AUTOMATION

AUTOMATIONIN
INMANUFACTURING
MANUFACTURING
Foo Jin Hoe, PhD.

jinhoe@fkm.utm.my
C23-408
+6(07)-5534703
 Foo Jin Hoe, PhD.

Certificate in Laboratory Testing (ILPP) - 1995

Advanced Diploma in Manufacturing Eng.
(RMIT, Australia) - 1998
B.Eng (Hons.) in Manufacturing Eng. (Coventry University,
UK) - 2000
M.Sc (Merit.) in Eng Management & Manufacturing.
(Coventry University, UK) - 2002
PhD Nanocomposite Material (Shibaura Institute of
Technology, Japan) - 2013
“Automation can be defined as a
technology concerned with the
application of electronic, mechanical
and computer- based systems to
operate and control the production”.
Automation
Automation

“To perform a task ,without

human intervention to improve
the productivity and quality”.
CNC Machines, Automated guided
vehicles, robots etc……
Reasons
Reasonsfor
forautomation
automation

1. To Increase labor productivity.

2. To reduce labor cost.
3. To mitigate the effects of labor shortages.
4. To reduce or eliminate routine manual and clerical tasks.
5. To improve worker safety.
6. To improve product quality
7. To reduce manufacturing lead time.
8. To accomplish processes that cannot be done manually.
Production
ProductionSystems
Systems

- That are used to manufacture products and the parts assembled

into those products.
- Production system is the collection of people equipment and
procedures organized to accomplish the manufacturing
process of a company.
Production
Productionsystems
systemscan
canbe
bedevided
devidedin
intwo
two categories
categories

Manufacturing
Manufacturingsupport
supportsystems
systems

Facilities :
Factory Equipment
 Facilities
Facilities

•The
•Thefacilities
facilitiesofofthe
theproduction
productionconsist
consistofofthe
thefactory,
factory,the
theequipment
equipmentinin
the
thefactory
factoryand
andthetheway
waythe
theequipment
equipmentisisorganized.
organized.
 Hard
Hardproduct
product

-The
-Thevariety
varietybetween
betweendifferent
differentproduct
productcategories
categories

Soft
Softproduct
product

-The
-Thevariety
varietybetween
betweendifferent
differentmodels
modelswithin
withinthe
thesame
sameproduct
productcategories
categories
a)a) Fixed-position
Fixed-positionlayout
layout
b)b) Process
Processlayout
layout
c)c) Cellular
Cellularlayout
layout
d)d) Product
Productlayout
layout

Various
Varioustypes
typesof
ofplant
plantlayout
layout
Fixed-position layout : Workers and processing equipment are
brought to the product, rather than moving the product to the
equipment .This type of layout referred to as fixed-position
layout.

Process layout: The individual parts that comprise these large

products are often made in factories that have a process layout.
Cellular layout: The term cellular manufacturing
often associated with this type of production. Each
cell is designed to produce a limited variety of part
configurations. That is the cell specializes in the
production of a given set of similar parts or products
according to the principles of group technology.

Product layout: The collection of stations is designed

specifically for the product to maximize efficiency.
Types of facilities and layouts used for different levels of
production quantity and product variety
Automation Principles and Strategies

 Automation is not always the right answer for a given

production situation. A certain caution and respect must be
observed in applying automation technologies.

 Three approaches for dealing with automation projects

1. USA Principle
2. Ten Strategies for Automation and Production Systems
3. Automation Migration Strategy
USA
USAPrinciple
Principle

1.1. Understand
Understandthe
theexisting
existingprocess
process

2.2. Simplify
Simplifythe
theprocess
process

3.3. Automate
Automatethe
theprocess
process

USA
USAapproach
approachisisapplicable
applicabletotonearly
nearlyany
anyautomation
automationproject
project
 Understand the existing process

The first step in the USA approach is to comprehend the current

process in all of its details.
* What are the inputs? What are the outputs ?
* What exactly happens to the work unit between input and
output?
* What is the function of process?
* How does it add value to the product?
* What are the upstream and downstream operations in the
product sequence, and can they be combined with the process
under consideration?.
 Simplify the process

*Once the existing process is understood, then the search can

began for ways to simplify. This often involves a checklist of
questions about the existing process.
Unnecessary steps can be eliminated without detracting from the
function.
 Automate the process

*Once the process has been reduced to its simplest form

then automation considered. The possible form of
automation include those listed in the ten strategies.
Ten Strategies for Automation and Production
Systems
 Automation seems a feasible solution to improving
productivity, quality, or other measure of performance
then the following ten strategies for these improvements
discussed.
1. Specialization of operations: The first strategy involves
the use of special-purpose equipment designed to perform
one operation with the greatest possible efficiency. This is
analogous to the concept of labor specialization. Which is
employed to improve labor productivity.
2. Combined operations: Production occurs as a sequence of
operations. Complex parts may require dozens, or even
hundreds, of processing steps. The strategy of combined
operations involves reducing the number of distinct
production machines or work stations.
3. Simultaneous operations: A logical extension of the combined
operations strategy is to simultaneously perform the operations
that are combined at one work-stations. In effect two or more
processing (assembly) operations are being performed
simultaneously on the same work part.

4. Integration of operations: Another strategy is to link several

work stations together into a single mechanism, using automated
work handling devices to transfer parts between stations.

5. Increased flexibility: This strategy attempts to achieve

maximum utilization of equipment for job shop and medium value
situations by using the same equipment for a variety of parts or
products.

6. Improved material handling and storage: A great opportunity

for reducing non-productive time exists in the use of automated
material handling and storage systems.
7. On-line inspection: Inspection for quality of work is traditionally
performed after the process is completed. This means that any
poor-quality product has already been produced by the time it is
inspected.

8. Process control and optimization: Manual control to automated

control by optimization we can give the best parameters. Then
the individual process can be reduced.

9. Plant operation control: Those which are not related fabrication

process, each division specify automate. Business functions,
product design.

10. Computer- integrated manufacturing: Input from market

delivery to the final customer every operation is integrated to the
computer. Business functions, product design etc…..
Automation Migration strategy

Owing the competitive pressures in the marketplace,

often needs to introduce a new product in the shortest
possible time. A typical automated strategy is shown.
Phase 1: Manual production using single station manned
cells operating independently.
Phase 2: Automated production using single station
automated cells operating independently.
Phase 3: Automated integrated production using a multi
station automated system with serial operations and
automated transfer of work units between stations.
AAtypical
typicalautomation
automationmigration
migrationstrategy
strategy
Manual
ManualAssembly
AssemblyLines
Lines

-Most
-Mostmanufactured
manufacturedconsumer
consumerproducts
productsare
areassembled.
assembled.Each
Eachproduct
product
consists
consistsofofmultiple
multiplecomponents
componentsjoined
joinedtogether
togetherby
byvarious
variousassembly
assembly
processes.
processes.These
Thesekinds
kindsofofproducts
productsusually
usuallymade
madeon
onaamanual
manualassembly
assembly
Line.
Line.Factors
Factorsfavoring
favoringthe
theuse
useofofmanual
manualassembly
assemblylines
linesinclude
includethe
the
following.
following.
 Demand for the product is high or medium .
 The products made on the line are identical or similar
 The total work required to assemble the product can be
divided into small work elements.
 It is technologically impossible or economically infeasible
to automate the assembly operations.
 Configuration
Configurationofofaaproduction
productionline
line

AAmanual
manualassembly
assemblyline
line isisaaproduction
productionlinelinethat
thatconsists
consistsofofaa
Sequence
Sequenceofofworkstations
workstationswherewherethetheassembly
assemblytasks
tasksare
areperformed
performed
by
byhuman
humanworkers.
workers.Products
Productsare areassembled
assembledasastheytheymove
movealong
alongthe
the
line.
line.At
Ateach
eachstation,
station,aaportion
portionofofthethetotal
totalwork
workisisperformed
performedon oneach
each
Unit.
Unit.
 Products usually made on Manual Assembly Lines
Audio
Audioequipment
equipment Lamps
Lamps Refrigerators
Refrigerators
Automobiles
Automobiles Luggage
Luggage Stoves
Stoves
Cameras
Cameras Microwave
Microwaveovens
ovens Telephones
Telephones
Cooking
Cookingranges
ranges Personal
Personalcomputers
computersand
and Toasters
Toasters
Dishwashers
Dishwashers peripherals
peripherals Toaster
Toasterovens
ovens
Dryers
Dryers Power
Powertools(saws,
tools(saws,drills
drillsetc)
etc) Video
Videocassette
cassette
Electric
Electricmotors
motors Pumps
Pumps Washing
Washingmachines
machines
Manual Assembly Lines are so productive
compared with alternative methods.

Specialization of labor: Called “Division of labor”, this

principle asserts that when a large job is divided into
small tasks and each task is assigned to one worker, the
worker becomes a specialist.

Interchangeable parts: In which each component is

manufactured to sufficiently close tolerances that any part
of a certain type can be selected for assembly with its
mating component. Without interchangeable parts
assembly would require filing and fitting of mating
components.
Work principle, in material handling, which provides
that each work unit flows smoothly through the
production line , traveling minimum distances
between stations.

Line pacing: Workers on an assembly line are usually

required to complete their assigned tasks on each
product unit within a certain cycle time, which paces
the line to maintain a specified production rate.
 Fundamentals of Manual Assembly Lines

AAmanual
manualassembly
assemblyline
lineisisaaproduction
productionline
linethat
thatconsists
consistsofof
Sequence
Sequenceofof workstations
workstationswhere
whereassembly
assemblytasks
tasksareareperformed
performed
by
byhuman
humanworkers.
workers.Products
Productsareareassembled
assembledasastheytheymove
movealong
alongthe
the
line.
line.At
Ateach
eachstation
stationaaportion
portionofofthe
thetotal
totalwork
workisisperformed
performedon oneach
each
unit.
unit.Base
Baseparts
partsonto
ontothe
thebeginning
beginningofofthe
theline
lineatatregular
regularintervals.
intervals.Each
Each
base
basepart
parttravels
travelsthrough
throughsuccessive
successivestations
stationsand
andworkers
workersandandcomponents
components
through
throughprogressively
progressivelybuild
buildthetheproduct.
product.

1.1. Assembly
Assemblyworkstations
workstations

2.2. Work
Worktransport
transportsystem
system

3.3. Line
Linepacing
pacing
 Assembly
AssemblyWorkstations
Workstations

AAworkstation
workstationononaamanual
manualassembly
assemblyline
lineisisaadesignated
designatedlocation
locationalong
along
The
Theworkflow
workflowpath
pathatatwhich
whichone
oneorormore
morework
workelements
elementsare
areperformed
performed
By
Byone
oneorormore
moreworkers.
workers.The
Thework
workelements
elementsrepresent
representsmall
smallportions
portionsofof
the
thetotal
totalwork
workthat
thatmust
mustbebeaccomplish
accomplishtotoassemble
assemblethe
theproduct.
product.

Some
SomeWorkstations
Workstationsare aredesigned
designed for
forworkers
workerstotostand,
stand,while
whileother
otherallow
allowt
workers
workerstotosit.
sit.When
Whenthe theworkers
workersstand,
stand,they
theycan
canmove
moveabout
aboutthe
thestation
station
Area
Areatotoperform
performtheir
theirassigned
assignedtask.
task.Example
Examplelike likecars,
cars,trucks……
trucks……
The
Thetypical
typicalcase
caseisiswhen
whenthe theproduct
product isismove
moveby byaaconveyor
conveyoratatconstant
constant
Velocity
Velocitythrough
throughthe thestation.
station.The
Theworker
workerbegins
beginsthetheassembly
assemblytasktasknear
near
the
theupstream
upstreamside sideofofthe
thestation
stationan
anmoves
movesalong
alongwith
with the
thework
workuntil
untilthe
the
task
taskisiscompleted,
completed,The Thewalks
walksback
backtotothe
thenext
nextwork
workunit
unitan
anrepeats
repeatsthe
the
cycle.
cycle. For
Forsmaller
smallerassembled
assembledproducts
productssuch
suchasassmall
smallappliances,
appliances,
Electronic
Electronicdevices
devicesan ansubassemblies
subassembliesusedusedononlarger
largerproducts.
products.TThe heworkers
worker
To sit.
 Typical Assembly Operations performed on a
Manual Assembly Lines

Application
Applicationofofadhesive
adhesive Riveting
Riveting
Arc
Arcwelding
welding Shrink
Shrinkfitting
fittingapplications
applications
Brazing
Brazing Soldering
Soldering
Cotter
Cotterpin
pinapplications
applications Spot
Spotwelding
welding
Expansion
Expansionfitting
fittingapplications
applications Stapling
Stapling
Insertion
Insertionofofcomponents
components Stitching
Stitching
Press
Pressfitting
fitting Threaded
Threadedfastener
fastenerapplications
applications
For
Foraamanual
manualassembly
assemblyline,
line,the
themanning
manninglevel
levelofofwork
workstation
stationi=1,2…n
i=1,2…n
And
Andn=n=number
numberofofworkstations
workstationson onthe
theline.
line.The
Thegeneric
genericcase
caseisisone
one
worker
workerMMi=1.
i=1.
InIncases
caseswhere
wherethetheproduct
productisislarge
largesuch
suchasascar
carororaatruck,
truck,multiple
multiple
workers
workersare
areoften
oftenassigned
assignedone
onestation,
station,so
sothat
thatMMi>1.
>1.
i

Multiple
Multiplemanning
manningconserves
conservesvaluable
valuablefloor
floorspace
spaceininthe
thefactory
factoryand
and
reduces
reducesline
linelength
lengthand
andthroughput
throughputtime
timebecause
becausefewer
fewerwork
workstations
stationsare
are
required.
required.The
Theaverage
averagemanning
manninglevel
levelofofaamanual
manualassembly
assemblyline
lineisissimply
simply
the
thetotal
totalnumber
numberofofworkers
workerson
onthe
theline
linedivided
dividedby
bythe
thenumber
numberofof
stations.
stations.That
Thatisis
M= w
n
Where M=average manning level of the line (workers/station)
Where M=average manning level of the line (workers/station)
W=
W=number
numberofofworkers
workersononthe
theline
line
n=
n=number
numberofofworkstations
workstationson
onthe
theline
line
Manual assembly lines often include more workers than
those assigned to stations, so that M is not a simple average of
Mi values. These additional workers called utility workers, are
not assigned to specific workstations; instead they are
responsible for functions such as
1) Helping workers who fall behind, 2) relieving workers for
personal breaks, and 3) Maintenance and repair duties.
Including the worker count we have

M = wu+∑ wi (where i= 1 to n)
n
Where
Where wwu u==number
numberofofutility
utilityworkers
workersassigned
assignedtotothethesystem
system
wwi==number
numberofofworkers
workersassigned
assignedspecifically
specificallytotostation
stationi ifor
fori=i=1,2,….n
1,2,….n
i
Work
WorkTransport
TransportSystems
Systems

There
Thereare
aretwo
twobasic
basicways
waystotoaccomplish
accomplishthe themovement
movementofofwork
work
units
unitsalong
alongaamanual
manualassembly
assemblyline
line
1)1)manually
manuallyoror
2)2)by
byaamechanized
mechanizedsystem.
system.
Both
Bothmethods
methodsprovide
providethe
thefixed
fixedrouting
routing(all
(allwork
workunits
unitsproceed
proceed
through
throughthe
thesame
samesequence
sequenceofofstations)
stations)that
thatisischaracteristic
characteristicofof
production
productionlines.
lines.

Manual
ManualMethods
MethodsofofWorkWorkTransport:
Transport:InInmanual
manualworkworktransport,
transport,the
the
units
unitsofofproduct
productarearepassed
passedfrom
fromstation-to-station
station-to-stationbybyhand.
hand.TwoTwo
problems
problemsresult
resultfrom
fromthis
thismode
modeofofoperation:
operation:Starving
Starvingand
andblocking.
blocking.
Starving
Starvingisisthe
thesituation
situationininwhich
whichthe
theassembly
assemblyoperator
operatorhas
hascompleted
completed
the
theassigned
assignedtasktaskononthe
thecurrent
currentwork
workunit,
unit,but
butthe
thenext
nextunit
unithas
hasnot
notyet
yet
arrived
arrivedatatthe
thestation.
station.The
Theworker
workerisisstarved
starvedfor
forthe
thework.
work.
When
Whenaastation
stationisisblocked,
blocked,ititmeans
meansthat
thatthe
theoperator
operatorhas
hascompeted
competed
the
theassigned
assignedtasktaskononthe
thecurrent
currentwork
workunit
unitbut
butcannot
cannotpass
passthe
theunit
unit
totothe
thedownstream
downstreamstationstationbecause
becausethat
thatworker
workerisisnot
notyet
yetready
readytoto
receive
receiveit.it.The
Theoperator
operatorisistherefore
thereforeblocked
blockedfrom
fromworking.
working.

To
Tomitigate
mitigatethetheeffects
effectsofofthese
theseproblems,
problems,storage
storagebuffers
buffersare
are
sometimes
sometimesusedusedbetween
betweenstations.
stations.InInsome
somecases,
cases,the
thework
workunits
units
made
madeatateach
eachstation
stationare
arecollected
collectedininbatches
batchesand
andthen
thenmoved
movedtotothe
the
next
nextstation.
station.InInother
othercases
caseswork
workunits
unitsare
aremoved
movedindividually
individuallyalong
along
aaflat
flattable
tableororun
unpowered
poweredconveyor.
conveyor.
 Mechanized
MechanizedWork
WorkTransport
Transport

owered conveyors
Powered conveyorsandandother
othertypes
typesofofmechanized
mechanizedmaterial
materialhandling
handling
quipment
quipmentare arewidely
widelyused
usedtotomove
movealong
alongunits
unitsalong
alongaamanual
manual
sembly line.
ssembly line.These
Thesesystems
systemscan canbe
bedesigned
designedtotoprovide
providepaced
pacedoror
n paced
un pacedoperation
operationofofthe
theline.
line.Three
Threemajor
majorcategories
categoriesofofwork
worktransport
transport
ystem ininproduction
System productionline.
line.

)) Continuous
Continuoustransport
transport

) Synchronous
b) Synchronoustransport
transport

)) Asynchronous
Asynchronoustransport
transport
Velocity-distance
Velocity-distancediagram
diagramandandphysical
physicallayout
layoutfor
forthree
threetypes
typesofof
Mechanized
Mechanizedtransport
transportsystems
systemsused
usedininproduction
productionlines
lines
a)a)Continuous
Continuoustransport
transportb)b)Synchronous
Synchronoustransport
transportc)c)asynchronous
asynchronoustranspo
transpo
Introduction
Introductionto
toMaterial
MaterialHandling
Handling


Material handling is defined by the Material Handling
Industry of America as “ the movement, storage,
protection and control of materials throughout the
manufacturing and distribution process including their
consumption and disposal”.

The handling of materials must be performed safely,
efficiently, at low cost, in a timely manner, accurately and
without damage to the materials.
( the right materials in the right quantities to the right
locations)
Material
Materialhandling
handlingininthe
theproduction
productionsystem
system
This cost of material handling is a significant portion of
total production cost, estimates averaging around 20 –
25 % of total manufacturing labor cost in the united
states. The proportion may varies , depending on the
type of production and degree of automation in the
material handling function.
Some material handling devices are
- pallet shuttles in NC machining centers
- Conveyors in manual assembly lines
- transfer mechanisms in automated transfer lines
- parts feeding devices in automated assembly
Overview
Overviewof
ofMaterial
MaterialHandling
HandlingEquipment
Equipment

 Material handling equipment is available commercially

1. Transport equipment
2. Storage systems
3. Unitizing equipment
4. Identification and tracking systems
Material
MaterialTransport
TransportEquipment
Equipment

 Material transport includes equipment that is used to move

materials inside a factory, ware house, or other facility. This
equipment can be divided into the following five categories
1. Industrial trucks: Industrial trucks divided into two types
powered and non-powered.
Non-powered trucks are platforms or containers with wheels
that are pushed or pulled by human workers to move the
materials.
Powered industrial trucks are steered by human workers.
They provide mechanized movement of materials.
2. Automated guided vehicles (AGVs): AGVs are battery –
powered, automatically steered vehicles that follow defined
pathways in the floor. AGVs are used to move unit loads
between load and unload stations in the facility. Routing
variations are possible ( Different loads move between different
stations)
3. Monorails and other rail guided vehicles: These are self-
propelled vehicles that ride on a fixed rail system . The vehicles
operate independently and are usually driven by electric
motors that pick up power from an electrified rail.
Routing variations are possible
4. Conveyors: Conveyors constitute a large family of material
Transport equipment that are designed to move materials over
fixed paths, generally in large volumes.
Powered conveyors roller, belt and tow-line and non-powered
by human workers
5. Cranes and hoists: These are handling devices for
lifting , lowering, and transporting materials, often as
very heavy loads. Hoists accomplish vertical lifting.
Both manually operated and powered types are
available. Cranes provide horizontal travel and
generally include hoists.
a)a) Fork
Forklift
lifttruck,
truck,industrial
industrialtruck
truckb)b)unit
unitload
loadautomated
automatedguided
guidedvehicle
vehicl
c)c) Monorail
Monoraild)d)roller
rollerconveyor
conveyore)e)jib
jibcrane
cranewith
withhoist
hoist
Storage systems: It is generally desirable to reduce the storage of
materials in manufacturing, it seems unavoidable that raw
materials and work-in process will spend sometime being stored,
even if only temporarily. And finished products are likely to spend
sometime in a ware house or distribution center before being
delivered to the final customer.
Storage methods and equipment can be classified as follows
a) Bulk storage: It consists of simply storing materials in an open
floor area, generally in pallets or containers. It requires little or no
storage equipment
b) rack systems: These are structural frames designed to stack
unit loads vertically, thus increasing the vertical storage efficiency
compared to bulk storage

c) Shelving and bins: Steel shelving comes in standard widths,

depths, and heights to serve a variety of storage requirements.
Shelves can include bins, which are containers for loose items.
d) Drawer storage: This storage medium is more costly than
shelves, but is more convenient. Finding items stored in shelves
can be difficult if the shelf level is too high or too low or too
deep. It is generally used for tools, hardware and other small
items.
e) Automated storage systems: Automated and semi automated
systems are available to deposit and withdraw items into and
from the storage compartments.
There are two basic types: automated storage or retrieval
systems: consists of rack and shelf systems 2) Carousel systems
that rotate storage bins past a stationary load or unload station.
Unitizing equipment:
It refers to 1) containers used to hold individual items
during handling 2) equipment used to load and
package the containers. Containers include pallets,
boxes, baskets, barrels, and drums.

Identification and tracking systems: Material

handling must include a means of keeping track of
the materials being moved or stored. We assign label
to the item.
Examples
Examplesofofunit
unitload
loadcontainers
containersfor
formaterial
materialhandling
handling
a)a)Wooden
Woodenpallet
pallet b)b)pallet
palletbox
boxand
and c)c)tote
totebox
box
 The
The10
10Principles
Principlesin
inMaterial
Material Handling
Handling
The
The10
10principles
principlesofofmaterial
materialhandling
handlingareareexplained
explainedbelow.
below.
Implementing
Implementing these
these principles
principles will
will result
result inin safer
safer operating
operating conditions
condition
lower
lower costs,
costs, and
and better
better utilization
utilization and
and performance
performance ofof materia
materi
handling
handlingsystems.
systems.

The
Theunit
unitload
loadprinciples
principlesstandsstandsasasoneoneofofthe
themost
mostimportant
importantandandwidely
widely
applied
appliedprinciple
principleininmaterial
materialhandling.
handling.InInmaterial
materialhandling,
handling,aaunit
unitload
loadisis
Simply
Simplythethemass
massthat
thatisistotobe
bemoved
movedororotherwise
otherwisehandled
handledatatone
onetime.
time.
There
Therearearegood
goodreasons
reasonsfor forusing
usingunitunitloads
loadsininmaterial
materialhandling
handling
1)1) Multiple
Multipleitems
itemscancanbe behandled
handledsimultaneously
simultaneously
2)2) The
Therequired
requirednumber
numberofoftrips tripsisisreduced
reduced
3)3) Loading
Loadingandandunloading
unloadingtimes timesarearereduced
reduced
4)4) Product
Productdamage
damageisisdecreased.
decreased.These Thesereasons
reasonsresult
resultininlower
lowercost
cost
and
andhigher
higheroperating
operatingefficiency.
efficiency.
Principle
Principle1.1.PLANNING
PLANNINGPRINCIPLE:
PRINCIPLE:All Allthe
thematerial
materialhandling
handlingshould
should
be
bethe
theresult
resultofofaadeliberate
deliberateplan
planwhere
wherethe
theneeds,
needs,performance
performanceobjectives
objective
And
Andfunctional
functionalspecification
specificationofofthe
theproposed
proposedmethods
methodsarearecompletely
completely
Defined
Definedatatthe
theoutset.
outset.

Principle
Principle2.2.STANDARDIZATION
STANDARDIZATIONPRINCIPLE:PRINCIPLE:Material
Materialhandling
handling
Methods,
Methods,equipment,
equipment,controls,
controls,and
andsoftware
softwareshould
shouldbe
bestandardized
standardized.It
.It
means
meansless
lessvariety
varietyand
andcustomization
customizationininthe
themethods
methodsand
andequipment
equipment
employed.
employed.

Principle
Principle3.3.WORK
WORKPRINCIPLE:
PRINCIPLE:Material
Materialhandling
handlingwork
workshould
shouldbe
be
minimized
minimizedwithout
withoutsacrificing
sacrificingproductivity
productivityororthe
thelevel
levelofofservice
service
required
requiredofofthe
theoperation
operation
Simplifying
Simplifyingthetheprocesses
processesbybyreducing,
reducing,combining,
combining,shortening,
shortening,oror
eliminating
eliminatingunnecessary
unnecessarysteps
stepswill
willreduce
reducework.
work.
Principle
Principle4.4.ERGONOMIC
ERGONOMIC PRINCIPLE:
PRINCIPLE:HumanHumancapabilities
capabilitiesand
and
limitations
limitationsmust
mustbe
berecognized
recognizedand
andrespected
respectedininthe
thedesign
designofofmaterial
material
handling
handlingtasks
tasksand
andequipment
equipmenttotoensure
ensuresafe
safeand
andeffective
effectiveoperations.
operations.

Principle
Principle5.5.UNIT
UNITLOAD
LOADPRINCIPLE:
PRINCIPLE:AAunit unitload
loadisisone
onethat
thatcan
canbebe
stored
storedorormoved
movedasasaasingle
singleentity
entityatatone
onetime,
time,such
suchasaspallet,
pallet,container
container
totes
totesetc..
etc..
Less
Lesseffort
effortand
andwork
workare
arerequired
requiredtotocollect
collectand
andmove
movemanymanyindividual
individual
items
itemsasasaasingle
singleload
loadthan
thantotomove
movemany manyitems
itemsone
oneatataatime.
time.

Principle
Principle6.6.SPACE
SPACEUTILIZATION
UTILIZATIONPRINCIPLE:
PRINCIPLE: Effective
Effectiveand
andefficie
efficie
use
usemust
mustbebemade
madeofofall
allavailable
availablespace
space
Space
Spaceininmaterial
materialhandling
handlingisisthree
three–dimensional
–dimensionaland
andtherefore
thereforeisiscounte
count
Cubic
Cubicspace.
space.
 Principle 7. SYSTEM PRINCIPLE: Material movement and storage
activities should be fully integrated to form a co-ordinate ( receiving,
inspection, storage, production, assembly etc.)

 Principle 8. AUTOMATION PRINCIPLE: Material handling operations

should be mechanized and or automated to improve the operating
efficiency, increase responsiveness , decrease cost etc..

Principle 9. ENVIRONMENTAL PRINCIPLE: Environmental impact

and energy consumption should be considered as criteria.

Principle 10. LIFE CYCLE COST PRINCIPLE: Economic analysis should

account for the entire life cycle of all material handling equipment.
Applications
Applicationsof
offive
fivecategories
categoriesof
ofmaterial
materialhandling
handlingequipment
equipmen

Material
MaterialHandling
Handlingequipment
equipment Features
Features Applications
Applications

Industrial
Industrialtrucks,
trucks,manual
manual Low
Lowcost
cost Moving
Movinglight
lightloads
loads
ininaafactory
factory

Industrial
Industrialtrucks,
trucks,powered
powered Medium
Mediumcost
cost Movement
Movementofofpallet
pallet
loads
loads
AGV’S
AGV’S High
Highcost,
cost, Movement
Movementofofpallet
pallet
loads
loads
Monorails
Monorailsand
andother
otherrail
rail High
Highcost,
cost, Moving
Movingsingle
singleproduc
produ
Guided
Guidedvehicles
vehicles Flexible
Flexiblerouting
routing assemblies
assemblies

Conveyors,
Conveyors,powered
powered Variety
Varietyofofequipment
equipment Moving
Moving product
product
along
alongassembly
assemblylil
Industrial trucks:
Opening
OpeningWindchill
WindchillPDMLink
PDMLink

Browser based and web

style navigation
Windchill PDMLink Home page
Personalized Product
Workspace with information on
assigned user activities

Subscription provides
notifications of actions
that modify parts and
documents
Creation
Creationof
ofOrganization
Organization
Creation
Creationof
ofOrganization
OrganizationAdministrator
Administrator
Creation
Creationof
ofUsers
Users
Creation
Creationof
ofGroups
Groups
Adding
AddingUsers
UserstotoGroup
Group
Creation
Creationof
ofLibraries
Libraries&&Products
Products
* Creation of Libraries
Creation
Creationof
ofRoles
Rolesfor
forLibraries
Libraries&&Products
Products
Customization
Customizationof
ofPDM
PDMsoftware
software

• Creation of Attributes
• Creation of Document Type.
• Creation Life Cycle.
• Creation Of Workflow.
• Creating Access Permissions.
• Creation of Folders.
Creation
Creationof
ofAttributes
Attributes

An attribute represents a characteristic of an

object, such as a part. Examples of attributes
are part number, page count, length, and fax
number.
Creation
Creationof
ofAttributes
Attributes

* Creation of Attribute Organizer

Creation
Creationof
ofAttributes
Attributes
* Creation of Attribute
Creation
Creationof
ofDocument
DocumentTypes
Types
The Type Manager allows us to create new
subtypes of parts, documents, change
objects (all of which are modeled, or hard
types) and types created using the Type
Manager (soft types).
Creation
Creationof
of Document
DocumentTypes
Types
Creation
Creationof
ofDocument
DocumentTypes
Types
* Adding Attributes Type
Creation
Creationof
of Document
DocumentTypes
Types

DWG
Fixture

My Test
Document

Design Document

Reference
Document
Creation
Creationof
ofWorkflows
Workflows

Workflow is an E-mail System Which can

used to transfer the data through out the
enterprise securely.
Creation
Creationof
ofWorkflows
Workflows
Creation
Creationof
ofWorkflows
Workflows
Creation
Creationof
ofWorkflows
Workflows
Creation
Creationof
ofWorkflows
Workflows
* Fixture Drawing Workflow
Creation
Creationof
ofLifecycles
Lifecycles

Life cycle is an automated, graphical model,

which employs phases and gates to manage
business objects as they progress from
conceptualization through obsolescence.
Creation
Creationof
ofLifecycles
Lifecycles
* Process DWG Lifecycle
Creation
Creationof
ofLifecycles
Lifecycles
* Fixture Drawing Lifecycle
* Assigning Life Cycle to a Type
Creation
Creationof
ofAccess
AccessControls
Controls

 Policy Administrator

Policy Administrator is used to manage

administrative domains and the access
control, indexing, and notification policies for
those domains.
Creation
Creationof
ofAccess
AccessControls
Controls
Uploading
UploadingPro-E
Pro-Edrawing
drawingdirectly
directlyin
in
Windchill
WindchillPDMLink
PDMLink
Creating
CreatingaaDocument
Document under
underLibrary
Librarytab:
tab:
Creating
CreatingaaDocument
Document under
underLibrary
Librarytab
tab
Creation
Creationof
ofReports
Reports

A Report is the output of a predefined

search and is used for generating
statistics and metrics against business
information.
Creation
Creationof
ofReports
Reports