport equipment III. Storage and retrieval equipment IV. Automatic identification and communication equipment

  13. Examples of stackable and nestable containers

  14. Designing material handling systems Types of wooden pallets (2-way and 4-way)

  15. Designing material handling systems Relationship among various elements in a distribution system

  16. Designing material handling systems Container-Pallet system with progressive dimensions

  17. Designing material handling systems Common design of wooden pallets

  18. Designing material handling systems Stacking patterns for wooden pallets

  19. Designing material handling systems Schematic layout of a manufacturing subsystem of packaging, palletizing, Storage and shipping

  20. Pallet (48” x 40”) patterns for different carton sizes

  21. Pallet patterns (36”x 36”) for different carton sizes

  22. Designing material handling systems Container and Pallet Pooling

  23. Categories of Material Handling equipment: I. A-Containers and B-unitizing equipment II. Material transport equipment III. Storage and retrieval equipment IV. Automatic identification and communication equipment Pallets Skids Containers

  24. Categories of Material Handling equipment: I. A-Containersand B-unitizing equipment II. Material transport equipment III. Storage and retrieval equipment IV. Automatic identification and communication equipment Carton Palletizer Sretchwrap equipment

  25. Categories of Material Handling equipment: I. Containers and unitizing equipment II. Material transport equipment-Conveyors III. Storage and retrieval equipment IV. Automatic identification and communication equipment Flat belt conveyor Spiral chute conveyor

  26. Categories of Material Handling equipment: I. Containers and unitizing equipment II. Material transport equipment-Vehicles III. Storage and retrieval equipment IV. Automatic identification and communication equipment Pallet jack Lift truck Fork Truck AGV (Automated Guided Vehicle)

  27. Categories of Material Handling equipment: I. Containers and unitizing equipment II. Material transport equipment-Monorails, Hoists and Cranes III. Storage and retrieval equipment IV. Automatic identification and communication equipment Hoist Monorail Tower Crane Jib Crane

  28. Categories of Material Handling equipment: I. Containers and unitizing equipment II. Material transport equipment-Monorails, Hoists and Cranes III. Storage and retrieval equipment-Racking systems IV. Automatic identification and communication equipment Block Stacking Pallet Stacking

  29. Categories of Material Handling equipment: I. Containers and unitizing equipment II. Material transport equipment-Monorails, Hoists and Cranes III. Storage and retrieval equipment IV. Automatic identification and communication equipment Hybrid Truck Cabinets Drawers Bin Shelving

  30. Categories of Material Handling equipment: I. Containers and unitizing equipment II. Material transport equipment-Monorails, Hoists and Cranes III. Storage and retrieval equipment IV. Automatic identification and communication equipment Mobile storage or sliding racks

  31. Categories of Material Handling equipment: I. Containers and unitizing equipment II. Material transport equipment-Monorails, Hoists and Cranes III. Storage and retrieval equipment IV. Automatic identification and communication equipment Mobile batch pick cart

  32. Categories of Material Handling equipment: I. Containers and unitizing equipment II. Material transport equipment-Monorails, Hoists and Cranes III. Storage and retrieval equipment IV. Automatic identification and communication equipment Order pick truck

  33. Categories of Material Handling equipment: I. Containers and unitizing equipment II. Material transport equipment-Monorails, Hoists and Cranes III. Storage and retrieval equipment IV. Automatic identification and communication equipment Vertical carousel Horizontal carousel

  34. Automated storage automated retrieval systems

  35. Categories of Material Handling equipment: I. Containers and unitizing equipment II. Material transport equipment-Monorails, Hoists and Cranes III.Storage and retrieval equipment IV. Automatic identification and communication equipment Contact reader Product identification codes

  36. Categories of Material Handling equipment: I. Containers and unitizing equipment II. Material transport equipment-Monorails, Hoists and Cranes III.Storage and retrieval equipment IV. Automatic identification and communication equipment RF Terminal Bar code scanner

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