Lecture

Material Handling and Storage Systems

Ch10-11

Material Handling Systems

Handling, storing and controlling of materials
Materials are:
Raw materials
Work in progress
Sub-assemblies
Finished assemblies

The goal in material handling is:

Right amount of material

Delivered safely
To a required location
At the right time
At a minimum possible cost

Depends on the business, material handling cost might take up

to 10 to 80% of total cost
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Design Considerations
in Material Handling

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

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Material Characteristics
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, corrosive
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Flow Rate, Routing, and Scheduling

Flow rate - amount of material moved per unit time
Examples: pieces/hr, pallet loads/hr, tons/hr
Whether the material must be moved in individual units,
as batches, or continuously
Routing - pick-up and drop-off locations, move distances,
routing variations, conditions along the route
Scheduling - timing of each delivery
Prompt delivery when required
Use of buffer stocks to mitigate against late deliveries

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Plant Layout
Material handling equipment considerations must be
included in the plant layout design problem
Correlation between layout type and material handling
equipment:

Plant layout type

Material handling equipment
Fixed-position Cranes, hoists, industrial trucks
Process Hand trucks, forklift trucks, AGVS
Product Conveyors for product flow
Trucks to deliver parts to stations
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Unit Load Principle

In general, the unit load should be as large as practical for the
material handling system that will move and store it
A unit load is the mass that is to be moved or otherwise
handled at one time
Reasons for using unit loads in material handling:
Multiple items handled simultaneously
Required number of trips is reduced
Loading/unloading times are reduced
Product damage is decreased
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Unit Load Containers

(a) Wooden pallet, (b) pallet box, (c) tote box

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Material Handling Equipments

Industrial Trucks

Hand trucks
Two-wheeled, Four-wheeled,
Hand lift, Forklift

Conveyors

Belt, Chute, Roller, Wheel, slat, chain, bucket, trolley, tow screw,
vibrating, and pneumatic

Monorails
Hoists
Cranes

Bridge, Gantry, Tower, Stacker

Automated guided
vehicle systems

Unit load carriers, towing, pallet trucks, fork trucks and assembly
lines

Automated storage and

retrieval systems

Unit load, mini-load, person-on-board, deep lane, storage carousel

systems

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Powered Trucks
Forklifts, Tractors, Trailer trains,
Crane trucks, Side loaders

Power Roller Conveyor

The direction of pallet movement is accomplished by changing the rotational

direction of the rollers
Sequential move of pallets
Inflexible
Inexpensive
Suitable for heavy workpieces and short cycle times

(Courtesy of Kearney
& Trecker
Corporation)
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Types of Conveyors
Non-powered
Powered
Belt conveyors, driven by chains and cables

Conveyor operations
Continuous
Asynchronous

Conveyor directions
Single direction
Continuous loop
Recirculating

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Rail Guided Vehicles

Rail guided linear transporter:
Transporter is powered by servomotor equipped with encoder to maintain
position accuracy
Inflexible for modification, create floor obstacles

Rail guided vehicles

Routing variations possible through the use of switches, turntables
Power picked up from an electrified rail
http://www.youtube.com/watch?v=wkddDUkKxsg

FMS using rail guided transporter (courtesy of Fritz Werner machine tool corporation)
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Rail Guided Vehicles

FMS using rail guided vehicles (courtesy of Kearney & Trecker Corporation)

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Robots
In an FMS, the majority of robot use is for handling small
workpieces and tools within and between different modules
Due to the small size of working envelope, part work fixtures and
modules have to be implemented around robots
It is generally used as a secondary handling system

Stationary robot performing the task of

loading and unloading of conveyored parts to
and from grinding machines (Courtesy of
Cincinnati Milacron)
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Robots

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Automated Guided Vehicles

AGVs is a material handling system that uses independently
operated, self-propelled vehicles along defined pathways.
AGVs are powered by rechargeable batteries (8-16hr)
AGV pathways are unobtrusive
Appropriate where different materials are moved from various load
points to various unload points.
AGVs can be classified in three types based on their guidance
technology:
Wire guided
Paint strips
Self-guided

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Automated Guided Vehicles

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Types of AGVs
Forklift and Pallet Trucks

Outrigger Type Pallet AGV

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Reach Type
Forklift AGV

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Forklift

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Types of AGVs (cont.)

Conveyor Deck
type AGV

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Lift Deck type

AGV

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Custom made
AGVS

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Wire Guided AGVs

Electrical wires are placed in small channel, after the

installation the channel is filled with cement.
Wires emit electromagnetic waves of low frequency, low
current AC signal, which is picked up by coil sensors
mounted on vehicles.

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Wire Guided AGVs

A typical AGV layout contains multiple loops, branches etc.

There are two principal method for deciding which path to take:
1.
2.

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Frequency select method:Depending on its programmed destination, it

selects by following one of the frequencies
Path switch select method: The power is turned of in all other branches
except the one that the vehicle is to travel on

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Paint Strip AGVs

It has the advantage of being very flexible and easily rerouted
It uses an optical sensor which detects the light reflected by
fluorescent paint or tape on the floor.
It is useful in environments where electrical noise makes the wire
system unreliable.
It can not be used in an environment where dirt and grime exist.
The application is limited to clean environments, such as electronic
assembly.

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Self Guided Vehicles

SGVs operate without continuously defined pathways.
The vehicle locates its position through laser scanning of bar code
targets and by sensing steering wheel angle and rotation.
An on-board computer reads the position and compares the result to
the stored path program
SGV pathways are defined in software. The path network can be
changed by entering data to the navigation computer

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Self Guided Vehicles

Routing of Self Guided Vehicles under
the control of supervisory and landbased computers sending and
receiving signals through a radio link

Laser guidance allows the use of

AGVs without any tracks

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Vehicle Management and Safety

Traffic Control: To minimize interference between vehicles and to
prevent collisions:
On-board vehicle sensing (forward sensing)
Zone Control

Forward sensing uses sensors like optical and ultrasonic devices.

The effectiveness of the system depends on the capability of the
sensors.
The systems are most effective on straight pathways and less
effective at turns

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Safety

Traveling speed is usually slower than walking pace of a human

Automatic stopping of the vehicle if it deviates from the guide path
On-board sensor used for traffic control can also detect the obstacles
Emergency bumper

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Zone Control

AGV layout is divided into separate zones, no vehicle is permitted to

a zone if it is already occupied by another vehicle.
The issues considered are:
Number of vehicles in the system
Size and complexity of the layout
Minimize the number of separate zone controls

Use of separate control units along the guide path or,

Use of a central computer to monitor the location of each vehicle
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Vehicle Dispatching

Dispatch methods for AGVs:

1. On-board computer panel:

Manual vehicle control, vehicle programming

Simplest form of AGV

2. Remote call stations

A press button is used to send signal to AGV for calling it to

load/unload station then the use of on-board computer for
dispatching
Vehicles destination can be sent at the same time the vehicle is
called

3. Central computer control

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Automatic dispatching of vehicles according to a preplanned

schedule of pick-ups and deliveries
The central computer has the information on the location and state
of the vehicles in order to make an efficient dispatching
The central computer issues commands for dispatching the
vehicles using RF radio frequency links.
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AGV Examples

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Analysis of Vehicle Based Systems

1.

From-To-Chart

From

To

9/50 5/120 6/205 0

2/85 3/170

8/85

9/80

Flow rate [loads/hr] / Travel Distance [m]

1.

Flow diagram

1
6/205

9/80
5/120
3/170

5
8/85
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3
2/85
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Delivery Cycle Time

Assumptions
Vehicle operates at constant velocity
Acceleration and deceleration effects ignored
Delivery cycle consists of:

Loading at the pickup station

Travel time to drop-off station
Unloading at the drop-off station
Empty travel time of the vehicle between deliveries

TC= delivery cycle time (min/del)

Ld
Le
Tc TL
TU
vc
vc

TL=loading time (min)

LD=distance between load and unload station (m)
vC=carrier velocity (m/min)
TU=unloading time (min)
Le=empty travel distance until next cycle (m)

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Delivery Cycle Time

TC is an ideal value because it ignores time losses due to the

reliability, traffic congestion etc..

LD and LE are considered to be average values for the distances

traveled by the vehicle during a shift.

TC can be used to determine:

1.
2.

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Rate of deliveries per vehicle

Number of vehicles required to satisfy a specified delivery requirement

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Traffic Factor

Possible time losses for TC are:

Availability (A)
Traffic Congestion (Ft= Traffic factor)

Worker efficiency (Ew)

Typical values for Ft for an AGVs range between 0.85 and 1.0
Available time per hour per vehicle:
AT 60 A Ft Ew

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AT= available time (min/hr per vehicle)

A= availability
Ft= Traffic factor

Ew= worker efficiency

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Performance Parameters
1. Rate of deliveries per vehicle:
Rdv
Del./hour per vehicle

2.

Available minutes in 1hr.

AT
TC

Delivery cycle time min/del

Number of vehicles required to satisfy a specified delivery requirement:

Total workload needs to be defined

WL R f Tc
Workload (min/hr)
Flow rate of deliveries (del/hr)

The number of vehicles required :

Number of carriers required

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Workload (min/hr)

WL
nc
AT

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Problem 10.9 page 305

A rail-guided vehicle system is being planned as part of an assembly cell. The system consists of
two parallel lines, as in Figure. In operation, a base part is loaded at station 1 and delivered to
either station 2 or 4, where components are added to the base part. The RGV then goes to either
station 3 or 5, respectively, where further assembly of components is accomplished. From stations
3 or 5, the product moves to station 6 for removal from the system. Vehicles remain with the
products as they move through the station sequence; thus, there is no loading and unloading of
parts at stations 2, 3, 4, and 5. After unloading parts at station 6, the vehicles then travel empty
back to station 1 for reloading. The hourly moves (parts/hr) and distances (ft) are listed in the table
below. RGV speed = 100 ft/min. Assembly cycle times at stations 2 and 3 = 4.0 min each, and at
stations 4 and 5 = 6.0 min each. Load and unload times at stations 1 and 6 respectively are each
0.75 min. Traffic factor = 1.0 and availability = 1.0. How many vehicles are required to operate the
system?

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To
1

1
0

2
3
4
5
14L/2000
9L/1500
14L/5
0
0
0
0

6
0

From 3

14L/150

0
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9L/15
0
0
0
9L/100
35

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Performance Parameters (cont.)

Traffic factor accounts for the delays experienced by the vehicles

but it does not include the delay encountered by workstation that
must wait for the vehicle.
The formulas presented do not take into account the idle time of
the machines and its impact on operating cost
If the idle time is to be minimized, mathematical models based on
queueing theory is appropriate to analyze more complex situations
http://www.youtube.com/watch?v=nd5WGLWNllA

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Automated Storage Systems

Mechanized and automated storage equipment to reduce the
human resources required to operate a storage facility
Significant investment
Level of automation varies
In mechanized systems, an operator participates in each
storage/retrieval transaction
In highly automated systems, loads are entered or
retrieved under computer control

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Objectives and Reasons for Automating

Storage Operations

To increase storage capacity

To increase storage density
To recover factory floor space currently used for WIP
To improve security and reduce pilferage
To reduce labor cost and/or increase productivity
To improve safety
To improve inventory control
To improve stock rotation
To improve customer service
To increase throughput
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Storage Location Strategies

Randomized storage - incoming items are stored in any
available location
Usually means nearest available open location
Dedicated storage - incoming items are assigned to specific
locations in the storage facility
Typical bases for deciding locations:
Items stored in item number sequence
Items stored according to activity level
Items stored according to activity-to-space ratios

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Comparison of Storage Strategies

Less total space is required in a storage system that uses a
randomized storage strategy
Dedicated storage requires space for maximum
inventory level of each item
Higher throughput rates are achieved in a system that uses
dedicated storage strategy based on activity level
The most active items can be located near the
input/output point
Compromise: Class-based dedicated storage
Items divided into classes according to activity level
Random storage strategy used within each class
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Conventional Storage Methods

Bulk storage - storage in an open floor area
Problem: achieving proper balance between storage
density and accessibility
Rack systems - structure with racks for pallet loads
Permits vertical stacking of materials
Shelving and bins - horizontal platforms in structural frame
Steel shelving comes in standard sizes
Finding items can be a problem
Drawer storage - entire contents of each drawer can be
viewed
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Types of Automated Storage System

1. Automated Storage/Retrieval System (AS/RS)
Rack system with mechanized or automated crane
to store/retrieve loads
2. Carousel Storage System
Oval conveyor system with bins to contain
individual items

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Automated Storage and Retrieval Systems AS/RS

AS/RS Examples

HIGH-SPEED, HIGHDENSITY STORAGE FOR

BOXES AND TOTES

General AS/RS systems

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Automated Storage and Retrieval Systems

The system is capable of moving material in and out of the storage
area without human intervention.
It records incoming material, the number of units, where they are
placed to provide accurate inventory control function
In FMS, it is also possible to use AS/RS for material handling
The loads include raw material, work-in-process, finished goods,
fixtures and machine pallets

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AS/RS

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AS/RS

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AS/RS
An AS/RS consists of one or more storage aisles that are serviced by
a storage/retrieval machine.
Storage racks are used to hold materials on the aisle
S/R machines are used to deliver material to racks and retrieve
material from the racks
Pickup & Deposit stations are used as input/output stations.
P&D stations can be manually operated or interfaced with a material
handling system such as conveyor or AGV
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Unit Load AS/RS

Unit Load AS/RS is an automated system designed to store pallets

or other type of containers
The system is computer controlled and S/R machines are
automated.

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Deep Lane AS/RS

Deep Lane AS/RS - high density unit load storage system
that is appropriate when large quantities are to be stored but
the number of separate types of material is relatively small.

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Mini Load AS/RS

It is used to handle small loads that are contained in bins or drawers

S/R machines deliver the bin to P&D station to retrieve the item from
the bin
The bin must be returned to its location in the system
Often enclosed for security reasons

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Man-on-board AS/RS

Man-on-board AS/RS - represents an alternative approach to the

problem of storing and retrieving individual items in the system.
This system permits the individual items to be picked directly at
their storage locations.
A human operator riding on the carriage of the S/R machine is used
to retrieve the items from the bins

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Automated Item Retrieval System

Automated Item retrieval system - designed for retrieval of
individual items or small unit loads such as cases of product in a
distribution warehouse. Items are stored in single file lanes instead
of bins.

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AS/RS Applications
Unit load storage and handling - Warehousing for finished
goods/products.
Order picking - Used to store and retrieve materials in less than full unit
load quantities, such as man-on-board or mini-load applications.
Work-in-process - Support just-in-time production activities, buffer
storage, and as integral part of assembly systems.

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WIP Storage Systems

Minimize the WIP and managing it effectively is the objective of
manufacturing facilities.
AS/RS and carousel applications in batch and job-shop production
are suitable to use as a storage between processes.
Some problems encountered with WIP in batch production are:

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Time spent searching orders among different batches waiting on the floor
Loss of parts
Orders not being processed according to their priorities
Orders spending too much time in the factory due to poor control in WIP

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Benefits of AS/RS
Use of AS/RS as a buffer storage between processes
Support of just-in-time delivery
Kitting parts for assembly
Compatible with automatic identification systems such as bar code
readers
Computer control and tracking of material
Support of factory wide automation
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Components and features of AS/RS

Storage structure is the rack framework which supports the loads

contained in AS/RS

S/R machine is used to deliver loads from the input station into
storage and retrieving loads from storage and deliver to output
station

Storage modules are the unit load containers such as pallets, steel
wire baskets, plastic tote pans and special drawers

Pick-and-Deposit (P&D) stations is where loads are transferred

into and out of the AS/RS combined with an external handling
system
Computer control system is used to determine the required
location and guide the S/R machine.

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AS/RS components

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Analysis of AS/RS - Size

Capacity per aisle = 2 ny nz
ny numberofhorizontalcompartments
nz numberofverticalcompartments
Dimensions of the rack structure (W, L, H)
W = 3 (x + a)
L = ny (y + b)
H = nz (z + c)
W, L, and H are the width, length, and height of one aisle of the AS/RS
x, y, z are the dimensions of the unit load
a,b,c are the allowances for the storage compartment

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Analysis of AS/RS - Throughput

System throughput is defined as the hourly rate of S/R transactions
that AS/RS can perform.
Single command cycle involves either depositing or retrieving a load
from storage
Dual command cycle accomplishes both transaction in one cycle.
AS/RS cycle time calculation assumptions:

Randomized storage of loads in the AS/RS

Storage compartments are of equal size
P&D station is located at the end of the aisle
Constant horizontal and vertical speeds of the S/R machine
Simultaneous horizontal and vertical travel

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Single Command vs. Dual Command Cycles

Single Command Cycle:
Either a storage or retrieval operation is performed
Not both
S/R machine
at P/D
Station

Machine
Picks-up a
load

Travels to
Storage
location

Deposits the
load

Dual Command Cycle:

Both storage and retrieval operations are performed
S/R machine at
P/D Station
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Machine
Picks-up a load

Travels to
Storage
location
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Deposits the
load

Go to retrieval
location and
pick up a load
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Single Command Cycle Time

P&D

H
L

Single command cycle

Single command cycle time:

0.5 L 0.5H
L H
Tcs 2Max
,
, 2T pd
2T pd Max
v z
v y
v y v z
vzverticalspeed(m/min,ft/min)
vyhorizontalspeed(m/min,ft/min)
Tcssinglecommandcycletime(min/cycle)
Tpdpickupanddeposittime(min)
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Dual Command Cycle Time

H
P&D

P&D

H
L

Single command cycle

Dual command cycle

Dual command cycle time:

0.75 L 0.75H
1.5 L 1.5 H
Tcd 2Max
,
,
4Tpd Max
4T pd
v z
v z
v y
v y
vzverticalspeed(m/min,ft/min)
vyhorizontalspeed(m/min,ft/min)
Tcddualcommandcycletime(min/cycle)
Tpdpickupanddeposittime(min)
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AS/R System Throughput

System throughput depends on the number of single and dual command
cycles performed by the system.
Amounts of time spent each hour:
RcsTcs Rcd Tcd 60 U

Rcs=number of single command cycles performed per hour

Rcd=number of single command cycles performed per hour
Rc Rcs Rcd
Total S/R cycle rate cycles/hr

Rt Rcs 2 Rcd
Total number of transactions per hour

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Example 11.3 p.329

Consider an AS/RS in which an S/R machine is used for each aisle.

The length of the storage aisle is 280ft and its height 46ft. Suppose
horizontal and vertical speeds of the S/R machine are 200ft/min and
75ft/min respectively. The S/R machine requires 20sec. To
accomplish a P&D operation.
a) Find the single and dual command cycle times per aisle
b) Throughput per aisle under the assumptions that storage system
utilization = %90, and the number of single command and dual
command cycles are equal

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 Class based dedicated storage strategy.

2 classes of activity level. More active stock is located in
the half closest to pickup drop-off station
Within each class random storage is used
More active stock accounts 75% of the transactions and the
less active stock accounts for 25% of the transactions
Determine the throughput of AS/RS

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