Modern Material Handling and Storage Systems

Material handling is the movement, storage, protection & control of

material throughout the manufacturing & distribution process including their
consumption & disposal.
Material handling needs to be:

Safe
Efficient
Low cost
On time
Accurate

MH Equipment

Transport
Storage
Unitizing equipment
Identification & tracking System

Transport

Industrial track
AGV
Monorails
Conveyors (belt/roller)
Cranes

Storage

RM/WIP/FG
Bulk on the floor
Rack structural frames
Shelving & bins standard width, depth & height
Drawer for tools/hard ware
AS/RS

Unitizing

Containers to hold items (Pallet)

Equipment used to load & package the containers (Palletizer)

Identification & Tracking

Keeping trade of the material being moved/stored

Affix label on carton

o Bar codes
Consideration for MH system design
1.

Material characteristics

2.

Physical state solid/liquid

Size
Weight
Shape square, round
Condition hot, cold, sticky
Risk of damage fragile
Safety risk explosive, flammable, toxic
Flow rate/Routing/Scheduling

Flow rate

Large quantity dedicated handling system

Small quantity, different types need to share

Routing

Distance pickup & drop off locations

Different flow patterns

Scheduling
Timing of each individual delivery
Maintain performance & efficiency
Must be responsive for timely pick-up & delivery

Quantity

Conveyor

Conveyors
AGV trains

Hand trucks

Powered Truck
Unit load AGV
Distance

3.

Plant layout

For new facility, design of MH system should be considered part of layout

design.

Fixed-position

Large object
Cranes, powered trucks

Process

Flexible to deal with variation

Hand trucks, Fork lift trucks to move WIPs
Recently AGV

Product

Identical parts with high quantity

Fixed route, mechanized, large flow rates
Conveyor, trucks to deliver

Automated Guided Vehicle (AGV)

Battery powered driverless vehicles with programming capabilities for
destination, path, selection & positioning.

Can move in complicated & changing paths

Handle wide variety of material & loads
Provide high degree of flexibility
Can perform loading/unloading operations
Interaction with machines
Communicate with factory computer control system

Components to an AGVS

Vehicle
Guided path
Control unit
Computer interface

Types of Vehicles
1.

AGV Towing Vehicle

2.

For heavy loads (4000 to 25000 kg) over long distance

No intermediate pickup or drop-off
AGV Unit Load Carrier

3.

Move unit loads from one station to other

Equipped with decks powered roller, moving belt,
mechanized lift platforms

AGV Pallet Truck

4.

Lift, maneuver & transport pallets

Along pre-determined routes Automatic / Manual
AGV Fork Truck

5.

Automatic pick up & drop off of loads at different levels

From floor to stands
AGV Light Load Transporter

6.

Handle small light parts over moderate distance

Distribute parts bet storage & Work stations
AGV Assembly Line Vehicle

Adaptation of small, light load AGV for assembly process

AGV Guidance Techniques

1.

Wire Guided
o Electric line below floor
o High frequency AC current
o At junction point, different frequency measured by programmed
sensors
o Sensor pickup electromagnetic signal

Disadvantage:

2.

Cannot change line easily

Line Guided

o Fluorescents paint
o Use optical sensor (photo sensor)
o UV light source reflection
Disadvantage:
Paint deteriorated
Need to maintain, repaint
3.

Free-ranging/Self-Guided
Paths are software programmable & therefore are easily alterable.
Combination of dead reckoning & beacons located throughout the plant
Identified by on-board sensors

Dead reckoning capability of a vehicle to follow a given route in absence of

a defined pathway on the floor
Movement along the route is accomplished by the wheel rotation in
sequence of specified steering angles.
Computations performed by vehicles on board computer
Position accuracy decease as the route length increases
Locate of vehicles must be verified periodically with known positions.
Beacons located strategically throughout the plant.
Beacons may be

Bar coded mounted along aisles recognized by laser

Magnetic imbedded in the floor along pathway

Advantages:
Flexibility software based
Cam be extended or changed without major alteration to facility.

Basic Functions of AGV

Guidance Ability to follow pre-determined route

Routing Selection of optimum route to specific destination
Traffic Management Ability to avoid collation & maximizing vehicle
flow.
Load transfer Pick-up / Delivery
System management Method of system control used to dictate
system operation.

Central
Computer

AGV

Vehicle scheduling program

and control software

Regional
Computer

Vehicle routing command

for each zone

Regional
Computer

Local
Computer

Vehicle routing command

for each AGV

Local
Computer

AGV

AGV

AGV

AGV

AGV

Total number of vehicles required in a system

Ld Total average loaded travel distance
Le Total average empty travel distance

Th handling time = Loading + Unloading time

Ft Traffic factor

o blocking & waiting of vehicles in line & at intersections

o if only one vehicles vale is 1.0 normally let 0.85 ~ 1.0
V c AGV velocity/speed

Total time / delivery / vehicle Tv =

No of Deliveries / vehicle / hr. = 60

Ld
Le
+
+ Th
Vc
Vc

Ft
Tv

No of Deliveries / hr

# Vehicles = No of Deliveries / vehicle / hr

Automated storage System

Reduces or eliminate amount of human intervention required to
operate the System.
In less-automated System, human operator is required in each
storage/retrieval transaction
In highly automated system, loads are entered or retrieval under
computer control, with no human participation
Objectives

Increased storage capacity better floor utilization

Improved security, reduced pilferage
Reduced labor cost
Improved safety & customer service
Improved control over inventories

Automated Storage and Retrieval System

A combination of equipment and controls that handle stores & retrieves
material with precision, accuracy and speed under a defined degree of
automation.
Consists of a series of storage aisles that are serviced by one or more
S/R machines
Aisles have storage racks
S/R machines (cranes) are used to deliver & retrieve material to from
racks
Each aisle has one or more input/output stations (P&D)
Types of AS/RS

Unit load AS/RS typically a large system designed to handle unit

loads stored on pallets.
o Computer controlled
o S/R machines are automated & designed to handle the unit load
containers

Mini load AS/RS for small loads contain in bins or drawers

Man-on-board AS/RS individual items to be picked directly at storage

location

Automated item retrieval system also for individual item stored in

lanes rather than bins. Pushed from lanes & drop on conveyor

Deep lane AS/RS another variation of multi-load

o High density up to 10 items per row instead of 1 or 2

Enter from one side deliver other side

Automatic Data Capture

It refers to the technologies that provide direct entry of data into a
computer or other microprocessor-controlled system without using a
keyboard.

Reduced error
Reduced time
Reduced man power

Overview

Encoded data code is a set of symbols or signals representing

alphanumeric characters
o When data are encoded, the characters are translated into
machine-readable code

Machine reader/scanner reads encoded data &

converts to electrical signal

Decoder transforms electrical signal into digital data &

finally back into original alphanumeric character
Bar code is the leading ADC

Six categories of different technology

Optical high contrast graphical symbol

1D&2D bar codes

Magnetic recording tape credit card

Electromagnetic Radio frequency identification

Smart card chip card, IC card

Touch touch screen

Biometric vocal commands voice recognition, finger print, eye scan

Error in ADC
FRR first read rate probability of a successful (correct) reading by
the scanner in its initial attempt
SER substitution error rate probability or frequency with which the
scanner incorrectly reads the encoded character
Bar code Technology
1D Bar Code (Linear)
o

Most widely used automatic identification & data

collection technique

Types

Height modulated varying height

Width modulated varying width of bars & spaces

Width Modulated
Symbol consists of a sequence of wide & narrow colored bass separated by
wide & narrow spaces.

Black & white for high contrast

Bar code readers interpret the code by scanning & decoding the sequence of
bars.

Consist of scanner & decoder

Scanner

Emits a beam of light

Swept past the code
Senses light reflections to distinguish between bars & spaces
Light reflections are sensed by a photo detector
Converts the spaces into electrical signal & bass into absence of signal
Duration of corresponding signal is related to the width of the bars and
spaces

Decoder analyzes the pulse train to interpret corresponding data

Grocery & Retail stores UPC Numeric

Department of Defense Code 39 Alphanumeric

Bar code symbol

Code 39 uses a series of wide & narrow elements (bars & spaces) to
represent alphanumeric & other characters.
Wide element 1
Narrow element 0

Both bars & spaces

9 elements are used for each number or character

Any 3 elements are wide, 9 are narrow either bar or space
2D Bar Code
High area density can store much greater amount of data
Special scanning equipment is required more expensive
Stacked Bar code multiple rows of linear conventional bar codes stacked on
to of each other
Matrix Bar code capability of containing more data than stacked code
o More complicated
o Both horizontally & vertically
Bar code Reader
Manual contact using pens
Automatic non-contact
Manual: memory device capable of storing data acquired during operation
Automatic: light beam on bar code photo detector reads the reflected signal
to interpret the code

Fixed beam stationary mounted

Moving beam highly focused light bean laser is
used . High rotational speed of mirror (around 1440 scans/ sec)

Stationary
Portable

Group Technology & Cellular Manufacturing

Group Technology
GT is a manufacturing philosophy in which similar parts are identified
and grouped together to take advantage.
Similar parts are arranged into part families:
Each family processes similar design & manufacturing characteristics
Similar processing increased efficiency
Arrange production equipment into machine groups/cells
o Facilitate work flow
Cellular Manufacturing
Grouping the production equipment into machine cells where each cell
specializes in the production of a part family.
Application
In plants currently uses traditional batch production

& process layout

For parts those can be grouped into part families

Steps
Identify part families
Rearranging production machines into machine cells
Advantages

Standardization of tooling / fixture

Reduced material hand ling
Team work
Reduced WIP
Reduced manufacturing time

Part Families
Part family is a collection of parts that are similar either because of
geometric shape & size or because similar processing steps are required in
their manufacture.

Similarities are close enough

Grouping parts into families is the toughest job

Visual
Part classification & coding
Production flow analysis (PFA)
Visual
Least sophisticated, least expensive
Performed by looking at parts or photographs
Least accurate

Parts classification & coding

Most time consuming

Similarities are identified
Related in a coding system
Design Attribute geometry, size, material
Manufacturing Attribute sequence of processing steps

Reason to use coding system

Design retrieval search for design
CAPP search for process plan
Machine cell design producing all members of a part family
Features
Design attributes
Manufacturing attributes
Both design & manufacturing attributes
In terms of meaning of symbols
Hierarchical 2nd digit depends on 1st
Chain-type independent meaning
Mixed mode
Opitz system
Introduced by H. Opitz
Intended for machine parts
12345
form code

6789
supplementary code

ABCD
secondary code

Form code and supplementary code are the basic codes.

Form code primary design attributes

External shape

Machined features
Supplementary some other attributes

Dimension, material
Secondary serve own particular need

Identify production and operation type & sequence

Example:
L/d
1.5
Stepped both sides Thread
Through hole
No shape
No pane surface
Auxiliary hole

1
5
1
0
0

Production Flow Analysis (PFA)

PFA is a method for identifying part families & associated machine
groupings. Work parts with identical & similar routings are classified into part
families.
Uses manufacturing data rather than design data

Steps of PFA
-

Data collection part number & operation sequence

Sorting of processing Routes

Parts are arranged into groups according to route
similarity
Arrange parts into packs

PFA chart
Display
Part-machine incidence matrix 1 or 0

Cluster analysis groupings are identified & rearranged into

new pattern.
Rank order clustering

Example:

machin
e
1
2
3
4
5
6
7

28

27

26

25

24
23
Parts
E
F

22

21

20

1
1
1

1
1
1

1
1
1

1
1
1

1
1

Equiv Rank
290
17
81
136
258
65
140

1
7
5
4
2
6
3

machin
e
1
5
7
4
3
6
2

Equiv
Rank

96
1

1
1

Parts
E
F

1
1
1

machine
1
5
7
4
3
6
2

A
1
1

6
8

H
1
1

64
3

D
1

26
25
24
23
22
21
20

1
1
1
1

1
24
4

1
1

1
1
1
1

5
9

24
5

16
6

96
2

Parts
B
F

1
1
1

1
1

1
1

1
1

7
7

Cellular Manufacturing
Grouped parts are produced using GT machine cells rather than traditional
This is an application of GT in which dissimilar machines or
processes have been aggregated into cells, each of which is dedicated
to the production of a part family.

Cell Design
-

Single machine cell

One machine does all operations

Group machine with manual handling

Group machine with semi-integrated handling loading /

unloading is manual

FMS fully integrated

Key Machine
-

More expensive & perform critical operations

Need to utilize full time bottleneck

Others are supporting machines

Used in designing cell

In line

Loop

Rectangular

Layout

Example: Machine sequence in cell

From

To
1

2
5

30

15

45

10

40

50

4
To

10
50

0
45

0
0

0
40

10
135

From

MACHINE

3
0

4
25

30

From/ To

0.6

0.25

From Maximum to Minimum

3

10

50 IN

40

15

30

25

30 OUT

10
20 OUT

Application of GT

Manufacturing

Product Design

Network Communication
A communication network is the backbone of enterprise integration.

Links all the devices together irrespective of their physical location

Through network, we can integrate the whole enterprise, including
suppliers & customers

Sales

Design

MRP

Manufacture

Delivery

To facilitate rapid interdepartmental responses, well-developed

enterprise network is necessary.
An organization can be mapped onto a communication hierarchy that
includes:
-

Enterprise level
Plant level
Cell level
Equipments level

Network requirements is different in terms of

Communication device
Distance
Physical transmission media
Bandwidth
Protocol functions.

To unify the enterprise, 3 types of network technologies are required to

interconnect different levels:
-

Equipment level sub-networks NC machines & Robots

Plant-wide network connect cells & other departments.

Enterprise-wide networks globally link various plants/sites.

NETWORK
Communication network is a collection of equipment & physical media
that interconnects two or more computers.
-

Local Area Network (LAN) interconnect within same building or

organization

Metropolitan Area Network (MAN) covers a large city or

suburb
o Interconnects
area

LANs

within

metropolitan

Wide Area Network (WAN) uses common career facilities over

long distances.
o Uses to connect sites & equipment

Hierarchical structure

Enterprise Level

Computer

Sales / Marketing /Finance/

CAD/CAM (Design)

Plant Level

Computer

Payroll/Cost accounting
CAD/CAM (Manufacture)
Control/
Coordinate

Cell Level
Satellite
Computer

Satellite
Computer
Enterprise Level

Computer

Computer

Computer

Computer

Computer

Computer

Machine

Machine

Machine

Machine

Machine

Machine

Data management Manufacturing planning & control, MRPII, Order

processing
Data automation

Bar-code reader, Scanner

Selection of Network Technology

Number of factors should be considered:
-

Communication medium
Network topology
Medium access control method
Signaling method

Communication medium
-

Physical material that carry electrical signal of encoded data

Transmit data over short/long distances
Open-wire pairs obsolete now a days
Twisted pair cables good for short distance
Co-axial cables LAN -10 Mb/s transfer rate
Fiber-optic system high data transmission
Wireless media High bandwidth, high cost

Network Topology
It describes the relationship between the nodes in communication system.
1.

Star
-

Central computer is located at the center

Each user is connected directly to the host
High data transfer rate

Computer
Computer

Computer
Central
Computer
Computer

Computer
Computer
2.

Ring
-

Each device is connected to two others

Devices are attached to ring cable if one device fails, ring continues
to function
Number of device connected is not limited by number of slots
Computer
Router
Computer

Computer

Router

Router

Router

Router
Router
Computer

Computer

Computer

3.

BUS
-

One of the most commonly used

Devices are connected to cable
Requires less cable than star
All devices need to share cable.

Computer

Computer

Computer

4.

Computer

Computer

Tree
-

Devices are connected to hub that passes the message from one
device to other
Very flexible layout
Network survives if one cable fails.

Computer

Computer

Computer

Computer

Computer

Access Control

Computer

Information / Data access to network

Token passing Token is a special code. Token is passed to the network in a
predetermined sequence

Some machine may get higher priority

A station may transmit only when it receives the token
Manufacturing network uses this method

CSMA/CD Carrier-sense multiple access with collision detection

Developed by Xerox
Any station wants to send signal, listens whether line is busy or not -then send signal if not busy.
If same time collision occurs.
If collision is detected, sender waits for a while before re-transmitting
the signal.

Signaling method
Data are propagated from one point to another by means of signals
-

Signals are electromagnetic representation of transmitted data

Data/signal converters convert data to signals for transmission on the
sending end & back to data at receiving end

Broad band

LAN converts data into signals before transmission, transmit signals, &
the convert the signals into data at receiving end
Many independent messages can be transmitted simultaneously.
Serves as backbone that supports many channels.

Base band

Uses data itself as a signal by impressing the data directly onto the
communication wire
Works well in small network
Only one signal can be transmitted

MAP/TOP
MAP (Manufacturing Automation Protocol)

Developed by GM
Uses BUS network
Broadband transmission
Token passing access method
Suitable for shop floor

TOP (Technical & Office protocol)

Developed by Boeing
Uses CSMA/CD access method

MAP & TOP are compatible the two can be connected through a bridge.
Bridge - Connects two similar or dissimilar LANs to form a large network at
data link layer
Repeater Interconnects segments of an intended network with identical
protocols & speeds at physical layers
Both MAP & TOP follow 7 layers OSI (Open system interconnection) model,
proposed by ISO.
Application

Application

Presentation

Presentation

Session

Session

Transport

Transport

Network

Network

Data Link

Data Link

Physical

Physical
Medium

Physical

Consists of hardware that drives network & circuits.

Deals with mechanical, electrical, functional
characteristics to access physical medium

&

procedural

Data link

Transfer information across physical link

Error control, flow control of functions

Network

Decides which outgoing line will be used to send the message to a

node

Transport

Provides transported transfer of data to & from the session layer

without disruption

Session

Controls communication between applications

managing & terminating virtual connections
applications

by establishing,
bet cooperating

Presentation

Performs certain decoding & conversation operations on data to match

the device & network requirement.

Application

Provides the user interface to the networking system

Written by the user.