TOOL AND MANUFACTURING

ENGINEERS HANDBOOK
FOURTH EDITION

VOLUME IX
MATERIAL AND PART HANDLING
IN MANUFACTURING

A reference book for manufacturing engineers, managers, and technicians

Philip E
E.. Mitchell, CMfgT
Handbook Editor

Society of Manufacturing Engineers

One SME Drive
Dearborn, Michigan 48121

PREFACE
The first edition, published as the Tool Engineers Handbook in 1949, established a useful and authoritative editorial format that was successfully expanded and improved on in the publication of highlyacclaimed subsequent editions. Further expansion of the Handbook is needed because of advances in
manufacturing technology, increasing competitive pressure, and a significant diversification of information requirements for modern manufacturing.
Although greatly expanded and updated to reflect the latest in manufacturing technology, the coverage process in this edition is deeply rooted in the heritage of previous editions. Earlier volumes constituted a unique compilation of practical data detailing the specification and use of modern manufacturing
equipment and processes. Other volumes in this Handbook series include: Volume I, Machining, published in 1983; Volume II, Forming, in 1984; Volume III, Materials, Finishing and Coating, in 1985;
Volume IV, Quality Control and Assembly, in 1987; Volume V, Manufacturing Management, in 1989;
Volume VI, Design for Manufacturability, in 1992; Volume VII, Continuous Improvement, in 1993; and
Volume VIII, Plastic Part Manufacturing, in 1996.
The scope of this edition is multifaceted, offering a ready reference source of authoritative manufacturing information for daily use by engineers, managers, and technicians, yet providing significant coverage of the fundamentals of manufacturing processes, equipment, and tooling for study by the novice
engineer or student. Uniquely, this blend of coverage has characterized the proven usefulness and reputation of SME Handbooks in previous editions and continues in this edition to provide the basis for
acceptance across all segments of manufacturing.
In this, and other TMEH volumes, in-depth coverage of all subjects is presented in an easy-to-read
format. Each chapter has an extensive bibliography compiled to provide further user resources. A comprehensive index cross-references all subjects, facilitating quick access to information. The liberal use of
drawings, graphs, and tables also speeds information gathering and problem solving. Equations are included to show how different factors relate to each other and are used as a practical tool for quantifying
portions of the manufacturing process.
The contributors and reviewers are listed at the beginning of each chapter. No written words of
appreciation can sufficiently express the special thanks due to these professionals. Their work is deeply
appreciated by the Society; but more importantly, their contributions will undoubtedly serve to advance
the understanding of manufacturing throughout industry and will certainly help spur major productivity
gains in the years ahead. Industry as a whole will be the beneficiary of their dedication. Much effort was
made to acknowledge other material used in the handbook and is listed in the reference section of each
chapter.
Philip E. Mitchell, CMfgT

ii

CONTENTS
VOL
UME IXMA
TERIAL AND PPART
ART HANDLING IN MANUF
ACTURING
OLUME
IXMATERIAL
MANUFA

Preface ........................................................................................................................................................ v
Symbols and Abbreviations ....................................................................................................................... xvii

Chapter 1Strategy Determination and Production Requirements

Introduction ............................................................................................................................................. 1-1
Basic Manufacturing Concepts .................................................................................................................. 1-1
The Production Environment/Lead Times/Inventory Management/Push and Pull Manufacturing
Resource Planning and Scheduling Concepts ............................................................................................. 1-7
Serving the Customer/The Planners Tool Kit/Manufacturing Resource Planning/
Process Re-engineering
Process Planning and Flow Analysis ........................................................................................................ 1-15
Phase IPlanning/Phase IIDesign/Phase IIIImplementation/Define Material and Information
Flow/What to Change/Analysis: As-is Conditions/Define the Processes
Problem Definition ................................................................................................................................. 1-21
Constraints/Physical Material Flow/Information Flow/Quality/Resource Limitations/
Handling and Storage

Chapter 2Material Handling Analysis

Principles and Economics of Material Handling ......................................................................................... 2-1
Overview/Labor Utilization/Inventory Turnover/Facility Utilization/Equipment Utilization/
Material Cost/Synergistic Effect of Integration/System Service Life and Flexibility
Potential Benefits of Material Handling Solutions ....................................................................................... 2-5
Automated Storage and Retrieval System (AS/RS)/Automated Transportation/Controls
Realizing Benefit Potential ......................................................................................................................... 2-6
Determine Objectives for the System/Define and Quantify Current Levels of Resource Functions/
Estimate Future Levels of Resource Functions/Value Economic Requirements/Prepare for
Meeting Economic Requirements/Prepare a Thorough Project Justification/Sell the Project to Top
Management/Manage Carefully Planned Procurement and Implementation/Track the
Savings Targets After Implementation/Summary
Analysis Tools and Methods .................................................................................................................... 2-15
Computer-based Analysis Tools/Computer-based Simulation/Work Simplification/Analyzing Load
Size/Analyzing Plant Layout
Requirements Definition .......................................................................................................................... 2-40
Key Considerations/Data Collection/Flow Analysis/Data Analysis/Document Understanding/
Opportunities and Problems/Alternative Solutions
Project Management .............................................................................................................................. 2-52
Overview/Planning and Analysis/Design and Development/Procurement/Implementation/Support
and Modification/Summary

Chapter 3Product Identification and Tracking

Introduction ............................................................................................................................................. 3-1
Identification of Ledgered Stock-keeping Units ........................................................................................... 3-1
Unique SKU/Engineering and Purchasing Responsibilities/Numbering Systems/Sizes of Stock Materials/Units of Measure/Nonledgered Parts/Tracing and Tracking/Controlling Changes by Part
Identification
Automated Data Capture (ADC) ............................................................................................................... 3-3
Considerations for ADC/Linear Bar Codes/Two-dimensional Symbologies/Radio-frequency Data
Communications

iii

iii

Integrating Sensors and Control ..............................................................................................................

Sortation/Automatic Storage and Retrieval Systems/Automated Guided Vehicles
Data Storage and Postprocessing ...........................................................................................................
Partially Automated Systems ...................................................................................................................
Data Collection Points ............................................................................................................................
Product Data Management ....................................................................................................................

3-10
3-12
3-12
3-12
3-13

Chapter 4Storage and Inventory Planning

Introduction ............................................................................................................................................. 4-1
Key Storage Planning Phases .................................................................................................................... 4-1
Select a Storage Project Team/Phase I: Define General Storage Design Requirements/Phase II:
Define/Evaluate/Select Storage Strategy
Defining the Material Storage Environment ............................................................................................... 4-3
Survey Organization to Develop Goals/Identify Storage Plan Rules that Must be Satisfied/
Define Tangible Goals and Evaluation Criteria/Define Intangible Goals and Evaluation Criteria/
Kepner-TregoeTM (KT) Methodology
Storage Plan Goals and Criteria by Business Organization ........................................................................ 4-5
Evaluation Criteria
Business Computer Systems Criteria for Storage Functions ......................................................................... 4-6
Computer Software Capabilities
Inventory Storage and Flow Characteristics ............................................................................................... 4-7
Inventory Put-away Unit of Measure (UOM)/Storage Capacity by Type/Special Storage
Environment Needs/Special Inventory Vendor and Owner Needs/Special Material Transportation
Needs/Inventory Pick Frequency/Inventory Handling
Calculate Storage Equipment Quantity and Floor Area .............................................................................. 4-8
Centralization versus Decentralization Strategies ..................................................................................... 4-10
Financial/Service and Transportation/Operations
Inventory Storage Method Alternatives .................................................................................................... 4-11
Conventional Storage Methods/Bulk (Reserve) Inventory Storage Methods/Forward (Loose)
Inventory Storage Methods/Automated Storage Methods/Temporary Storage Methods/
Inventory Dating Systems (Storage Life)
Storage Planning Summary .................................................................................................................... 4-13

Chapter 5Logistics
Introduction ............................................................................................................................................. 5-1
Ordering and Receiving Processes ............................................................................................................ 5-1
Determining What, When, and How Much to Order/Placing Traditional Orders/Receiving/
Electronic Data Interchange for Ordering
Shipping to Meet Customer Expectations ................................................................................................... 5-7
Lean Manufacturing and JIT/Shipping/Supplier Responsibilities/Trading Partnerships
EDI Service Providers .............................................................................................................................. 5-10
Inventory Management .......................................................................................................................... 5-11
Conclusion ............................................................................................................................................ 5-12

Chapter 6Maintaining Material Handling Systems and Equipment

Introduction ............................................................................................................................................. 6-1
Maintenance Program Objectives/Maintenance Types
Equipment Condition and Performance Analysis ........................................................................................ 6-2
Determining What Equipment Should be Inspected/Inspection Criteria/Inspection Frequency/Inspection Schedule
Maintenance Suggestions ......................................................................................................................... 6-3
Flexible Wheeled Handling Equipment/Conveyors/Overhead Handling and Lift Devices/Storage
Equipment/Transport Packaging/Automated Material Handling Systems

iv

Chapter 7Ergonomics and Manual Handling Systems

Introduction .............................................................................................................................................
Determining Physical Limits ......................................................................................................................
Psychophysical Assessment Methods/Biomechanical Assessment Methods/Physiological
Assessment Methods/Multidisciplinary Risk Assessment Methods
Reducing MMH Risks ................................................................................................................................
Administrative Control of Risk Factors/Engineering Control of Risk Factors
Solving MMH Ergonomic Issues ................................................................................................................
Work Parameters and Indicators/Selection Guide/Database/Reducing Musculoskeletal Injury Hazard/Supplier Build and Prototype Buy-off/The Need for More Research/Manual Handling Systems
Model Application
Safety Aspects of MMH .............................................................................................................................

7-1
7-1

7-2
7-6

7-7

Chapter 8Flexible Wheeled Handling Equipment

The Industrial Fork Lift Truck ...................................................................................................................... 8-1
Impact on Industry/Classes of Industrial Trucks
Counterbalanced Lift Trucks ...................................................................................................................... 8-3
Typical Applications/Tires/Mast Types and Operations/Hydraulic System and Operation
Reach Trucks ............................................................................................................................................ 8-4
Attachments to Standard Lift Trucks
Special Lift Trucks ..................................................................................................................................... 8-4
Sideloaders in Manufacturing ................................................................................................................... 8-5
Special Features
Powering Fork Lift Trucks ........................................................................................................................... 8-5
Batteries/Gasoline/Propane/Dual-fuel Lift Trucks/Diesel/Compressed Natural Gas/Exhaust
Treatment/Power Comparison
Lift Truck Attachments ............................................................................................................................... 8-8
Attachments and Safety/Sideshifters/Clamps/Rotators/Load Pushes and Load Push/Pulls/Fork
Positioners/Load Stabilizers/Fork Rotators/Mechanical Attachments
Powered Walkie Lift Trucks ...................................................................................................................... 8-10
Economics/Maintenance Factors/Types/Selection
Two-wheel Hand Trucks ........................................................................................................................... 8-11
Terminology/Hand Truck Types/Special Designs/Wheel Selection/Weight and Bearings/
Attachments/Worker Preferences
Hand Pallet Trucks .................................................................................................................................. 8-15
Fork Dimensions/Wheels/Pallet Entry Devices/Maintenance/Applications
Floor Trucks ........................................................................................................................................... 8-17
Running Gear/Wheel Selection/Frames/Decks/Size and Capacity
Fleet Management ................................................................................................................................. 8-18
Standardizing the Lift Truck Fleet/Tracking Fleet Maintenance Costs/When to Replace Trucks/Lift
Truck Selection/Maintenance/Conduct Operator Training
Purchasing Used Fork Lift Trucks .............................................................................................................. 8-23
Rebuilt Trucks/As-is Trucks/Reconditioned Trucks/Where to Buy/Warranties

Chapter 9Conveyors for Unit Load Handling

Design Considerations ............................................................................................................................. 9-1
Nonpowered Conveyors ........................................................................................................................... 9-3
Skate Wheel/Gravity Roller/Ball Transfer Tables and Omnidirection Wheels
Powered Conveyors .................................................................................................................................. 9-4
Powered Belt/Live Roller/Accumulation/Sortation Equipment
Powered Conveyors for Large Unit Loads ................................................................................................ 9-12
Multiple Strand Chain/Slat/Flat Top/In-floor Towline/Inverted Power-and-free
Specialty In-floor Conveying Systems ...................................................................................................... 9-18
Inverted Automated Electrified Monorail/Spinning Tube/Walking Beam/Automated Guided
Vehicles/Linear Induction Motors
Software and Controls ............................................................................................................................ 9-20
Equipment Control Devices/System Control Software/Emulation

Justification ............................................................................................................................................ 9-23

Costs/Savings/Return on Investment/Dealing with Uncertainty
Conveyor Safety ..................................................................................................................................... 9-24
Establishing a Safety Program/Common Hazards/Safety Devices/Training/Noise Considerations

Chapter 10Overhead Handling and Lifting Devices

Introduction ........................................................................................................................................... 10-1
Equipment Selection
Manual and Powered Overhead Cranes .................................................................................................. 10-2
Bridge Crane Fundamentals/Major Types of Overhead Cranes/Comparison of Overhead Cranes
Overhead Trolley Conveyors ................................................................................................................. 10-11
Overhead Trolley Conveyor Selection/Major Types of Overhead Trolley Conveyors/
Comparison of Overhead Trolley Conveyors
Overhead Power-and-free Conveyors .................................................................................................... 10-17
Power-and-free Conveyor Selection/Major Types of Overhead Power-and-free Conveyors/
Comparison of Overhead Power-and-free Conveyors
Automated Electrified Monorails ........................................................................................................... 10-21
Automated Electrified Monorail Selection/Aluminum-alloy Track Automated Electrified Monorails/
Comparison of Automated Electrified Monorails/Linear Induction Motor Systems
Drop/Lift Transfers ................................................................................................................................ 10-27
Drop/Lift Transfer Selection/Major Types of Drop/Lift Transfers/Comparison of Drop/
Lift Transfers
Conclusion .......................................................................................................................................... 10-35

Chapter 11Storage Equipment

Applications and Planning ......................................................................................................................
Guidelines .............................................................................................................................................
Selection Criteria/Layout Plans/Storage Specifications/Other Equipment Considerations
Fixtures and Holding Devices ..................................................................................................................
Specialty Frames/Baskets/Tubs and Skids with Crane Hairpins/Mobile Storage
Pallets and Racks ....................................................................................................................................
Pallet Racks/High-density Storage Racks/Drive-in Racks/Drive-through Racks/Pushback Racks/Flow
Racks/Cantilever Racks/Steel Pallet Racks/Considerations for Pallet Moving Equipment

11-1
11-2
11-4
11-5

Chapter 12Transport Packaging

Protective Packaging .............................................................................................................................. 12-1
Loose Fill/Wrapping Materials/Fabricated Packaging/Molded Packaging/Selection Guidelines
Corrugated Cartons ............................................................................................................................... 12-4
Design Considerations/Recycled Corrugated Fiberboard/A Film Alternative
Returnable Containers ............................................................................................................................ 12-4
Container Design/Application Guidelines/Maximizing the Return-on-investment (ROI)
The Unit Load Base ................................................................................................................................ 12-7
Wood Pallets/Plastic Pallets/Corrugated Fiberboard Pallets/Slip-sheets/Pallet Design/Pallet
Standards/Handling without Pallets
Fire Protection and Packaging .............................................................................................................. 12-16
Product Identification ........................................................................................................................... 12-17
Label Requirements/Bar Code Printers/Weighing Systems
Unit Load Forming ............................................................................................................................... 12-19
Palletizing Methods/Load Protecting and Securing
Integrating the Packaging Function ....................................................................................................... 12-22

Chapter 13Automated Material Handling Equipment

Automated Guided Vehicle Systems ........................................................................................................ 13-1
Types of AGV Systems/Guidance Systems/AGV Controls/Battery Requirements/Selection
Criteria/System Sizing/Cost Estimating and Justification/Benefits/Safety Considerations/System
Maintenance/Future Trends

Automated Storage and Retrieval Systems ............................................................................................... 13-7

Automated Storage and Retrieval System Types/Pallets/Control Systems/Selection Criteria/
System Sizing/Cycle Time/Cost Estimating and Justification/Benefits/Safety Considerations/
System Maintenance/Future Trends
High-density Dynamic Storage Systems ................................................................................................. 13-15
Types of Systems/Controls/Selection Criteria/System Sizing/Cost Estimating and Justification/Benefits/Safety Considerations and Maintenance/Future Trends
Carousel Storage and Retrieval Systems ................................................................................................ 13-19
Types of Systems/Control Systems/System Sizing/Cycle Time/Cost Estimating and
Justification/Benefits/Safety Considerations and System Maintenance/Future Trends
Specialized Systems ............................................................................................................................. 13-25
Automatic Item Dispensers/Robotic Order-selection Systems/Tool-dispensing Systems/Controls/
System Sizing/Benefits/Safety Considerations and Maintenance
Industrial Robots .................................................................................................................................. 13-27
Types of Robots/Benefits and Applications/Control Systems/System Sizing/Safety Considerations
and Maintenance/Future Trends
Automated Packaging Equipment ......................................................................................................... 13-28
Types of Equipment

Chapter 14Worker Productivity and Ergonomic Assists

Lifting Devices ........................................................................................................................................ 14-1
Reasons for Use/Lifting Tables/Balancers and Hoists/Manipulators/End Effectors and Tooling/Typical
Interfaces
Enclosed-track Workstation Cranes ....................................................................................................... 14-22
Configuration/Application
Positioning Devices .............................................................................................................................. 14-25
Lifter/Tilter and Dumper/Turntable/Lift and Tilter/Lift and Turntable/Load Leveler/Choosing the
Right Equipment

Chapter 15Metalcutting
Introduction ........................................................................................................................................... 15-1
Considerations for Automated Machine Loading/Automation Issues
Bandsawing ........................................................................................................................................... 15-2
Automating Infeed and Outfeed/Application Examples
Bar Work ................................................................................................................................................ 15-3
Bar Feeding and Loading Systems/Cut Feeding/Bar Loading of Centerless Grinders
Chucking Work ...................................................................................................................................... 15-8
Gantry Loading/Gantry Applications for Horizontal Chucking/Gantry Applications Other than
Turning/Robot Loading/Simple Loaders for Lathes/Vertical Chucking
Prismatic Parts ...................................................................................................................................... 15-26
Pallets and Pallet Loading Systems/Small Pallets for Electrical Discharge Machining
and Other Uses
High-volume Systems ........................................................................................................................... 15-30
Synchronous Transfer Lines/Asynchronous Transfer Lines/Transfer Line Flexibility/Application: Simulating an Engine Plant
Cutting Tool Management .................................................................................................................... 15-35
Computerized Tool Management/Automatic Storage Equipment for Tools/Automated Tool
Delivery and Loading/Application: Machining Cell Tool Management
Chip Management ............................................................................................................................... 15-37
Rapid Accumulation of Chips/Stand-alone Primary Chip Handling/Chip Processing/Continuous
Chip Processing/Stand-alone Chip Wringers/Central Chip Handling Systems/Cold Briquetting
Coolant Filtration Management ............................................................................................................ 15-40
High-pressure Coolant Systems/Space Planning/Future Trends

Chapter 16Metal Forming

Introduction ........................................................................................................................................... 16-1
Stamping Plants ..................................................................................................................................... 16-1

Stackers ....................................................................................................................... .......................... 16-2

Destackers ..................................................................................................................... ........................ 16-2
Washers and Lubricators ........................................................................................................................ 16-9
Coil Feeding .......................................................................................................................................... 16-9
Types of Coil Feeding/Accuracy Control/High-speed Feeding/Feeding Techniques
In-press Transfer Systems ...................................................................................................................... 16-15
New Technology Advantages/Transfer Press Size Classification/Transfer Feed Technology/
Material Handling Considerations/Flexible Universal Stations/Press Construction/
Hydraulic Presses
Between-press Transfer Systems ............................................................................................................. 16-26
Tandem Press Lines
In-die Transfer Systems ......................................................................................................................... 16-29
Design of a Three-axis Transfer Die
Robots ................................................................................................................................................. 16-30
Robotic Shuttle Devices/Swing-arm Robot/Pendulum-arm Robot/Robot Selection for
Press-to-press Transfer
Automated Parts Racking ...................................................................................................................... 16-33
Conveyors ........................................................................................................................................... 16-34
Flexible Handling Systems .................................................................................................................... 16-36
Automation Economics/Automated Material Handling Benefits/Bulk Material Handling/
Just-in-Time/Sheet Metal Operation

Chapter 17Plastic Manufacturing

Raw Material Storage and Handling ....................................................................................................... 17-1
Manual Methods/Semi-automatic Material Conveyance Methods/Automatic and High-volume
Resin Handling Systems/Feeding and Blending Systems/Material Conditioning Systems
Handling of Molded Parts ..................................................................................................................... 17-12
Free-drop Systems for Molded Parts Handling/Conveying Systems for Part Handling/
Robotic Systems for Parts Orientation/Planning and Implementing an Automated Molding Cell

Chapter 18Assembly
Introduction ........................................................................................................................................... 18-1
Understanding the Application/Sizing the Equipment/Justifying the Automation Project/
Considerations for Parts
Automated Parts Supply Systems ............................................................................................................. 18-2
Basic Hopper/Movable-wall Hoppers/Hopper-elevator Combination/Bulk Feeder Supply/
Coil Spring Hopper/Wire Form Hoppers/Portable Hoppers/Liners
Parts Orientation Equipment ................................................................................................................... 18-5
Vibratory Bowl Feeders/Orienting on Linear Vibratory Conveyors/Linear Fiber Vibratory Feeders/
Horizontal Belt Feeders/Centrifugal Feeders/Hopper Elevators/Precision Rolls/
Drum Feeders/Sensing/Part Quality
Oriented Parts Transfer ......................................................................................................................... 18-13
Gravity Tracks/Linear Vibratory Feeders/Belts with Guides/Tube Transfer/Chain Transfer
Oriented Parts Placement ..................................................................................................................... 18-14
Gravity Tracks/Force Feeding into Pockets Using Linear Feeders/Reciprocating Plunger and Jaw
Combinations/Pick-and-place Mechanisms/Robots/Fastener Devices
Assembly Machines and Systems .......................................................................................................... 18-15
Qualification of Parts/Rate Comparisons for Assembly Systems/Operator-assisted Workstation/
Synchronous AssemblyRotary Index Table/Synchronous AssemblyCarousel/Linear
Asynchronous Assembly/Asynchronous Pallet Loop SystemsLevel One/Asynchronous Pallet Loop
SystemsLevel Two/Summary
Pneumatic Devices for Automation ........................................................................................................ 18-21
Application Criteria/Grippers/Rotary Actuators/Multimotion Actuators/Powered Slides/Cylinders/
Escapements, Switches, and Sensors
Flexible Automation for Assembly ......................................................................................................... 18-23
Flexible Parts Feeders/Flexible Assembly Systems

Chapter 19Finishing, Painting, and Coating

Design Elements .................................................................................................................................... 19-1
Product and Carrier Relationship/Conveyance Equipment/Finishing Equipment Considerations/
System Layouts
Planning for an Integrated Paint System .................................................................................................. 19-9
Chain Monorail System/Tow Chain Conveyor System
Summary ............................................................................................................................................. 19-25

Chapter 20Moving and Handling Scrap and Waste

Introduction ........................................................................................................................................... 20-1
Types of Metal Scrap/Conveyor Utilization
Types of Metal Scrap Handling Conveyors .............................................................................................. 20-3
Standard Drive Configuration Conveyors/Eccentric-driven Oscillating Conveyors/Rotary-driven
Screw Conveyors/Hydraulic Fluid-driven Conveyors/Pneumatic Conveyors/Hydraulic and Sluice
Fluid-motion Conveyors
Chuting and Distribution Systems .......................................................................................................... 20-10
Electrical Controls ............................................................................................................ .................... 20-11
Application Examples ........................................................................................................................... 20-11
Single-unit Machined Chips and Turnings Collection/In-floor Systems for Machined Chips and
Turnings/Above-floor Stamping Scrap Collection/In-floor Stamping Systems/Die Cast Scrap
Handling Systems
Prepurchase Strategies ......................................................................................................................... 20-16
Economic Justification/Collect Application Information

Appendix AIndustry Associations and Standards

Belgium ...................................................................................................................................................
Czech Republic ........................................................................................................................................
England ...................................................................................................................................................
France .....................................................................................................................................................
Germany .................................................................................................................................................
Italy .........................................................................................................................................................
Netherlands .............................................................................................................................................
Poland .....................................................................................................................................................
Spain .......................................................................................................................................................
Sweden ....................................................................................................................................................
Switzerland ..............................................................................................................................................
United Kingdom ......................................................................................................................................
United States ...........................................................................................................................................

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