Industrial Engineering Tutorials

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1) What are the key definitions of material handling (MH)?
1. Material handling is the art and science of moving, storing, protecting, and controlling
material.
2. Material handling means providing the right amount of the right material, in the right
condition, at the right place, at the right time, in the right position, in the right sequence,
and for the right cost, by using the right method(s).

2) What are the objectives of materials handling?

Main objective is to reduce the number of units as well as the overall cost of material
handling and equipment and reducing the distances through which the materials are handled
or storage. The other objectives:
• To provide better control of the flow of materials.
• Lower unit material handling and storage costs.
• Improved working conditions and greater safety in movement of materials.

3) Name at least eight principles of material handling.

Planning Principle - Standardization Principle - Work Principle - Ergonomic Principle -
Unit Load Principle - Space Utilization - System Principle - Automation Principle -
Environmental Principle - Life-Cycle Cost Principle.

4) Briefly discuss five principles of material handling.

1. Planning Principle: A plan is prescribed course of action that is defined in advance of
implementation. In its simplest form, a material handling plan defines material (what)
and moves (when and where); together they define method (how and who).
2. Standardization Principle: Standardization means less variety and customization in
the methods and equipment employed.
3. Work Principle: The measure of work is material flow (volume, weight, or count per
unit of time) multiplied by the distance moved.
4. Ergonomic Principle: Ergonomics is the science that seeks to adapt work or working
conditions to suit the abilities of the worker.

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5. Unit Load Principle: A unit load is one that can be stored or moved as a single entity
at one time, such as a pallet, container, or tote, regardless of the number of individual
items that make up the load.
6. Space Utilization: Space in material handling is three-dimensional and therefore is
counted as cubic space.
7. System Principle: A system is a collection of interacting and/or interdependent entities
that form a unified whole.
8. Automation Principle: Automation is a technology concerned with the application of
electromechanical devices, electronics, and computer-based systems to operate and
control production and service activities. It suggests the linking of multiple mechanical
operations to create a system that can be controlled by instructions.
9. Environmental Principle: Environmental consciousness stems from a desire not to
waster natural resources and to predict and eliminate the possible negative effects of
our daily actions on the environment.
10. Life-Cycle Cost Principle: Life-cycle cost include all cash flows that will occur from
the time the first dollar is spent to plan or procure a new piece of equipment, or to put
in place a new method, until that method and/or equipment is replaced.

5) Draw a schematic diagram showing the material handling system equation.

6) What is meant by material flow and how to develop material flow system?
The combination of material characteristics and move or flow requirements is referred to
as material flow.
To develop material flow system requirements, one should focus on the material to be
handled, stored, and controlled and the flow or throughput requirements for the system.
Material flow is transformed to material handling by the method of handling, storing, and
controlling the material.

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7) Briefly discuss the six-phased engineering process used in material handling

systems design and improvement.
In designing new or improved material handling systems, the six-phased engineering
design process should be used as:
1. Define the objectives and scope for the material handling system.
2. Analyze the requirements for moving, storing, protecting, and controlling material.
3. Generate alternative designs for meeting material handling system requirements.
4. Evaluate alternative material handling system designs.
5. Select the preferred design for moving, storing, protecting, and controlling material.
6. Implement the preferred design, including the selection of suppliers, training of
personnel, installation, debug and startup of equipment, and periodic audits of system
performance.

8) What are the advantages and disadvantages of material handling system?

The advantages are: (reduce costs - reduce damage - increase space and equipment
utilization - increase throughput - increase productivity - improve working conditions).
The disadvantages are: (increased capital requirements - decreased flexibility - decreased
reliability, maintainability, and operability).

9) What are the design considerations in material handling system?

Material characteristics - Flow rate, routing, and scheduling - Plant layout - Unit load
principle.

10) What are the different characteristics of materials that affect the selection of
material handling equipment?
Material characteristics affect type of transport and storage equipment required:
Solid, liquid or gas – Size – Weight – Shape (long, flat, bulky) - Condition (hot, cold, wet,
dirty) - Risk of damage (fragile, brittle, sturdy) Safety risk (explosive, flammable, toxic).

11) Material handling equipment must be included in the plant layout design, show
the correlation between layout type and material handling equipment.
Correlation between layout type and material handling equipment:
Plant layout type Material handling equipment
Fixed-position Cranes, hoists, industrial trucks
Process layout Hand trucks, forklift trucks, AGVs
Product layout Conveyors for product flow Trucks to deliver parts to stations.

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12) What is the definition of unit load and what are the components of unit load?
The concept of a unit load is derived from the unit size principle; a unit load can be defined
simply as the unit to be moved or handled at one time. In some cases, the unit load is one
item of production; in other situations, the unit load is several cartons, each containing
numerous items of production.
The unit load includes the container, carrier, or support that will be used to move materials.
Unit loads consists of material in, on, or grouped together by something.

13) Why are the unit loads used in material handling?

Reasons for using unit loads in material handling:
1. Multiple items handled simultaneously.
2. Required number of trips is reduced.
3. Loading/unloading times are reduced.
4. Product damage is decreased.

14) Write down examples of shape and size of pallets.

Shapes and sizes of pallets:
a) Standard single-deck wooden pallet
b) Double-faced nonreversible pallet for pallet truck handling
c) Four-way block-leg pallet
d) Double-wing-type (stevedore) pallet
e) Three-board single-deck expandable shipping pallet.

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15) Name examples of stacking patterns.

Stacking patterns for different pallet sizes:
a) Block pattern
b) Row pattern
c) Pinwheel pattern
d) Honeycomb pattern
e) Split-row pattern
f) Split-pinwheel pattern
g) Split-pinwheel pattern for narrow boxes
h) Brick pattern.

16) Classify the main types of material transport equipment.

The main types of material transport equipment:
1. Industrial trucks
2. Automated guided vehicles
3. Monorails and other rail guided vehicles
4. Conveyors
5. Cranes and hoists

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17) Compare between different types of industrial trucks.

There are two basic categories of industrial trucks:
1. Non-powered: Human workers push or pull loads.

2. Powered trucks: Self-propelled, guided or driven by human - Common example:

forklift truck.
a) Walkie Truck: Wheeled forks insert into pallet openings - No provision for riding;
truck is steered by worker using control handle at front of vehicle.

b) Forklift Truck: Widely used in factories and warehouses because pallet loads are so
common - Capacities from 450 kg up to 4500 kg - Power sources include on-board
batteries and internal combustion motors.

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c) Towing Tractor: Designed to pull one or more trailing carts in factories and
warehouses, as well as for airport baggage handling - Powered by on-board batteries
or IC engines.

18) What is meant by AGV and what are the main types of AGVs?
An Automated Guided Vehicle System (AGVS) is a material handling system that uses
independently operated, self-propelled vehicles guided along defined pathways in the
facility floor. Types of AGV:
1. Driverless trains
2. Pallet trucks
3. Unit load AGVs.

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19) What are the applications of AGVs?

1. Driverless train operations - movement of large quantities of material over long
distances
2. Storage and distribution - movement of pallet loads between shipping/receiving docks
and storage racks
3. Assembly line operations - movement of car bodies and major subassemblies (motors)
through the assembly stations
4. Flexible manufacturing systems - movement of workparts between machine tools
5. Miscellaneous - mail delivery and hospital supplies.

20) Briefly discuss the technologies used in vehicle guidance.

Three main technologies are used in vehicle guidance:
1. Imbedded guide wires: guide wires in the floor emit electromagnetic signal that the
vehicles follow.
2. Paint strips: optical sensors on-board vehicles track the white paint strips.
3. Self-guided vehicles: vehicles use a combination of
• Dead reckoning: vehicle counts wheel turns in direction to move without guidance
• Beacons located throughout facility: vehicle uses triangulation to compute locations

21) What is meant by an industrial robot and what is the importance of using it?
An industrial robot is a general-purpose, programmable machine possessing certain
anthropomorphic characteristics. Mechanical arm is the most common characteristic of an
industrial arm and is used to perform various industrial tasks. Making decisions, capability
to communicate with other machines, and capability to respond to sensory inputs are the
important attributes of an industrial robot.
Importance of using robot:
1. Robots can be substituted for humans in hazardous or uncomfortable work
environments. A robot performs its work cycle with a consistency and repeatability that
cannot be attained by humans.
2. Robots can be reprogrammed. When the production run of the current task is completed,
a robot can be reprogrammed and equipped with necessary tooling to perform an
altogether different task.
3. Robots are controlled by computers and can therefore be connected to other computer
systems to achieve computer integrated manufacturing.

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22) Classify robots according to physical configuration and control system.

On the basis of physical configuration industrial robots are classified in four different types:
a) cartesian configuration,
b) cylindrical configuration,
c) polar configuration, and
d) jointed-arm configuration.

On the basis of control system industrial robots are classified in three different types:
a) Point-to-point (PTP) control robot
b) Continuous-path (CP) control robot
c) Controlled-path robot

23) What are the types of conveyors? Briefly discuss each type.
1. Roller Conveyor: Pathway consists of a series of rollers that are perpendicular to
direction of travel - Loads must possess a flat bottom to span several rollers - Powered
rollers rotate to drive the loads forward - Unpowered roller conveyors also available.

2. Skate-Wheel Conveyor: Similar in operation to roller conveyor but use skate wheels
instead of rollers - Lighter weight and unpowered - Sometimes built as portable units
that can be used for loading and unloading truck trailers in shipping and receiving.

3. Belt Conveyor: Continuous loop with forward path to move loads - Belt is made of
reinforced elastomer - Support slider or rollers used to support forward loop - Two
common forms (Flat belt – V shaped for bulk materials).

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4. In-Floor Tow-Line Conveyor: Four-wheel carts powered by moving chains or cables

in trenches in the floor - Carts use steel pins (or grippers) to project below floor level
and engage the chain (or pulley) for towing - This allows the carts to be disengaged
from towline for loading and unloading.

5. Overhead Trolley Conveyor: A trolley is a wheeled carriage running on an overhead

track from which loads can be suspended - Trolleys are connected and moved by a
chain or cable that forms a complete loop - Often used to move parts and assemblies
between major production areas.

6. Cart-On-Track Conveyor: Carts ride on a track above floor level - Carts are driven
by a spinning tube - Forward motion of cart is controlled by a drive wheel whose angle
can be changed from zero (idle) to 45 degrees (forward).

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24) Compare between cranes and hoists.

Cranes: Used for horizontal movement of materials
Hoists: Used for vertical lifting of materials
Cranes may include hoists so that the crane-and-hoist combination provides Horizontal
transport - Vertical lifting and lowering.

25) What are the different types of cranes?

1- Bridge Crane. 2- Gantry Crane. 3- Jib Crane.

26) What is meant by automated storage and retrieval system (ASRS or AS/RS)?
Automated Storage and Retrieval Systems (AS/RS)
• To get right parts, pallets, fixtures, and tools to the right place at the right time, an
efficient system for their storage and retrieval together with a material transportation
system is required.
• An integrated FMS, AGVS, and AS/RS system provides an efficient production system
for manufacturing low- to medium- volume and middle- to high-variety products.

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27) What is the function of AS/RS?

Function of storage systems and definition of AS/RS
• Receiving, identification and sorting, dispatching to storage, placing in storage, storage,
retrieving from storage, order accumulation, packing, shipping, and record keeping for
raw materials, purchased parts, work in process, finished product, pallets, fixtures,
tools, spare parts, rework and scrap, office supplies, and so forth have traditionally been
considered the functions of storage systems.
• An AS/RS attempts to achieve these functions by automating most of these procedures
in a cost-effective and efficient manner.
• In general, an AS/RS performs a basic set of operations without human intervention,
regardless of the specific type of system that is employed.
1. Automatic removal of an item from a storage location
2. Transportation of this item to a specific processing or interface point
3. Automatic storage of an item in a predetermined location, having received an
item from a processing or interface point.

28) Mention the benefits of using AS/RS.

• An AS/RS is highly space efficient. Space now occupied by raw stock, work in
process, or finished parts and assemblies can be released for valuable space.
• Increased storage capacity to meet long-range plans.
• Improved inventory management and control.
• Quick response time to locate, store, and retrieve items.
• Reduced shortages of inventory items due to real-time information and control.
• Reduced labor costs due to automation.
• Improved stock rotation.
• Improved security and reduced pilferage because of closed storage area.
• Flexibility in design to accommodate a wide variety of loads.
• Flexibility in interfacing with other systems such as AGVS, FMS, and inspection
systems such as coordinate measuring machines.
• Reduced scrap and rework due to automatic handling of parts.
• Reduced operating expenses for light, power, and heat.
• Helps implement just-in-time (JIT) concepts by getting the right parts, tools, pallets
and fixtures to the right place at the right time because of automatic control of storage
and retrieval functions and accurate inventory management.

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29) Briefly discuss the types of AS/RS?

Type of AS/RS
1. Unit load AS/RS: is used to store and retrieve loads that are palletized or stored in
standard-size containers.
2. Mini-load AS/RS: is designed to handle small loads such as individual parts, tools, and
supplies. The system is suitable for use where there is a limit on the amount of space
that can be utilized and where the volume is too low for a full-scale unit load system
and tool high for a manual system.
3. Person-on-board AS/RS: allows storage of items in less than unit load quantities.
4. Deep-lane AS/RS: is another variation on the unit load system. The items are stored in
multi-deep storage with up to 10 items per row rather than single or double deep. This
leads to a high density of stored items.
5. Automated item retrieval system.

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30) A new belt conveyor which is required as a flow line of dry sand from the
warehousing to the sand casting workshop, two types of belt conveyors can be
used (flat or troughed) as the following figure:

- The following data were available: width of sand (b) = 80 cm, dynamic angle of
repose (Φ) = 30o, sand density = 1600 kg/m3, conveyor speed is 0.5 m/s. Find the
conveying capacity for two types of belt conveyor.
- If the length of flat belt conveyor is 10 m, and the mass of belt per meter is 12 kg/m,
and the moving mass of carrying and return idlers are 15 kg/m and 3 kg/m
respectively, and the coefficient of friction between belt and idlers is 0.05. Find the
power required to drive this conveyor.

Solution
1) Finding conveying capacity (Q):
𝑄 =𝑣𝐴𝜌
- For the flat belt
𝐴 = 0.5 𝑏ℎ = 0.5 𝑏 (0.5 𝑏 tan(∅))
𝐴 = 0.5 𝑏ℎ = 0.5 × 0.8 (0.5 × 0.8 × tan(30)) = 0.092 𝑚2
𝑸 = 0.5 × 0.092 × 1600 = 𝟕𝟑. 𝟔 𝑲𝒈/𝒔
- For the troughed belt
𝐴 = 𝐴1 + 𝐴2 𝐴2 = 0.5(𝑏 + 0.4𝑏) × 0.3 𝑏 tan (20)
𝐴 = 0.092 + 0.5(0.8 + 0.4 × 0.8) × 0.3 × 0.8 tan(20) = 0.141 𝑚2
𝑸 = 0.5 × 0.141 × 1600 = 𝟏𝟏𝟐. 𝟖 𝑲𝒈/𝒔
2) Finding power required (P) (flat belt conveyor):
𝑇𝑒 × 𝑣
𝑃= 𝑇𝑒 𝑒ffective tension
1000
𝑇𝑒 = 𝜇 𝐿 𝑔 (𝑚𝑐 + 𝑚𝑟 + 𝑚𝑙 + 2𝑚𝑏 )
𝑇𝑒 = 0.05 × 10 × 9.8 (15 + 3 + (1600 × 0.092) + 2 × 12) = 927.08 𝑁
927.08 × 0.5
𝑃= = 0.463 𝐾𝑤
1000

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31) A single direction conveyor system has to be designed to meet a part flow rate of
60 parts per minute. Each container in the conveyor can hold 6 parts. The distance
between the loading and unloading points is about 10 m. Determine the required
conveyor speed and the allowable loading time if the spacing between the
containers is 1 m.

Solution
1) Calculating the required conveyor speed:
𝑆𝑅 1 × 60
𝑣= = = 10 𝑚/𝑚𝑖𝑛
𝑛 6
S  Space between containers, R Rate parts, n number of parts per container
2) Calculating the allowable loading time:
𝑆 1
𝐿≤ 𝑆𝑜 → 𝐿 ≤ 𝑚𝑖𝑛
𝑣 10
So, the loading time should not to be more than 0.1 min

32) An overhead conveyor has hooks and moves painted doors over a distance of 400
m in a single direction at 100 m/min between the paint station and the
intermediate storage area. The cycle time for painting a door is 2 min. Determine
the spacing between the hooks and the flow rate of parts in the conveyor system.
Assume the unloading time is equal to the paint cycle time.

Solution
1) Calculating spacing between hooks:
𝑆
𝑝𝑎𝑖𝑛𝑡𝑖𝑛𝑔 𝑐𝑦𝑐𝑙𝑒 + 𝑢𝑛𝑙𝑜𝑎𝑑𝑖𝑛𝑔 𝑡𝑖𝑚𝑒 ≤
𝑣
𝑆
2+2≤ 𝑆 = 400 𝑚
100
2) Calculating the flow rates of part:
𝑆𝑅 100 × 1
𝑣= → 𝑹= = 𝟎. 𝟐𝟓 𝑑𝑜𝑜𝑟/𝑚𝑖𝑛 = 15 𝑑𝑜𝑜𝑟/ℎ𝑟
𝑛 400

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33) A forklift truck initially costs L.E. 200,000 and has an expected life of 5 years. Fuel
cost is L.E. 100.00 per 8 hours of operation, and maintenance cost is L.E. 15.0 an
hour. If the truck travels an average of 3,000 meter per day, determine the cost
per meter. Assume that the truck operates 360 days a year and that the operator
is paid L.E. 25.00 an hour.

Solution

1) Total cost per hour:

Total cost per hour = (maintenance + fuel + depreciation + operator cost) / hr

200000
𝐷𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛 = = 𝐿. 𝐸. 13.9 /ℎ𝑟
5 × 360 × 8
100
𝑇𝑜𝑡𝑎𝑙 𝑐𝑜𝑠𝑡 = 15 + ( ) + 13.9 + 25 = 𝐿. 𝐸 66.4 /ℎ𝑟
8
2) Total cost per meter:

𝑇𝑜𝑡𝑎𝑙 𝑐𝑜𝑠𝑡/ℎ𝑟 66.4

𝐓𝐨𝐭𝐚𝐥 𝐜𝐨𝐬𝐭/𝐦 = = = 𝑳. 𝑬 𝟎. 𝟏𝟖 /𝒎
𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑡𝑟𝑎𝑣𝑒𝑙𝑙𝑒𝑑/ℎ𝑟 (3000/8)

34) A L.E. 100,000 tractor truck has an expected life of 8 years. The truck operates
280 days a year and travels an average of 5,000 meter per day. If the fuel costs
about L.E. 90.00 a day and maintenance costs are L.E. 7.5 an hour, determine the
cost per meter for operating this vehicle. Operator cost is L.E. 80.00/hour.

Solution
1) Total cost per hour:

Total cost per hour = (maintenance + fuel + depreciation + operator cost) / hr

100000
𝐷𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛 = = 𝐿. 𝐸 5.58 /ℎ𝑟
8 × 280 × 8
90
𝑇𝑜𝑡𝑎𝑙 𝑐𝑜𝑠𝑡 = 7.5 + ( ) + 5.58 + 80 = 𝐿. 𝐸 104.33 /ℎ𝑟
8
2) Total cost per meter:

𝑇𝑜𝑡𝑎𝑙 𝑐𝑜𝑠𝑡/ℎ𝑟 104.33

𝑻𝒐𝒕𝒂𝒍 𝒄𝒐𝒔𝒕/𝒎 = = = 𝑳. 𝑬 𝟎. 𝟏𝟔𝟔 /𝒎
𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑡𝑟𝑎𝑣𝑒𝑙𝑙𝑒𝑑/ℎ𝑟 (5000/8)

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35) Johnson and Johnson (JJ) is planning to integrate the AGVS and AS/RS with their
flexible manufacturing system. JJ is interested in estimating the number of AGVSs
required to satisfy the needs of the manufacturing system; that means the system
must be capable of making 65 deliveries per hour. JJ has already decided to install
a laser guide path system and unit load AGVS adequately serves company needs.
The following data have been collected: vehicle speed = 55 m/min, average loaded
travel distance per delivery = 165 m, average empty travel distance per delivery =
110 m, pickup lime = 0.5 min, drop off time = 0.5 min, traffic factor = 0.85.

Solution
1) Calculating the total delivery time of one AGV:
𝑑 (165 + 110)
𝑡𝑖𝑚𝑒 (𝐴𝐺𝑉 ) = + 𝐻 = + 0.5 + 0.5 = 6 𝑚𝑖𝑛
𝑣 55
2) Calculating the number of AGVs required:
𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑒𝑙𝑖𝑣𝑒𝑟𝑖𝑒𝑠/ℎ𝑟
𝑁=( ) /𝑡𝑟𝑎𝑓𝑓𝑖𝑐 𝑓𝑎𝑐𝑡𝑜𝑟
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑒𝑙𝑒𝑣𝑒𝑟𝑖𝑒𝑠 𝑝𝑒𝑟 𝐴𝐺𝑉/ℎ𝑟

65
𝑵=( ) = 𝟕. 𝟔𝟒 = 𝟖 𝑨𝑮𝑽
60
× 0.85
6

36) The proposed AGV system for a manufacturing unit must be capable of making
80 deliveries per hour. The type of AGV selected for this application has a velocity
of 50 m/min. Based on the current facility layout, the average loaded travel
distance will be 150 m and the average empty travel distance will be 100 m. The
total loading and unloading time will average about 1 min. Assuming a traffic
factor of 0.8, determine the number of AGVs required.

Solution
1) Calculating the total delivery time of one AGV:
𝑑 (150 + 100)
𝑡𝑖𝑚𝑒 (𝐴𝐺𝑉 ) = + 𝐻 = + 1 = 6 𝑚𝑖𝑛
𝑣 50
2) Calculating the number of AGVs required:
𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑒𝑙𝑖𝑣𝑒𝑟𝑖𝑒𝑠/ℎ𝑟
𝑁=( ) /𝑡𝑟𝑎𝑓𝑓𝑖𝑐 𝑓𝑎𝑐𝑡𝑜𝑟
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑒𝑙𝑒𝑣𝑒𝑟𝑖𝑒𝑠 𝑝𝑒𝑟 𝐴𝐺𝑉/ℎ𝑟

80
𝑵=( ) = 𝟏𝟎 𝑨𝑮𝑽
60
× 0.8
6

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37) An automated guided vehicle system is used inside a telephone repair facility. The
vehicles move repaired telephones from the repair facility to the packing area.
Owing to the nature of the layout, the loaded travel distance is 300 m and the
empty travel distance is 500 m. The system must be able to move 750 phones per
hour. The load and unload time is about 1 min and the speed of the vehicle is 120
m/min. Determine the number of AGVs required. Knowing that each vehicle
capacity is 20 phones.

Solution
1) Calculating the total delivery time of one AGV:
𝑑 (300 + 500)
𝑡𝑖𝑚𝑒 (𝐴𝐺𝑉 ) = + 𝐻 = + 1 = 7.7 𝑚𝑖𝑛
𝑣 120
2) Calculating the number of AGVs required:
𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑒𝑙𝑖𝑣𝑒𝑟𝑖𝑒𝑠/ℎ𝑟
𝑁=( ) /𝑡𝑟𝑎𝑓𝑓𝑖𝑐 𝑓𝑎𝑐𝑡𝑜𝑟
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑒𝑙𝑒𝑣𝑒𝑟𝑖𝑒𝑠 𝑝𝑒𝑟 𝐴𝐺𝑉/ℎ𝑟

750
𝑵=( ) = 𝟒. 𝟖 = 𝟓 𝑨𝑮𝑽
60 × 20
×1
7.7

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Industrial Engineering Tutorials

38) Suppose an AGV system is chosen for delivering small parts from storage to four
shops in a plant, as shown in Figure. (Most guided vehicles can carry a load of 1000
to 4000 Kg) Determine the number of vehicles needed, given the information in
Table. (Assume that each vehicle can carry parts to and from only one shop at a
time) The AGVs under consideration can travel at a rate of 60 m/min. (Between
60 and 78 m/min is the normal speed for an AGV), and a congestion factor of 0.85.

Table: AGV Distribution System Data

Distance from Number of trips Loading/Unloading
Shop No.
storage (m) (per hour) (min)
1 90 14 2
2 150 16 3
3 180 5 3
4 240 8 2

Solution
1) Calculating the total time travelled by AGVs (hour):
𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑜𝑓 𝑜𝑛𝑒 𝑡𝑟𝑖𝑝
𝑡𝑖𝑚𝑒 𝑡𝑟𝑎𝑣𝑒𝑙𝑙𝑒𝑑 = × 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑟𝑖𝑝𝑠
𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑎𝑔𝑣
𝑡𝑖𝑚𝑒 𝑡𝑟𝑎𝑣𝑒𝑙𝑙𝑒𝑑
(90 × 2) (150 × 2) (180 × 2)
=( × 14) + ( × 16) + ( × 5)
60 × 60 60 × 60 60 × 60
(240 × 2)
+( × 8) = 3.6 ℎ𝑟
60 × 60
2) Calculating the total time of loading and unloading of AGVs (hour):
2(14 × 2 + 16 × 3 + 5 × 3 + 8 × 2)
𝑡𝑖𝑚𝑒 (𝑙𝑜𝑎𝑑𝑖𝑛𝑔 + 𝑢𝑛𝑙𝑜𝑎𝑑𝑖𝑛𝑔) =
60
= 3.57 ℎ𝑟
3) Calculating the total time of AGVs (hour):
𝑡𝑖𝑚𝑒 = 3.6 + 3.57 = 𝟕. 𝟏𝟕 𝒉𝒓
4) Number of AGVs needed per hour:
7.17
𝑁 = = 8.43 = 𝟗 𝑨𝑮𝑽/𝒉𝒓
1 × 0.85

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Industrial Engineering Tutorials

39) Parts needed for production in departments 1, 2, and 3 are moved from storage
by AGVs. Using the distance from the storage to each department as shown in
Figure and given the number of trips that will be made per hour to each
department and the time needed for loading and unloading given in the
accompanying table. Determine how many vehicles are needed. Assume an AGV
speed of 60 m/min and a congestion factor of 0.85.

Number of trips Loading/Unloading

Department
(per hour) (min)
1 10 2
2 15 4
3 20 3

Solution
1) Calculating the total time travelled by AGVs (hour):
𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑜𝑓 𝑜𝑛𝑒 𝑡𝑟𝑖𝑝
𝑡𝑖𝑚𝑒 𝑡𝑟𝑎𝑣𝑒𝑙𝑙𝑒𝑑 = × 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑟𝑖𝑝𝑠
𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑎𝑔𝑣
𝑡𝑖𝑚𝑒 𝑡𝑟𝑎𝑣𝑒𝑙𝑙𝑒𝑑
(46 × 2) (64 × 2)
=( × 10) + ( × 15)
60 × 60 60 × 60
(141 × 2)
+( × 20) = 2.36 ℎ𝑟
60 × 60
2) Calculating the total time of loading and unloading of AGVs (hour):
2(10 × 2 + 15 × 4 + 20 × 3)
𝑡𝑖𝑚𝑒 (𝑙𝑜𝑎𝑑𝑖𝑛𝑔 + 𝑢𝑛𝑙𝑜𝑎𝑑𝑖𝑛𝑔) = = 4.67 ℎ𝑟
60
3) Calculating the total time of AGVs (hour):
𝑡𝑖𝑚𝑒 = 2.36 + 4.67 = 𝟕. 𝟎𝟑 𝒉𝒓
4) Number of AGVs needed per hour:
7.03
𝑁 = = 8.27 = 𝟗 𝑨𝑮𝑽/𝒉𝒓
1 × 0.85

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Industrial Engineering Tutorials

40) The oval of a top-driven carousel has a length of 15 m and a width of 1.5 m. The
speed of the carousel is 3 m/min, there are 60 carriers around the carousel and
each carrier contains only one bin, for a single and bidirectional carousel, compute
the average part retrieval time assuming a handling time of 30 s, Also, determine
the spacing between the carriers.

Solution
1) Calculating the total circumference of the path:
𝐶 = 2(15 − 1.5) + (𝜋 × 1.5) = 31.7 𝑚
2) Calculating the average retrieval time:
0.5𝐶 0.5 × 31.7 30
𝒔𝒊𝒏𝒈𝒍𝒆 𝒅𝒊𝒓𝒆𝒄𝒕𝒊𝒐𝑛: 𝑡 = +𝐻 = + = 𝟓. 𝟖 𝒎𝒊𝒏
𝑣 3 60
0.25𝐶 0.25 × 31.7 30
𝒃𝒊𝒅𝒊𝒓𝒆𝒄𝒕𝒊𝒐𝒏𝒂𝒍 𝒅𝒊𝒓𝒆𝒄𝒕𝒊𝒐𝒏: 𝑡 = +𝐻 = + = 𝟑. 𝟏𝟒 𝒎𝒊𝒏
𝑣 3 60
3) Calculating the spacing between carriers:
𝑆 = (𝐶/𝑛) = (31.7 /60) = 𝟎. 𝟓𝟑 𝒎

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Industrial Engineering Tutorials

41) Calculate the cycle and production rate for a single-machine robotic cell one or
two-handed gripper for an 8-hr shift if the system availability is 85 %. Also
determine the percent utilization of machine and robot. On average, the machine
takes 48 sec. to process a part. The other robot operation times are as follows:
Activities Time (sec)
Robot picks a shaft from the conveyor 4.5
Robot moves the shaft to the lathe 2
Robot loads the shaft onto the lathe 1
Robot unloads the shaft from the lathe 0.5
Robot moves the conveyor 2
Robot puts the shaft on the outgoing conveyor 0.75
Robot moves from the output conveyor to the input conveyor 5

Solution
1) Using one handed gripper:
Finding Cycle time:
𝐶𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒 = 48 + 4.5 + 2 + 1 + 0.5 + 2 + 0.75 + 5 = 𝟔𝟑. 𝟕𝟓 𝒔
Finding total production/day:
8 × 3600
𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = × 0.85 = 𝟑𝟖𝟒 𝒖𝒏𝒊𝒕𝒔/𝒅𝒂𝒚
63.75
Machine utilization %:
𝑀/𝑐 𝑐𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒 48
𝑀/𝑐 𝑢𝑡𝑖𝑙𝑖𝑧𝑎𝑡𝑖𝑜𝑛 % = = × 100 = 𝟕𝟓. 𝟑 %
𝑇𝑜𝑡𝑎𝑙 𝑐𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒 63.75
Robot utilization %:
𝑅𝑜𝑏𝑜𝑡 𝑐𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒 15.75
𝑅𝑜𝑏𝑜𝑡 𝑢𝑡𝑖𝑙𝑖𝑧𝑎𝑡𝑖𝑜𝑛 % = = × 100 = 𝟐𝟒. 𝟕 %
𝑇𝑜𝑡𝑎𝑙 𝑐𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒 63.75

2) Using two handed grippers:

Finding Cycle time:
𝐶𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒 = 48 + 0.5 + 1 = 𝟒𝟗. 𝟓 𝒔
Finding total production/day:
8 × 3600
𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = × 0.85 = 494.54 = 𝟒𝟗𝟓 𝒖𝒏𝒊𝒕𝒔/𝒅𝒂𝒚
49.5
Machine utilization %:
48
𝑀/𝑐 𝑢𝑡𝑖𝑙𝑖𝑧𝑎𝑡𝑖𝑜𝑛 % = × 100 = 𝟗𝟔. 𝟗𝟕 %
49.5
Robot utilization %:
15.75
𝑅𝑜𝑏𝑜𝑡 𝑢𝑡𝑖𝑙𝑖𝑧𝑎𝑡𝑖𝑜𝑛 % = × 100 = 𝟑𝟏. 𝟖 % = 𝟏𝟓. 𝟗 % 𝒇𝒐𝒓 𝒆𝒂𝒄𝒉 𝒉𝒂𝒏𝒅
49.5

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Industrial Engineering Tutorials

42) An Industrial robot is used in production facility load and unload workpieces from
a machine, these data table can be found:
Elemental Operation Times for a Robot
Activities Time (sec)
Machine operation time 25
Times associated with the robot
Unload unit 1.2
Move to the finished part conveyor 1.7
Release the unit 0.2
Move the arm to the input conveyor 2.6
Pick up a unit 0.3
Move to the machine 1.9
Load the machine 2.1

Find the cycle time using: one or two-handed gripper, then find the total
production units in an 8-hour-per-day operation with 80% efficiency.

Solution
1) Using one handed gripper:
Finding Cycle time:
𝐶𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒 = 25 + 1.2 + 1.7 + 0.2 + 2.6 + 0.3 + 1.9 + 2.1 = 𝟑𝟓 𝒔
Finding total production/day:
8 × 3600
𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = × 0.8 = 𝟔𝟓𝟖 𝒖𝒏𝒊𝒕𝒔/𝒅𝒂𝒚
35
2) Using two handed grippers:
Finding Cycle time:
𝐶𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒 = 25 + 1.2 + 2.1 = 𝟐𝟖. 𝟑 𝒔
Finding total production/day:
8 × 3600
𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = × 0.8 = 𝟖𝟏𝟒 𝒖𝒏𝒊𝒕𝒔/𝒅𝒂𝒚
28.3

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