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Chapter 5 Group 2

The document discusses components of modern material handling, including storage and handling equipment like racks and shelves, as well as engineered systems like conveyor systems and automated guided vehicles. It also discusses principles of material handling and automated storage and retrieval systems.
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0% found this document useful (0 votes)
36 views16 pages

Chapter 5 Group 2

The document discusses components of modern material handling, including storage and handling equipment like racks and shelves, as well as engineered systems like conveyor systems and automated guided vehicles. It also discusses principles of material handling and automated storage and retrieval systems.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Presented to the Department of Industrial Engineering

De La Salle University - Manila / Laguna


Term 1., A.Y. 2023-2024

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).

Different kinds of material handling equipments based on Thomas 2023


Storage and Handling equipments:
- Racks: Racks, such as pallet racks, drive-through or drive-in racks, push-back racks, and
sliding racks, are fundamental for storage. They efficiently utilize floor space while
ensuring easy access to stored contents.
- Stacking Frames: Stacking frames are stackable structures that allow the stacking of
items like crushable pallets or containers of liquids, optimizing space without causing
damage.
- Shelves, Bins, and Drawers: Shelves, bins, and drawers offer a versatile storage solution,
particularly suitable for smaller and more intricate materials and products. Various
shelving types, including boltless, cantilever, revolving, and tie-down, provide options for
organization.
- Mezzanines: Mezzanines are indoor platforms that expand floor space within a
warehouse or storage building. They are available in different types, such as modular,
movable, rack-supported, building-supported, and free-standing, and can accommodate
offices or additional storage.
- Work Assist Tooling: Work assist tooling aids in safe and efficient product handling in
various industries, particularly in assembly and manufacturing operations, enhancing
overall efficiency.
- Pallet Inverters: Pallet inverters are similar to upender inverters and are used to rotate or
reposition heavy items and fully loaded pallets with ease, facilitating material handling
processes.
Engineered Systems:
- Conveyor Systems: Conveyor systems are versatile and come in various types, including
vibrating, overhead, chain, vertical, and apron conveyors. The choice of conveyor type
depends on the specific material or items they are designed to transport.
- Automatic Guided Vehicles (AGV): AGVs are autonomous, computer-operated trucks
that follow predetermined paths. Equipped with sensors and detectors, they navigate and
transport loads without human intervention, ensuring collision avoidance during material
handling processes.

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

Types of automated storage and retrieval systems and illustrative examples


An instance of an automated storage and retrieval system can be seen in the form of a unit-load
system with red and blue components traveling on a designated track.

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.

2. Mitigation of Labor Constraints


- Even when an operation has the financial means to hire more workers, external
factors like geography, job market conditions, and demographic trends can limit
the availability of labor. AS/RS addresses these constraints by introducing
automation in place of human employees. This allows warehouse staff to be
redirected to more valuable tasks that enhance operational profitability, while
routine, lower-value tasks are handled by technology.

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.

4. Improved Precision, Productivity, and Efficiency


- As mentioned earlier, humans are prone to errors, regardless of their training or
diligence. These errors not only pose safety concerns and potential product
damage but also disrupt workflows and lead to inefficiencies. For instance,
delivering a pallet of products to the wrong department can cause confusion,
traffic congestion, and disruptions in order processing until the error is rectified.
Allowing AS/RS systems to automate certain aspects of your operation eliminates
these inefficiencies, ultimately reducing waste and increasing output. This, in
turn, enhances the accuracy and profitability of your operation.

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.

6. Optimal Space Utilization


- AS/RS systems provide a valuable benefit to operations with limited physical
space. By optimizing space utilization within a facility, AS/RS eliminates the
need for expensive facility redesigns or expansions. AS/RS systems typically
require narrower aisles compared to human-operated forklifts, allowing for
vertical storage space reclamation and facilitating high-density storage that is
challenging to achieve through conventional methods.
Disadvantages of AS/RS
1. Substantial Initial Investment
- In the long term, incorporating an automated storage and retrieval system has the
potential to reduce labor expenses and boost productivity. However, these
advantages come with an upfront cost: the initial investment required. Similar to
many automation initiatives, procuring an AS/RS system incurs higher short-term
expenses compared to hiring personnel or utilizing alternative equipment like
forklifts. This initial financial outlay can pose a challenge, especially for smaller
businesses without readily available capital, although leasing options for
equipment may alleviate this entry barrier for some enterprises.
2. Maintenance Considerations
- Like any equipment or technology, AS/RS systems will necessitate routine
maintenance and occasional repairs. This inevitably results in some operational
downtime when repairs and maintenance are performed. Although still more
cost-effective than the ongoing expenses associated with hiring and retaining
additional staff, it's important to factor in the costs of maintenance before
implementing a new system.

3. Suitability for Predictable Operations


- AS/RS, like all automation technologies, is most effective in operations
characterized by consistent, foreseeable, and repetitive tasks. Operations that
exhibit significant variability in the products or materials they handle from week
to week or month to month may encounter challenges in integrating AS/RS into
their business strategy. AS/RS systems operate based on predefined systems,
processes, and analyses, making rapid adjustments difficult to accommodate.

4. Technical Skill and Re-Training Requirements


- Introducing new AS/RS systems into your warehouse entails the need for
comprehensive training for your employees to ensure safe operation and optimal
utilization of the technology. This training period will naturally lead to some
downtime, and there may be a need for retraining current staff, potentially
impacting staff retention.

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.

Conveyor System Requirements


Space - Manufacturers of conveying systems assess the available space to establish the system's
configuration. During this phase, they identify points of interaction, clearance, potential
obstacles, or any zones that might impede the flow of materials. While automated systems are
prevalent, the decision between motorized or manual operation depends on the intended use of
the system.
Load Capacity - After designing the system and establishing its configuration, it's essential to
determine its material-carrying capacity, as overloading can result in damage or operational
interruptions. The load capacity is influenced by factors such as the system's length, bed width,
and the type of drive system it employs.
Speed - Conveying systems are typically measured in feet per minute (fpm), with an average
speed of 65 fpm, equivalent to the pace of a person carrying a 50 lb. package. However, this
speed can be adjusted up or down as needed for specific applications.
Powder or Liquid Material Handling - Handling powdered materials involves distinct
parameters compared to conveying systems designed for solid, bulky items. A properly designed
system for powders and liquids must maintain effective sealing to prevent leaks. Handling
materials like powders, granules, or chips may lead to dust accumulation, which is considered in
system design and may require filtration. As with any conveying system, a thorough evaluation
of the material's characteristics is essential.
Configuration - Conveying systems exhibit a broad range of shapes, designs, sizes, and
configurations, including vertical, angled, horizontal, curved, featuring pockets, slats, or
z-frames. Since each system is tailored for a specific purpose, it's impractical to detail all the
diverse setups. The crucial point to grasp is that incorporating a conveying system, regardless of
the application, generally involves few limitations.
Drive System - The driving mechanism in an automated conveying system is responsible for
propelling materials forward, featuring a counter bearing for continuous motion along the belt.
These systems can be engineered for bidirectional movement and positioned at various points
within the setup, including the middle, end, or beginning. Overhead systems, while sharing
similar drives, may utilize chain or sprocket drives. For conveying liquids, granular materials, or
powders, pneumatic power or screw drives may be employed. Drive systems can offer either
single or variable speeds, often operated by a motor-driven gear system. Variable speed drives
have gained popularity in modern conveying systems as they allow for adjustments in material
flow.

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.

Material Flow Control (Piani, 2023; Babbar et al., 1998)


What is material flow control
Material flow control is defined as the management of the flow of materials within a
company, often with a specific objective in mind. It takes into consideration all the parts of the
process — the body, communication, and objective — to further the goals and visions of the
company.

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.

Parts of material flow control


Body
The body is composed of all the tangible components of the material flow control
process. This may include people, equipment, or the materials themselves that are being
transferred across the warehouse.

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.

Example of material flow control optimizations


Inventory management
The warehouse manager must maintain optimal safety levels and delivery lead times to
reduce the amount of downtime that accumulates throughout a production cycle. Having optimal
safety levels ensures that the company never runs out of materials to work with during instances
of sudden supply disruption (Hung & Chang, 1999).
Supply Chain Coordination
Coordinating with the suppliers is another way to ensure proper material flow within a
company, for it is through such coordination that the warehouse manager will know when a
particular material will be available or delivered. This way, the company can ensure that
available materials will not go below the safety levels.

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.

Traditional Warehousing vs. Modern Warehousing


Traditional warehousing focuses on storage and inventory management; while modern
warehousing embraces a holistic approach as it integrates technologies, such as IoT and lean
principles to optimize operations Christiansen, H. (2015)

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.

Case Study: Amazon Fulfillment Centers


Amazon’s extensive use of AS/RS, robotics and advanced algorithms has revolutionized
the ecommerce industry (Dutta, S., & Evrard, A., 2018). Here’s how automation has
revolutionized Amazon:
- Vertical storage: The AS/RS systems utilize vertical space efficiently as they stack items
in multiple levels. This optimizes the use of warehouse space and allows for a vast
inventory to be stored in a relatively compact footprint.
- Error Reduction: Automation (Kiva Robots) reduces the potential for human error in
locating and picking items.
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https://www.britannica.com/technology/materials-handling

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efficient material handling. Custom Case Company.
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Christiansen, H. (2015). Effective warehouse management using Lean and Six Sigma (Master's
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Liker, J. K., & Choi, T. Y. (2004). Building deep supplier relationships. Harvard business review,
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