5/3/2015 IENG 471 Facilities Planning 1 IENG Lecture 14 Material Handling

5/3/2015IENG 471 Facilities Planning 2 Assignments Current Assignment: Finish HW 5 Next Assignment HW 6: Work in teams of TWO students Turn in ONE spreadsheet for both Put “IENG 471 HW 6” in subject line First line of message has BOTH student names Attach Excel spreadsheet Format your problems professionally Do NOT copy website (or other’s) text on Question 3.d & 3.e – your answer needs to be your understanding, in your words, in your spreadsheet format Due by 5:00 PM on 01 Nov

5/3/2015IENG 471 Facilities Planning 3 Material Handling The art and science of moving, storing, protecting, and controlling material. Material Handling provides for: The right amount Of the right material In the right condition At the right place In the right orientation In the right sequence For the right cost At the right time By the right method

5/3/2015IENG 471 Facilities Planning 4 Material Handling – Bill of ‘Rights’ The right amount – exactly what is needed (no more, no less) Of the right material – identification of correct material In the right condition – physically ready for use At the right place – at the point of use or storage In the right orientation – positioned for ease of handling

5/3/2015IENG 471 Facilities Planning 5 Material Handling – Bill of ‘Rights’ In the right sequence – helping to eliminate unnecessary/wasted efforts For the right cost – the most efficient method at the most reasonable cost over the lifetime of the system At the right time – on-time, not early or late By the right method – incorporating the impacts on safety, etc.. product safety, personnel safety, equipment safety, environmental safety, …

5/3/2015IENG 471 Facilities Planning 6 10 Material Handling Principles 1. Planning Principle 2. Standardization Principle 3. Work Principle 4. Ergonomic Principle 5. Unit Load Principle 6. Space Utilization Principle 7. System Principle 8. Automation Principle 9. Environmental Principle 10. Life-Cycle Cost Principle

5/3/2015IENG 471 Facilities Planning 7 10 Material Handling Principles 1) Planning Principle Defined in advance of implementation, covering: What When Where Whom How 2) Standardization Principle Reducing the variation in methods and equipment employed 3) Work Principle Measured in Flow X Distance 4) Ergonomic Principle Adapting the work to fit the abilities of the worker 5) Unit Load Principle The load that can be moved as a single entity regardless of the number of component units

5/3/2015IENG 471 Facilities Planning 8 Material Handling Principles 6) Space Utilization Principle Space is 3-Dimensional in Material Handling Unit is the cube 7) System Principle Combination of Interacting entities and Independent entities 8) Automation Principle High degree of mechanization, control, reprogrammablity Very rarely is it wise to use people as material handlers** 9) Environmental Principle Reuse of, and reduction of impact upon natural resources 10) Life-Cycle Cost Principle Incorporating all foreseeable cash flows from start to disposal

5/3/2015IENG 471 Facilities Planning 9 Material Handling Design Steps 1. Define objective & scope of operation 2. Analyze the operation’s requirements 3. Generate multiple alternatives 4. Evaluate each alternative on criteria 5. Select preferred design Based on reasonable weighting of criteria 6. Implement preferred design Plan (with schedule) for: Acquisition Installation Training & Verification Operation & Maintenance Removal & Disposal

5/3/2015IENG 471 Facilities Planning 10 Reusable Containers Reusable containers can increase efficiency of operations. Measures: Container Space Utilization Usable Cube divided by Exterior Container Envelope Storage Space Efficiency Usable Cube divided by Storage Cube Container Nesting Ratio Overall Container Dimension divided by Nested Dimension Trailer Space Utilization Trailer Usable Cube divided by Loaded Storage Cube Trailer Usable Cube = Usable Cube x Number of Containers in Trailer Trailer Return Ratio Total Unloaded Container Cube divided by Loaded Container Cube Progressive Dimension System Ratios: 1:1, 1:2, 1:4, 1:8, 1:16

5/3/2015IENG 471 Facilities Planning 11 Example Illustrations Container Space Utilization Usable Cube divided by Exterior Container Envelope Storage Space Efficiency Total Usable Cube divided by Storage Cube Container Nesting Ratio Overall Container Dimension divided by Nested Dimension

Full Size Container 5/3/2015IENG 471 Facilities Planning 12 Example Illustrations Progressive Dimension System Full Size Container Nested 1/2 - Size Container Nested 1/4 - Size Container Nested 1/8 - Size Container Nested 1/16 - Size Container Results in fewer container sizes while maximizing efficiency 1/16 1/8 1/16 1/4 1/2

5/3/2015IENG 471 Facilities Planning 13 Pallets Standard Sizes 32x40 40x48* 36x48 42x42 48x48 Typical Construction See Fig. 5.7, p. 180, and Fig. 5.8, p. 181 Two Classes Two-Way and Four-Way Materials Wood, PressBoard, Corrugated, Plastic, Metal Weight savings Durability improvement Repairability improvement Environmental impact Stacking Patterns See Fig. 5.9, p. 183

5/3/2015IENG 471 Facilities Planning 14 Pallets Aisle Width Requirements for Common Pallet Handling Equipment:

5/3/2015IENG 471 Facilities Planning 15 Pallets (Types & Stacking Patterns)

5/3/2015IENG 471 Facilities Planning 16 Material Handling Equipment Textbook Resources: Appendix 5A, pp. 206 – 213 has a checklist Appendix 5B, pp. 214 – 289 catalogs various equipment with photos Appendix 5C, pp. 290 – 296 describes automatically guided vehicles (AGVs) Online Resource:

5/3/2015IENG 471 Facilities Planning 17 Questions & Issues