Chapter 5 Group 2
Chapter 5 Group 2
In partial fulfillment
of the course
In Course COMPMFG XXE1
Written Report
Batallones, Jose Alfredo Miguel
Cruz, Winona Jeanne
Mapanoo, Darren Neil
Submitted to:
Professor Ronald Mariano
Date
September 26, 2023
Components of modern material handling
What is Material Handling?
Materials handling involves the transportation of raw materials from their origin to
manufacturing and distribution locations. In earlier systems, materials were managed
individually and in distinct stages. Modern practices prioritize streamlined and integrated
processes across various phases, achieved through large-scale transportation methods, the use of
machinery such as cranes and conveyors, and meticulous scheduling. When it comes to liquid
and gaseous materials, such as petroleum and natural gas, pipelines are commonly utilized for
transportation. For solid materials, shipping, trucking, and rail transport are widespread. The
range of materials handling equipment varies from basic carts to advanced machinery like cranes
and conveyors. The utilization of containers and frames plays a crucial role in enhancing
efficiency and reducing the need for excessive handling. Effective materials handling involves
striking a balance between the speed of shipment, its size, weight, and composition. Innovations
in the fields of trucking, rail transport, and shipping have led to increased efficiency and cost
reduction. Air travel stands out as the fastest mode of transportation, albeit the most costly, with
specialized equipment and containers designed to optimize space utilization (Britannica, 2023).
Additional Journals
Principles of material handling
According to a study from Kareem et al., storage and engineered systems assist
profoundly in improving reducing the number of defective products by virtue of shorter
operating cycles, reduced handling costs, and risky handling of materials (Kareem et al., 2022).
It is therefore recommended that companies take into consideration these suggestions to reduce
the risk of damaged goods and materials. Moreover, Heragu and Ekren (2009) suggest that
companies automate the material handling processes to improve operational efficiency,
consistence, and eliminate dangerous manual labour that may result in employees getting hurt.
Some suggestions they mention include gravity rollers, high-speed palletizers, and cube per order
index (COI) policies.
Automated guided vehicle systems
AGVs may utilize routing algorithms to determine the safest and most efficient paths
when traversing the complexities of a particular warehouse. This way, material travel times are
cut-short and risks for accidents are decreased (Li et al., 2011). More to the point, AVGs may
incorporate machine learning algorithms to better optimize AVG networks and adapt to the
ever-growing technologically-oriented manufacturing landscape (Bitsch and Schweitzer, 2022).
AS/RS
What is AS/RS
Automated storage and retrieval systems (AS/RS) are sophisticated computer and robot-assisted
setups designed to efficiently retrieve or store items in designated positions. These systems
typically consist of predetermined storage locations, enabling machines to follow pre-established
paths to access items.
When items are correctly placed in their designated spots, these systems enhance the speed and
precision of manufacturing and shipping operations. AS/RS systems are commonly employed in
situations where there's a need for swift and precise movement of high-volume loads. In this
discussion, we will delve into the primary categories of AS/RS systems, their operational
mechanisms, as well as their strengths and weaknesses (River Systems, 2023)
Types of AS/RS
AS/RS systems primarily fall into two categories: unit-load and mini-load systems. Unit-load
AS/RS are employed for handling substantial loads, such as full pallets or cases of products.
These systems are well-equipped to manage tasks involving objects or pallets weighing several
thousand pounds. Typically, unit-load AS/RS systems utilize either fixed-aisle cranes or
moveable-aisle cranes:
Fixed-aisle cranes remain stationary within a specific area or row of pallets, moving along a
predetermined path to retrieve items.
Moveable-aisle cranes share a similar purpose but are designed to retrieve or store items across
multiple areas rather than adhering to a single path or aisle.
On the other hand, mini-load AS/RS systems, like case-handling or tote-stacking systems,
employ smaller cranes or robots to handle lighter loads, such as trays or cartons. Mini-load
AS/RS systems typically rely on cranes or shuttles:
Mini-load AS/RS cranes navigate narrow aisles to retrieve or store products, resembling a
downsized version of fixed-aisle cranes.
Mini-load AS/RS shuttles operate on a track to transport items or move them between automated
racking systems, akin to a compact flatbed truck. These shuttles can function at different levels if
configured accordingly, but they mostly travel along a single route.
Additionally, there are alternative AS/RS systems like carousel-based setups and vertical lift
modules (VLM). Carousel-based AS/RS systems use a spinning mechanism, with an inserter
extractor, to position shelves or bins correctly for item placement or removal. These systems can
operate both vertically and horizontally within a confined space. Carousel-based AS/RS systems
typically handle tasks of smaller scale compared to heavy-duty unit-load systems.
Vertical lift modules (VLM) function similarly to carousel-based systems. In this case, the
inserter extractor is centrally located within an enclosed structure, surrounded by columns of
trays on both sides. It locates the appropriate tray and delivers it to an operator who then fulfills
the order and returns the tray to its position.
Advantages of AS/RS
1. Cost Savings through Automation
- Implementing an automated storage and retrieval system (AS/RS) can lead to
significant reductions in labor expenses in various ways. In some cases, AS/RS
can entirely replace manual picking labor, freeing up employees to focus on more
productive tasks. While this extreme scenario may not be the norm, a
well-executed AS/RS can bring about substantial efficiencies that positively
impact profitability. By eliminating the need to expand your workforce, the
one-time investment in purchasing and implementing AS/RS has the potential to
eliminate ongoing costs associated with hiring new personnel, such as healthcare,
payroll taxes, salary increases, and training.
3. Enhanced Safety
- Human errors are inevitable due to factors such as distraction, fatigue, hunger, and
psychological stress. These errors, especially when operating heavy machinery
like forklifts, can lead to tragic consequences. Integrating AS/RS systems into
your operation reduces the unpredictable human element by replacing workers
with machines that do not experience fatigue or distraction. This significantly
improves safety, reducing accidents and damage to products, structures, and
equipment.
5. Modular Implementation
- While implementing an AS/RS system can be a substantial initial expense, it
offers an often overlooked advantage: modularity. Operations can gradually
migrate inventory segments into AS/RS, starting with high-demand products,
thereby limiting the initial cost and enabling a gradual transition to full
automation.
Conveyors
What is a conveyor?
A conveyor system serves as a means to transport various items like packages, products,
supplies, components, and machinery, facilitating their movement for purposes such as
manufacturing, shipping, or relocation. There are several types of conveying systems available,
including pneumatic, screw, belt, and roller conveyors. The specific design of each system is
determined by the characteristics of the materials to be transported, including their weight, size,
and transportability.
While conveying systems are crucial for material handling and production, they also find utility
in production-related tasks like sintering, finishing parts and assemblies, and washing
components. In most instances, these systems are automated, although non-automated setups
utilizing chutes and rollers are prevalent in retail, material handling, and shipping applications.
Safety - Conveyor systems are subject to government safety regulations set by the Occupational
Safety and Health Administration (OSHA), and all manufacturers ensure compliance with these
rules. These systems serve as a preventive measure, eliminating the need for employees to
manually handle heavy materials. In the image provided, you can observe safety features such as
an emergency stop button, a keyed motor activation, and symbols indicating conveyor operation.
Types of Conveyors
Belt Conveyors - These are the most common conveyors with variable speeds, featuring a
moving belt supported by a steel frame.
Gravity Roller Conveyors - Equipped with equally spaced rollers connected to a side frame, they
rely on gravity for material movement, especially when tilted or mounted on an incline.
Chain Conveyors - Use chains to support and move items, ideal for uneven or heavy loads,
operating at slower speeds.
Motorized Roller Conveyors - Powered by motors distributed along the frame, they incorporate
rollers similar to gravity conveyors, with motor control to prevent material congestion.
Slat Conveyors - Similar in design to chain conveyors, using flat slats instead of chains, offering
a smooth surface for damage-free material movement, particularly suitable for automated
assembly processes
Overhead Conveyor Systems - Diverse designs with a common goal of optimizing floor space
and facilitating the movement of parts and components.
Why is it important?
Proper material flow control may reduce costs and increase efficiency through the
reduction of downtimes and wasted materials. More to the point, an effective material flow
control process may improve customer satisfaction by ensuring that their orders are met on time
and handled with grace and quality.
Communication
Any item, signal, or medium that communicates the flow of materials would fall under
the category of communication. A proper material flow system facilitates clear and efficient
communication between the people, machine, and materials. Some examples of communication
means include signages, lights, and labels.
Objectives
The objective is the most important part of the material flow control process, for every
part of the warehouse process revolves around this feature. The objective is peculiar to the
company; a baking company may want to organize its processes in such a way that maximizes
production without overproduction, while a circuit board manufacturer may want to have some
spares built in the event of a sudden influx of demand.
Warehousing
Supply chains are dependent on their warehousing for their management as it serves as the
crucial link between distribution and production (WiSys 2021). Warehousing is a critical
component which encompasses a variety of activities in the context of materials handling, such
as inventory management, storage, and transportation goods. The significance of efficient
warehousing cannot be overstated, thus impacting the overall performance and competitiveness
of companies in various industries.
Just-in-Time Inventory
Just-in-Time warehousing levels with the actual demand, thus reducIng lead time and carrying
costs. Toyota’s Production System is an example of JIT principles applied to modern
warehousing (Liker, J. K., & Choi, T. Y., 2004). This approach seeks to optimize inventory levels
by holding only what is needed, when it is needed. The key principles include:
- Minimized Inventory : The core principle of JIT is to hold what is needed only when it is
needed, as well as meeting customer demands.
- Demand-Driven: JIT warehousing relies on accurate demand and coordination Inventory
is ordered and/or produced based on forecasting and real-time data to trigger the
replenishment of inventory.
- Efficient Layouts: Warehouses designed for JIT often rely on layouts optimized for quick
and easy access to inventory.
- Improvement: Just-in_time warehousing embraces a culture of non-stop learning and
improvement. Teams are encouraged to identify and eliminate wastes and excess motion.
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