MANUAL ASSEMBLY LINES

Manual Assembly Lines

Most manufactured consumer products are assembled. Each product

consists of multiple components joined together by various assembly
processes. These kinds of products usually made on a manual assembly line.
Factors favoring the use of manual assembly lines include the following.

 Demand for the product is high or medium .

 The products made on the line are identical or similar
 The total work required to assemble the product can be
divided into small work elements.
 It is technologically impossible or economically infeasible
to automate the assembly operations.
 Configuration of a production line

A manual assembly line is a production line that consists of a

Sequence of workstations where the assembly tasks are performed
by human workers. Products are assembled as they move along the
line. At each station, a portion of the total work is performed on each
Unit.
 PRODUCTS USUALLY MADE ON MANUAL
ASSEMBLY LINES

Audio equipment Lamps Refrigerators

Automobiles Luggage Stoves
Cameras Microwave ovens Telephones
Cooking ranges Personal computers and Toasters
Dishwashers peripherals Toaster ovens
Dryers Power tools(saws, drills etc) Video cassette
Electric motors Pumps Washing
machines
MANUAL ASSEMBLY LINES ARE SO
PRODUCTIVE COMPARED WITH
ALTERNATIVE METHODS.

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

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

Interchangeable parts: In which each component is manufactured

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

Line pacing: Workers on an assembly line are usually required to

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

A manual assembly line is a production line that consists of

Sequence of workstations where assembly tasks are performed
by human workers. Products are assembled as they move along the
line. At each station a portion of the total work is performed on each
unit. Base parts onto the beginning of the line at regular intervals.
Each base part travels through successive stations and workers and
components through progressively build the product.

1. Assembly workstations

2. Work transport system

3. Line pacing
Assembly Workstations
A workstation on a manual assembly line is a designated location along
The workflow path at which one or more work elements are performed
By one or more workers. The work elements represent small portions of
the total work that must be accomplish to assemble the product.

Some Workstations are designed for workers to stand, while other allow the
workers to sit. When the workers stand, they can move about the station
Area to perform their assigned task. Example like cars, trucks……
The typical case is when the product is move by a conveyor at constant
Velocity through the station. The worker begins the assembly task near
the upstream side of the station an moves along with the work until the
task is completed, The walks back to the next work unit an repeats the
cycle. For smaller assembled products such as small appliances,
Electronic devices an subassemblies used on larger products. T he workers
To sit.
 TYPICAL ASSEMBLY OPERATIONS PERFORMED ON
A MANUAL ASSEMBLY LINES

Application of adhesive Riveting

Arc welding Shrink fitting applications
Brazing Soldering
Cotter pin applications Spot welding
Expansion fitting applications Stapling
Insertion of components Stitching
Press fitting Threaded fastener applications
Work Transport Systems
There are two basic ways to accomplish the movement of work
units along a manual assembly line
1) Manually or
2) Mechanized system.
Both methods provide the fixed routing (all work units proceed through the same
sequence of stations) that is characteristic of production lines.

Manual Methods of Work Transport: In manual work transport, the units of

product are passed from station-to-station by hand. Two problems result from this
mode of operation: Starving and blocking.

Starving is the situation in which the assembly operator has completed the
assigned task on the current work unit, but the next unit has not yet arrived at the
station. The worker is starved for the work.
When a station is blocked, it means that the operator has competed
the assigned task on the current work unit but cannot pass the unit to the
downstream station because that worker is not yet ready to receive it. The
operator is therefore blocked from working.

To mitigate the effects of these problems, storage buffers are sometimes used
between stations. In some cases, the work units made at each station are collected
in batches and then moved to the next station. In other cases work units are
moved individually along a flat table or un powered conveyor.
Mechanized Work Transport

Powered conveyors and other types of mechanized material handling

equipment are widely used to move along units along a manual
assembly line. These systems can be designed to provide paced or
un paced operation of the line. Three major categories of work transport
System in production line.

a) Continuous transport

b) Synchronous transport

c) Asynchronous transport
Velocity-distance diagram and physical layout for three types of
Mechanized transport systems used in production lines
a) Continuous transport b) Synchronous transport c) asynchronous transpo
Introduction to Material Handling

Material handling is defined by the Material Handling Industry of

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

Material handling equipment is available commercially

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

Material transport includes equipment that is used to move

materials inside a factory, ware house, or other facility. This
equipment can be divided into the following five categories
1. Industrial trucks: Industrial trucks divided into two types
powered and non-powered.
Non-powered trucks are platforms or containers with wheels
that are pushed or pulled by human workers to move the
materials.
Powered industrial trucks are steered by human workers.
They provide mechanized movement of materials.
2. Automated guided vehicles (AGVs): AGVs are battery –
powered, automatically steered vehicles that follow defined
pathways in the floor. AGVs are used to move unit loads between
load and unload stations in the facility. Routing variations are
possible ( Different loads move between different stations)
3. Monorails and other rail guided vehicles: These are self-
propelled vehicles that ride on a fixed rail system . The vehicles
operate independently and are usually driven by electric motors that
pick up power from an electrified rail.
Routing variations are possible
4. Conveyors: Conveyors constitute a large family of material
Transport equipment that are designed to move materials over fixed
paths, generally in large volumes.
Powered conveyors roller, belt and tow-line and non-powered by
human workers
5. Cranes and hoists: These are handling devices for lifting ,
lowering, and transporting materials, often as very heavy loads.
Hoists accomplish vertical lifting. Both manually operated and
powered types are available. Cranes provide horizontal travel and
generally include hoists.
a) Fork lift truck, industrial truck b) unit load automated guided vehicle
c) Monorail d) roller conveyor e) jib crane with hoist
Storage systems: it is generally desirable to reduce the storage of materials
in manufacturing, it seems unavoidable that raw materials and work-in
process will spend sometime being stored, even if only temporarily. And
finished products are likely to spend sometime in a ware house or
distribution center before being delivered to the final customer.
Storage methods and equipment can be classified as follows

a) bulk storage: it consists of simply storing materials in an open floor area,

generally in pallets or containers. It requires little or no storage equipment

b) rack systems: these are structural frames designed to stack unit loads
vertically, thus increasing the vertical storage efficiency compared to bulk
storage

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

Identification and tracking systems: Material handling must include a means

of keeping track of the materials being moved or stored. We assign label to the
item.
Examples of unit load containers for material handling
a) Wooden pallet b) pallet box and c) tote box
 The 10 Principles in Material Handling
The 10 principles of material handling are explained below.
Implementing these principles will result in safer operating conditions,
lower costs, and better utilization and performance of material handling
systems.

The unit load principles stands as one of the most important and widely
applied principle in material handling. In material handling, a unit load is
Simply the mass that is to be moved or otherwise handled at one time.

There are good reasons for using unit loads in material handling

1) Multiple items can be handled simultaneously

2) The required number of trips is reduced
3) Loading and unloading times are reduced
4) Product damage is decreased. These reasons result in lower cost
and higher operating efficiency.
Principle 1. PLANNING PRINCIPLE: All the material handling should
be the result of a deliberate plan where the needs, performance objectives
And functional specification of the proposed methods are completely
Defined at the outset.

Principle 2. STANDARDIZATION PRINCIPLE: Material handling

Methods, equipment, controls, and software should be standardized .It
means less variety and customization in the methods and equipment
employed.

Principle 3. WORK PRINCIPLE: Material handling work should be

minimized without sacrificing productivity or the level of service
required of the operation.

Simplifying the processes by reducing, combining, shortening, or

eliminating unnecessary steps will reduce work.
Principle 4. ERGONOMIC PRINCIPLE: Human capabilities and
limitations must be recognized and respected in the design of material
handling tasks and equipment to ensure safe and effective operations.

Principle 5. UNIT LOAD PRINCIPLE: A unit load is one that can be

stored or moved as a single entity at one time, such as pallet, container
totes etc..
Less effort and work are required to collect and move many individual
items as a single load than to move many items one at a time.

Principle 6. SPACE UTILIZATION PRINCIPLE: Effective and efficient

use must be made of all available space.
Space in material handling is three –dimensional and therefore is counted
as Cubic space.
Principle 7. SYSTEM PRINCIPLE: Material movement and storage activities
should be fully integrated to form a co-ordinate ( receiving, inspection, storage,
production, assembly etc.)

Principle 8. AUTOMATION PRINCIPLE: Material handling operations should

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

Principle 9. ENVIRONMENTAL PRINCIPLE: Environmental impact and

energy consumption should be considered as criteria.

Principle 10. LIFE CYCLE COST PRINCIPLE: Economic analysis should

account for the entire life cycle of all material handling equipment.
Applications of five categories of material handling equipment

Material Handling equipment Features Applications

Industrial trucks, manual Low cost Moving light loads

in a factory

Industrial trucks, powered Medium cost Movement of pallet

loads
AGV’S High cost, Movement of pallet
loads
Monorails and other rail High cost, Moving single products
Guided vehicles Flexible routing assemblies

Conveyors, powered Variety of equipment Moving product

along assembly line
Cranes and hoists lift capacity more large, heavy items
than 100 tons
 AUTOMATED STORAGE AND
RETRIEVAL SYSTEM(ASRS)

It consists of a variety of
computer-controlled systems for
automatically placing and
retrieving loads from defined
storage locations
BASIC STRUCTURE OF AS/RS

1) Storage structure
2) S/R machine (Storage /
Retrieval)
3) Storage modules (e.g.,
pallets for unit loads)
4) one or more pickup-and-
deposit stations
5) External handling system
BASIC STRUCTURE OF AS/RS

1. Storage structure
Fabricated steel
Rack frame work
Supports the load contained in
the AS/RS
To store Inventory items
2. Storage/Retrieval Machine
It is capable of both horizontal
and vertical movement
Used to move items in and out
of the inventory
BASIC STRUCTURE OF AS/RS
3. Storage Modules
Unit load containers is used to hold
an inventory items such as pallets,
steel wire baskets, containers etc
The modules are generally made to
a standard base size capable of
being stored in the structure and
moved by S/R Machines
4. Pickup and Deposit (P/D)
Stations
loads transferred to in and out of the
AS/RS stations
located at the end of aisles
Number of P/D Stations depends
upon the orgin point from incoming
and outgoing loads
BASIC STRUCTURE OF AS/RS

5. External handling
system
bring load to AS/RS
and takes load away
Eg- Pallet truck etc
SSI SCHAFER
16th January 1937
Fritz – Schafer (sheetmetal goods)
First Products
Transport containers
Kitchen Panels
SSI SCHAFER

1948 Tansport boxes

Reloacted Neunkirchen-Salchendorf.
SSI SCHAFER

1955 Rapid Production

Produce boxes
372 employees and 4000 boxes/day
SSI SCHAFER

Since its inception in 1937, SSI SCHAEFER has been an owner-operated, German family
company. With over 50 subsidiaries worldwide, SSI SCHAEFER is a strong and reliable
partner

We are one of the world's largest total solutions providers and components
manufacturers in the following sectors:
Logistics systems
Storage and conveying
Workstations
Logistics software
Waste Managements technology
CH 11 STORAGE
SYSTEMS
Sections:
1. Storage System Performance and Location Strategies
2. Conventional Storage Methods and Equipment
3. Automated Storage Systems
4. Engineering Analysis of Storage Systems

©2008 Pearson Education, Inc., Upper Saddle River, NJ.

All rights reserved. This material is protected under all
copyright laws as they currently exist.
No portion of this material may be reproduced, in any
form or by any means, without permission in writing from
the publisher. For the exclusive use of adopters of the
book
Automation, Production Systems, and Computer-
Integrated Manufacturing, Third Edition, by Mikell P.
Groover.
STORAGE SYSTEMS
Function – to store materials (e.g., parts, work-in-process, finished
goods) for a period of time and permit retrieval when required
Used in factories, warehouses, distribution centers, wholesale
dealerships, and retail stores
Important supply chain component
Automation available to improve efficiency

©2008 Pearson Education, Inc., Upper Saddle River, NJ.

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copyright laws as they currently exist.
No portion of this material may be reproduced, in any
form or by any means, without permission in writing from
the publisher. For the exclusive use of adopters of the
book
Automation, Production Systems, and Computer-
Integrated Manufacturing, Third Edition, by Mikell P.
Groover.
 STORAGE SYSTEM
PERFORMANCE
Performance measures for storage systems:
Storage capacity - two measures:
• Total volumetric space
• Total number of storage compartments (e.g., unit loads)
Storage density - volumetric space available for storage relative to
total volumetric space in facility
Accessibility - capability to access any item in storage
System throughput - hourly rate of storage/retrieval transactions
Utilization andInc.,availability
©2008 Pearson Education, Upper Saddle River, NJ.
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(reliability)
copyright laws as they currently exist.
No portion of this material may be reproduced, in any
form or by any means, without permission in writing from
the publisher. For the exclusive use of adopters of the
book
Automation, Production Systems, and Computer-
Integrated Manufacturing, Third Edition, by Mikell P.
Groover.
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
©2008 Pearson Education, Inc., Upper Saddle River, NJ.
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copyright laws as they currently exist.
No portion of this material may be reproduced, in any
form or by any means, without permission in writing from
the publisher. For the exclusive use of adopters of the
book
Automation, Production Systems, and Computer-
Integrated Manufacturing, Third Edition, by Mikell P.
Groover.
INVENTORY LEVEL AS
A FUNCTION OF TIME

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copyright laws as they currently exist.
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form or by any means, without permission in writing from
the publisher. For the exclusive use of adopters of the
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Automation, Production Systems, and Computer-
Integrated Manufacturing, Third Edition, by Mikell P.
Groover.
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
©2008 Pearson Education, Inc., Upper Saddle River, NJ.
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copyright laws as they currently exist.
No portion of this material may be reproduced, in any
form or by any means, without permission in writing from
the publisher. For the exclusive use of adopters of the
book
Automation, Production Systems, and Computer-
Integrated Manufacturing, Third Edition, by Mikell P.
Groover.
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
©2008 Pearson Education, Inc., Upper Saddle River, NJ.
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copyright laws as they currently exist.
No portion of this material may be reproduced, in any
form or by any means, without permission in writing from
the publisher. For the exclusive use of adopters of the
book
Automation, Production Systems, and Computer-
Integrated Manufacturing, Third Edition, by Mikell P.
Groover.
BULK STORAGE

BulkPearson
©2008 storage arrangements:
Education, (a)
Inc., Upper Saddle River, NJ. high-density bulk storage provides low
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accessibility,
copyright (b) bulk
laws as they currently exist. storage with loads forming rows and blocks for improved
No portion of this material may be reproduced, in any
accessibility
form or by any means, without permission in writing from
the publisher. For the exclusive use of adopters of the
book
Automation, Production Systems, and Computer-
Integrated Manufacturing, Third Edition, by Mikell P.
Groover.
PALLET RACK
SYSTEM
Pallet loads placed on racks in
multi-rack structure

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copyright laws as they currently exist.
No portion of this material may be reproduced, in any
form or by any means, without permission in writing from
the publisher. For the exclusive use of adopters of the
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Automation, Production Systems, and Computer-
Integrated Manufacturing, Third Edition, by Mikell P.
Groover.
DRAWER STORAGE

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copyright laws as they currently exist.
No portion of this material may be reproduced, in any
form or by any means, without permission in writing from
the publisher. For the exclusive use of adopters of the
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Automation, Production Systems, and Computer-
Integrated Manufacturing, Third Edition, by Mikell P.
Groover.
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
©2008 Pearson Education, Inc., Upper Saddle River, NJ.
All rights reserved. This material is protected under all
copyright laws as they currently exist.
No portion of this material may be reproduced, in any
form or by any means, without permission in writing from
the publisher. For the exclusive use of adopters of the
book
Automation, Production Systems, and Computer-
Integrated Manufacturing, Third Edition, by Mikell P.
Groover.
 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
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

©2008 Pearson Education, Inc., Upper Saddle River, NJ.

All rights reserved. This material is protected under all
copyright laws as they currently exist.
No portion of this material may be reproduced, in any
form or by any means, without permission in writing from
the publisher. For the exclusive use of adopters of the
book
Automation, Production Systems, and Computer-
Integrated Manufacturing, Third Edition, by Mikell P.
Groover.
AS/RS
Unit load AS/RS with
one aisle
 AS/RS TYPES

Unit load AS/RS - large automated system for pallet loads

Deep-lane AS/RS - uses flow-through racks and fewer access aisles
Miniload AS/RS - handles small loads contained in bins or drawers to
perform order picking
Man-on-board AS/RS - human operator rides on the carriage to pick
individual items from storage
Automated item retrieval system - picks individual items
Vertical lift storage modules (VLSM) - uses a vertical aisle rather than a
horizontal aisle as in other AS/RS types

©
AS/RS APPLICATIONS
1. Unit load storage and retrieval
• Warehousing and distribution operations
• AS/RS types: unit load, deep lane (food industry)
2. Order picking
• AS/RS types: miniload, man-on-board, item retrieval
3. Work-in-process storage
• Helps to manage WIP in factory operations
• Buffer storage between operations with different production rates
• Supports JIT manufacturing strategy
CAROUSEL STORAGE
SYSTEMS
Horizontal
• Operation is similar to overhead conveyor system used in dry
cleaning establishments
• Items are stored in bins suspended from the conveyor
• Lengths range between 3 m and 30 m
• Horizontal is most common type
Vertical
• Operates around a vertical conveyor loop
• Less floor space required, but overhead room must be provided
 HORIZONTAL CAROUSEL
STORAGE SYSTEM

Manually operated
horizontal carousel
storage system
CAROUSEL
APPLICATIONS
1. Storage and retrieval operations
• Order picking
• Kitting of parts for assembly
2. Transport and accumulation
• Progressive assembly with assembly stations located around
carousel
3. Work-in-process
• WIP applications in electronics industry are common
4. Unique applications
• Example: time testing of electrical products
 ENGINEERING ANALYSIS OF
AUTOMATED STORAGE
SYSTEMS
1. Automated Storage/Retrieval Systems
• Sizing the AS/RS
• AS/RS throughput analysis
2. Carousel storage systems
• Storage capacity
• Throughput analysis
SSI SCHAFER

Mechanism used
Automatic Order Picking
Handling system and Robots
Conveyor systems
Automated Guided vehicle
Storage and retrieval system
CONVEYORS