Part 2 Developing Alternatives: Concepts and Techniques

Chapter 5
Material Handling
5.1 Introduction
The design of the material handling system is an important component of the overall facilities
design. The layout design and the material handling system design are inseparable. The
integration between these two design functions is critical in the design of a new facility.
Material handling activities commonly account for at least 25% of labor costs, 55% of all factory
space, and 87% of production time. Material handling is estimated to represent between 15% and
70% of the total cost of a manufactured product. Frequently much more than that may be hidden
in overhead accounting practices. This function, which happens to be so obvious that we tend to
overlook it, is a major influence on such things as the utilization of expensive equipment, the
work-in-process inventory, quality, scrap, transportation, packaging, production control,
warehousing space and cost, and customer satisfaction. Look at the best factory, the best
warehouse, best transportation service, best distribution facility - and you'll find it is integrated
with a superb handling system.
Material handling and distribution operations are essentially systems. No longer are they
independent activities within one firm. Properly planned systems may begin on the design desks
of your suppliers and end on the shipping docks of your customers. How well your firm fares in
improving the productivity of this total cycle will depend on the role your systems planners are
prepared to assume. Material handling is a prime target for cost improvement, but this rapidly
changing field requires imagination, ingenuity, and awareness of current technical advances.
There exists a strong relationship between the layout design function, and the material handling
design function.

5.2 Material Handling Defined

Material handling can be defined simply as handling material. But a better definition is:

Material Handling uses the right method to provide the right amount of the
right material at the right place, at the right time, in the right sequence, in the
right position, in the right condition, and for the right cost.

This definition tells us that we should look at the material handling function from a broader
systems perspective instead of a simple material transfer activity. It involves handling, moving,
storing, protecting, and controlling material. As such, material-handling (MH) systems must be
designed with care to ensure they are properly integrated with 1) manufacturing; 2) distribution;
and 3) management information systems.
While taking a systems approach to MH, we must also bear in mind that, depending on the
product handled, anywhere from 20% to 70% of a product cost can be attributed to MH cost. The
objective in designing a MH system should be not only to minimize design and operational costs,
but also to come up with a system that supports all the activities on the shop floor effectively.

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In addition to describing material handling in terms of movement, time, and place, material
handling may be described in terms of quantity, position or orientation, condition, space, profit,
quality, safety, and productivity. These are because:
a) Material must be delivered undamaged, and must be used before becoming obsolete.
b) Material that is moving is much more dangerous than static material, therefore safety is important.
c) The impact of material handling on total operating system shows its significant improvements in total
productivity.

5.3 Material Handling Principles

Material handling is a vital function in a manufacturing or distribution system. In fact, it is a key
link between the processes in a system. Efficient handling of material allows a manufacturing or
service system to operate at high levels of productivity.

The Department of Commerce has identified material handling as one of the fastest growing
segments of the world economy. It is therefore extremely important to understand the principles
of material handling, as well as their design, implementation, operation, and control so that that
they can assure the cost effectiveness of this investment. These principles provide guidance and
perspective to material handling system designers. However, the use of these principles should
not be constructed as a substitute for good judgments and experience.

There are 20 material handling principles in total, based on two learning modules. From these
principles, a number of checklists have been developed to facilitate the identification of
improvement opportunities for existing systems.

The first module is titled 10 Principles of Material Handling and their definitions recently
adopted by the College-Industry Council of Material Handling Education (CIC-MHE), are as
follows:
1) Planning Principle.
Establish a plan to include basic requirements, desirable options, and the consideration of
contingencies for all material handling and storage activities. In its simplest form a material
handling plan defines the material (what) and the moves (when and where); together they define
the method (how and who).
2) Standardization Principle.
Standardize handling methods and equipment wherever possible. Standardization means less
variety and customization in the methods and the equipment employed.
3) Work Principle.
The measure of work is the material flow (volume, weight, or count per unit of time) multiplied
by the distance moved.
4) Ergonomic Principle.
Recognize human capabilities and limitations by designing material handling equipment and
procedures for effective interaction with the people using the system.
5) Unit Load Principle.
Handle product as a single entity at one time, such as a pallet, container, or tote, regardless of the
number of the individual items that make up the load.

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6) Space Utilization Principle.

Make effective utilization of all cubic space.
7) System Principle.
Integrate those handling and storage activities, which are economically viable into a coordinated
system of operation including receiving, inspection, storage, production, assembly, packaging,
warehousing, shipping and transportation.
8) Automation Principle.
Automation is a technology concerned with the application of computer-based systems,
electronics and electromechanical devices to operate and control production and service activities.
9) Environmental Principle.
Minimize adverse effects on the environment when selecting material handling equipment and
procedures by eliminating the possible negative effects of our actions on the environment.
10) Life Cycle Cost Principle.
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
totally replaced.

The remaining 10 principles and their definitions are listed below:

11) Energy Principle.
Include energy consumption of the material handling systems and material handling procedures
when making comparisons or preparing economic justifications.

12) Orientation Principle.

Study the system relationships thoroughly prior to preliminary planning in order to identify
existing methods and problems, physical and economic constraints, and to establish future
requirements and goals.

13) Flexibility Principle.

Use methods and equipment that can perform a variety of tasks under a variety of operating
conditions.

14) Simplification Principle.

Simplify handling by eliminating, reducing, or combining unnecessary movements and/or
equipment.

15) Gravity Principle.

Utilize gravity to move material wherever possible, while respecting limitations concerning
safety, product damage and loss.

16) Mechanization Principle.

Mechanize the handling process where feasible to increase efficiency and economy in the
handling of materials.

17) Safety Principle.

Provide safe material handling equipment and methods that follow existing safety codes and
regulations in addition to accrued experience.

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18) Layout Principle.

Prepare an operational sequence and equipment layout for all viable system solution, and then
select the alternative system, which best integrates efficiency and effectiveness.

19) Maintenance Principle.

Prepare a plan for preventive maintenance and scheduled repairs on all material handling
equipment.

20) Obsolescence Principle.

Prepare a long range and economically sound policy for replacement of obsolete equipment and
methods with special consideration to after-tax life cycle costs.

Note: Above-mentioned 20 material handling principles will be helpful in solving material

handling problems. Obviously, not all principles will apply in every material handling project.
These principles can also be used as a checklist but they should become second nature to
material handling system designers. Applications of these principles to day-to-day activities can
enhance material handling solutions.

5.4 Designing Material Handling Systems

In designing new or improved material handling system, the following six-step engineering
design could be used:
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.

To stimulate the development of alternative system designs, the following four-phased Ideal
Systems Approach is suggested:
Phase 1. AIM for the theoretical ideal system; a perfect system having zero cost, perfect quality, no safety
hazards, no wasted space, and no management inefficiencies.

Phase 2. CONCEPTUALIZE the ultimate ideal system; a system that would be achievable in the future, but
because of a lack of available technology, is not available at present time.

Phase 3. DESIGN the technologically workable ideal system; a system for which the required technology is
available, but costs or other conditions may prevent some components from being installed now.

Phase 4. INSTALL the recommended system; a cost-effective system that will work now without obstacles
to its successful implementation.

Throughout the design process, a questioning attitude should prevail. The basic questions of why,
what, where, when, how, who, and which should be asked constantly.

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Use of the question why? is essential to separate what must be from what has been:
Asking what and why defines the correct material to be handled.
Asking where, when, and why identifies necessary moves.
Asking how, who, and why establishes the correct method.
Asking which and why yields the preferred design.
The following expression defines the method of performing each move within a facility:

SUM moves [Why (Where + What + When)]

Each move should be evaluated by asking:

1) Can the move be eliminated?
2) Can the move be combined with another or within an in-transit operation?
3) Can the move be simplified?
4) Can the sequence of moves be changed to advantage?
Once it has been determined that a move will take place, the move must be studied to determine
the best method of performing the move. Such study is represented by the Where + What +
When. These questions all lead us to the recommended system. The material handling system
equation is given by:
Materials + Moves + Methods = Recommended System
Why?

What Where When? How? Who? Which

Material Moves Methods Preferred

+ Material Handling Systems

+
Alternatives
Figure 5.1 Material handling system equation.

Figure 5.2 Alternate ways of transporting a dry bulk ingredient from outside
Receiving area to a mixing operation in the plant.

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5.5 Unit Load design

The concept of a unit load is derived from the unit size principle; a unit load is simply the unit to
be moved or handled at one time. It consists of material in, on, or grouped together by
something. The Unit Load includes the container, carrier, or support that will be used to move
material. Its primary advantage is the capability of handling more items at a time and reducing
the number of trips, handling costs, loading and unloading times, and product damage. Figure
5.3 shows a few examples of unit loads.
The unit load size specification has a major impact on the specification and operation of the
material handling system. Large unit loads may require bigger and heavier equipment, wider
aisles, and high floor load capacities. Also, large unit loads increase work-in-process inventory.
A major advantage is fewer moves.

Figure 5.3 Examples of unit loads.

The integrity of the unit load can be maintained by Containerization.

1. Tote boxes, cartons, pallets, and pallet boxes can be used to "contain" the unit load.
2. Strapping, shrinkwraping, and stretchwraping can be used to enclose the unit load.

The determination of the size of the unit load and the method of containing it is influenced by a
number of factors. Among those are:
1) The material to be unitized.
2) Number of times unit load is handled before it is de-unitized.
3) The quantity of material to be handled.
4) Environmental conditions to which unit load is exposed.
5) The susceptibility of the material to damage, and its security.
6) The method of receiving, storing, shipping, and handling.
7) The other loads to be utilized within the system.

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It is suggested that in designing the unit load:

1) Determine the applicability of the unit load concept.
2) Select the type of unit load to be used.
3) Identify the most remote source of a potential unit load.
4) Establish farthest practicable destination for unit load.
5) Determine the size of the unit load.
6) Establish the configuration of the unit load.
7) Determine the method of building the unit load.

Unit Loads can be lifted in a variety of ways. The most common methods of unitizing a unit load
are containers, platforms, sheets, and racks.
1) Containers: Tote boxes, cartons, bins, crates, baskets, and bags.
2) Platforms: Skids and pallets.
3) Sheets: Cardboard, plywood, and polyethylene.
A popular method of building a unit load is to place one or more items on a pallet. Factors in
determining the style and size of the pallet are:
1) Size of the carrier in shipping and receiving.
2) Size and weight of items to be placed on pallet.
3) Dimensions of space for storing loaded/unloaded pallets.
4) Equipment used to move loaded/unloaded pallets.
5) Slave palet versus non-slave palet considration.
6) Costs, supply, and maintenance considerations.
7) Aisles width, door sizes, and clear stacking heights.

Stacking Pattern: The relationship between the container and the pallet referred to as the pallet-
loading (stacking pattern) problem.
The objective in the pallet-loading problem is to maximize the use of space (i.e., the pallet
cube). Quite often, load stability is an equally important consideration for reasons of uniform
loading on material handling equipment and safety. Another measure is based on cost (e.g., cubic
feet per dollar).
For a given pallet size, there exists a variety of different stacking patterns that can be used in
placing cartons on the pallet.

Note that:
1) Cube utilization per pallet varies with pattern employed.
2) One generally restricts the number of alternative pallet sizes to two or three popular sizes
and selects the size that yields a satisfactory utilization of cubic space for the most
popular items to be placed on the pallet.
3) When the items being stored are quite heavy, weight considerations may be more
important than volume.
4) Weight influences structural design of the pallet, capacities of handling equipment, and
storage racks.
5) Pallet dimensions will also influence and be influenced by the dimensions of the space to
be used for storing loaded and unloaded pallets.

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Figure 5.4 shows different shapes and sizes of pallets and different loading/stacking patterns.

Figure 5.4 Stack 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.

An interesting Design Question is:

Should the material handling system be designed around the Unit Load or should the unit
load be designed to fit the material handling system?
The Response: Neither, but in reality, the first one is preferred.

The specification of the carton size is perhaps the most critical element on the design of the unit
load system. The carton size selected dictates the number of parts contained in each carton and
the total number of cartons that may be packaged and transported to the palletizer. Based on
parts flow rate to the packaging stations and the time required to package each carton, the carton
flow rate to the palletizer is determined.
The next step is the formation of the pallet load through a palletizer. The type and size of the
pallet selected. The rate at which full pallet load are formed is a function of the capacity of the
palletizer, the carton size and pallet size.

From the palletizer, the full pallet loads are stored in a warehouse with either a selective-rack or
open-rack design.

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The next step is the loading of the pallet loads into a highway trailer-truck for delivery to the
customer.
In cases where an existing material handling system is to be improved, the unit load
specifications may be influenced by the physical configuration of an existing building. Door
widths, column spacing, aisle widths, turning radii of the material handling vehicles, maximum
stacking heights of the lift trucks are among the many factors that will influence the design of the
unit load system.
The unit load system design problem is one that must be done concurrently with the other
elements pf the overall material handling system design.

5.6 Material Handling Equipment

For many, material handling is synonymous with material handling equipment. But, there is
much more to material handling than the method employed. Note that:
1) In some applications, the best method of handling material may not require equipment
2) We should focus:
First on the material.
Second on the move.
Third on the method.
3) It is a natural reaction to encounter a problem situation and to immediately begin thinking of
equipment to solve it. Resist such temptations.
A number of different types of material handling equipment are now available for moving
material between stations on a shop floor. Most of the equipment moves materials via paths on
the shop floor, but there are some (e.g., cranes hoists, and overhead conveyors) that utilize the
space above the machines. The choice of a specific type of equipment depends on a number of
factors including the cost, shape, weight, size, and volume of the loads; space availability; and
types of workstations.
Different categories of material handling equipment are:
1) Material transport equipment
Conveyors
Industrial vehicles
Monorails, hoists, and cranes

2) Containers and utilizing equipment

3) Storage and retrieval equipment

Unit load storage equipment
Unit load retrieval equipment
Small load storage and retrieval equipment

4) Auxiliary and other equipment
Automatic data collection and communication equipment
Automatic identification and recognition
Automatic paperless communications

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Material transport equipment is distinguished from the other categories of material handling
equipment by their primary function: material transport. Material transport equipment types are
distinguished from one another by their
Degree of automation (walking, riding, and automated),
Flow pattern (continuous vs. intermittent, synchronous vs. nonsynchronous),
Flow path (fixed vs. variable),
Location (underground, in-floor, floor level, overhead),
Throughput capacity.

1) Conveyors are used when material is to be moved frequently between specific points.
Conveyors should be considered when large volumes of parts and materials are to be
transported. It is also advisable to use conveyors only when the material transported is
relatively uniform in size and shape. Conveyors can be categorized by:
a) The type of product being handled (as bulk, or unit): Bulk material might be conveyed using chute,
belt, pneumatic, screw, bucket, or vibrating conveyors. Unit material might be conveyed using chute,
belt, roller, wheel, slat, vibrating, pneumatic, trolley, or tow conveyors.
b) The location of the conveyor (as overhead, or floor).

2) Industrial vehicles are extensively used in manufacturing facilities and warehouses. Their
main advantage is that the material handling path need not be fixed, and they are particularly
useful when the unit load moved varies in size, shape, and weight. When there is a low
volume of parts or material to be moved, relatively few trips are required for each part.
Industrial vehicles vary widely in their features, cost, and functionality.
Three categories of industrial vehicles can be defined:
a) Walking industrial vehicles
b) Riding industrial vehicles
c) Automated industrial vehicles
Walking industrial vehicles are capable of handling several hundred pounds of load and are
available with outriggers, straddles, and other attachments. The operator can steer the self-
powered truck that can move forward to backward in a variety of speeds. This type of
vehicle is desirable when material movements are relatively short, require low lifts, and
volume is relatively low.
Riding industrial vehicles allow the operator to ride to, from, and between locations. These
are typically used for longer moves than walking vehicles and are useful when the aisle is
narrow; Riding vehicles also offer additional weight and storage height capacity.
The category of automated vehicles is distinguished from the other industrial vehicles by
the elimination intervention from powering and guiding the movement of the vehicle.
Automated Vehicles are variable path devices whose movement is guided by electrified
wires buried in the floor, magnetic tape lined along the floor, rails mounted in the ceiling,
cameras mounted on the vehicle, or inertial guidance systems. The types of vehicles
include in this category are all types of automated guided vehicles (AGVs), automated
electrified monorails (AEMs), and sorting transfer vehicles (STVs).
AGV is essentially a driverless industrial truck. It is a steer able, wheeled vehicle, driven by
electric motors using storage batteries, and it follows a predefined path along an aisle. AGVs
may be designed to operate as a tractor, pulling one or more carts, or may be unit load carriers.

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The vehicle incorporates a path-following system, typically electromagnetic. There are

smart vehicles that can navigate for short distances without an electromagnetic or optical
path.
3) Monorails, hoists, and cranes are preferred when the parts to be moved are bulky and require
more space for transportation. Because the space above machines is typically utilized only
for carrying power and coolant lines, there can be room to transport bulky material. These
material handling equipment types utilize the space above machines. Thus material
movement doesnt interfere with production activities or production personnel. However,
these can be expensive and time consuming to install, requiring elaborate foundations and
support.
All three provide more flexibility in the movement path than conveyors, however, they do
not have the degree of flexibility provided by variable path equipment, such as industrial
trucks.
A monorail consists of an overhead truck on which a carrying device rides. The carrier can
be either top running or under hang powered or no powered. The monorail functions like a
trolley conveyor, expect the carrying devices operate independently and the truck need not
be a closed loop.
Hoists are used to facilitate positioning, lifting, and transferring of material in a vertical
direction, within a small area. A hoist is a lifting device that is frequently attached to a
monorail or crane. This lifting device may be manual, electrical, or pneumatic.
Cranes transport material in a horizontal direction using hooks mounted on long beams.
The beams themselves can move horizontally, thus allowing a crane to access any point on
the shop floor. Of course, this access is limited to a certain range that depends on the length
of the horizontal beams and the space they can transverse.

Containers and unitizing equipment:

1) Containers are frequently used to facilitate the movements and storage of loose items.
Depending on the size and configuration of items to be moved or stored, containers might be
placed on a pallet or a skid to facilitate their movement and storage using lift trucks or other
material handling equipment.
Containers:
a) Pallet, pallet box, skid, skid box, and tote pans are popular containers in developing unit loads.
b) Bulk container is becoming popular in process industry.
c) Intermodal container is an important item of equipment in designing physical distribution systems.

2) Unitizers: In addition to the use of containers to unitize a load, special equipment has been
designed to facilitate the formation of a unit load. Unitizers are available as:
a) Stretchwrap, shrinkwrap, strapping, and banding equipment
b) Automatic palletizers and de-palletizers

Stretchwrapping and shrinkwrapping are performed using plastic film. The strapping process
can be performed manually or mechanically and is best suited for compact load.

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Palletizers are high-speed automated equipment used to palletize unit loads coming off
production or assembly lines. They receive products and place them on a pallet according to
prespecified patterns; de-palletizers receive pallet loads and remove the product from the pallet
automatically. A variety of sizes and styles are available for both palletizers and de-palletizers.

Storage and Retrieval equipment is distinguished from material transport equipment by its
primary function to house material for staging or building inventory and to retrieve material for
use. There are two major classifications of storage and retrieval equipment are defined unit
load and small load systems.
Unit load systems typically house large loads such as full pallets, large boxes, and/or large rolls
of material.
Small load storage and retrieval systems typically house small inventory quantities of one or
more items in a storage location. The maximum storage capacity for each storage location is
typically less than 500 lbs.
Unit load storage and retrieval systems are further subdivided into unit load storage systems,
which house unit loads, and unit load retrieval systems, which allow access to unit load for
retrieval.
1) Unit load storage equipment types are distinguished from one another by their rack
configuration, line depth capacity, stacking capacity, unit load access, and capital expense.
2) Unit load retrieval equipment types are distinguished from one another by their degree of
automation, capital expense, lift height capacity, and aisle width requirements. Equipment
offering greater lift height capacity, operating in narrower aisles, and offering greater degree
of automation comes with higher prices. Those higher prices may be justified for the
associated space and labor saving.
Two popular devices for retrieving unit loads are walkie stackers and counterbalanced lift
trucks.
The other major categories of unit load retrieval equipment are narrow-aisle vehicles and
automated storage retrieval (AS/R) machines.
Automated Storage/Retrieval System (AS/RS) is a combination of controls, which handles, stores, and
retrieves material with precision, accuracy, and speed under a defined degree of automation.
Unit Load AS/RS are used to store and retrieve loads that are palletized and weigh over 500lb.

Note that:
Stacker crane is top supported, but the S/R machine is mounted on a rail along the floor.
The handling mechanism on the S/R machine usually consists of a shuttle table, or a
mechanical clamp.
It can also be a vacuum- or magnet- based mechanism for handling sheet metal and coils.
If throughput requirements do not justify dedicating an S/R machine to each aisle, end-of-
aisle transfer cars are used to transfer the S/R machine between aisles.

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Miniload AS/RS is appropriate for storing/retrieving small parts that can be stored in a
storage bin or drawer. It is often used to perform end-of-aisle order picking and
replenishment.
Man-on-Board AS/RS. The operator on board of the machine operates the AS/RS to
store and retrieve in less than unit load quantities.
Deep Lane AS/RS is similar to the unit load AS/RS with the exception that loads may
be stored to greater depths in the storage rack, thus saves space.
Automated Item Retrieval System allows individual items or cases to be automatically
retrieved from storage onto a conveyor for delivery to an accumulation line.
Storage Carrousel consists of a set of horizontal revolving storage baskets or bins. The
drive mechanism rotates the carriers in order to bring the appropriate basket to the
picking station. Carrousels can be controlled so that individual items on an order are
picked in a sequence that minimizes rotation time.
3) Small load storage and retrieval equipment
Small load S/R equipment is classified as operator-to-stock (OTS, sometimes referred to as
man-to-part or in-the-aisle systems), if the operator travels to the storage location to retrieve
material and as stock-to-operator (sometimes referred to as part-to-man or end-of-aisle
systems) if the material is mechanically transported to an operator for retrieval.
Stock-to-operator equipment types often offer higher productivity, easier supervision, and
better item security and protection than operator-to-stock alternatives. At the same time,
stock-to-operator options often are more expensive, more difficult to reconfigure, and require
more maintenance than operator-to-stock options. In OTS options, the design and selection of
the storage mode may be separated from the design and selection of the retrieval mechanism.
The three principal operator-to-stock equipment types for housing small loads are bin
shelving, modular storage drawers in cabinets, and gravity flow rack. To improve space
utilization, each of the storage systems can be incorporated into mezzanine or mobile storage
configurations. In operator-to-stock alternatives, the operator either walks or rides a vehicle
to the pick location. The four retrieval options distinguished include picking carts, order
picker trucks, person abroad AS/R machines, and robotic retrieval.
In stock-to-operator options, the travel time component of total order picking time is shifted
from the operator to a device for bringing locations to the picker. Also, the search time
component of total order picking time is reduced since the correct location is automatically
presented to the operator. In well-designed systems, the result is a large increase in
productivity.
The three most popular classes of stock-to-operator equipment are: carousels, miniload
automated storage and retrieval machines, automated dispensers. Carousels are mechanical
devices that house and rotate items for storage and retrieval. Three classes of carousels are
horizontal, vertical, and independently rotating racks. In the miniload automated storage and
retrieval system, a miniload storage/retrieval (S/R) machine travels horizontally and vertically
simultaneously in a storage aisle, transporting storage containers to and from an order picking
stations located at one end of the system. An automatic dispenser works much like vending
machines for small items of uniform size and shape.

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Auxiliary and other equipment include automatic identification and recognition devices,
automatic paperless communications, robots, and lift tables. Note that:

Robots are used to perform in-process handling operations in a variety of environmental

conditions.
Mechanical grippers and surface-lift devices permit industrial robots to perform material
handling.
Robot should be considered when rate of handling is on the order of 15 or less individual
pieces per minute, weight of load is less than 1000 lb, and orientation of the object to be
grasped is consistent.
Robot can be used when fumes, noise, and heat are present.
Lift tables are designed to provide a working surface at a variety of heights and positions.
Some are portable, and can be adjusted to provide desired working height.
Below-hook lifters are attachments used with hoists and cranes to facilitate the lifting operation being
performed.
Extremely heavy, bulky equipment can be moved easily when supported on a film of air.

Automatic data collection and communication equipment

Automated status control of material requires that real-time awareness of the location,
amount origin, destination and schedule of material be achieved automatically by use of
automatic identification and communication technologies. Automatic identification has had a
dramatic impact on material handling. They combine machine-readable coding of goods-in-
process for reading by strategically deployed code readers for purposes of accounting,
tracking, and movement control.
Examples of automatic identification and communication technologies include
A vision system reading and interpreting labels
A laser scanner to relay the inventory levels of a small parts warehouse to a computer
A voice recognition system
A radio frequency (RF) or surface acoustical wave (SAW) tag used to permanently identify a tote pan or
pallet
A card with a magnetic stripe that travels with a unit load to identify the load through the distribution
channels
An automatic identification and recognition technology includes:
Bar coding
Optical character recognition
Radio frequency tags
Magnetic strips
Machine vision

1) Bar coding:
A bar code consists of a number of printed bars and intervening spaces. The structure of
unique bar/space patterns represents various alphanumeric characters. The same
bar/space pattern may represent different alphanumeric characters in different codes.

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Bar code system components:

a) Bar code readers
Contact scanners can be portable or stationary and use a wand or light pen. As the wand/pen
manually passed across the bar code, the scanner emits either white or infrared light from the
wand/pen tip and reads the light pattern that is reflected from the bar code.
Contact readers are an excellent substitute for keyboard or manual data entry.
Wand scanners
Light pen scanners
b) Noncontact readers
A noncontact reader is usually stationary and includes fixed-beam, moving-beam scanners, and
charged couple device (CCD) scanners.
Fixed-beam readers use a stationary light source to scan a bar code. They depend on the motion
of the object to the scanned to move past the beam.
Moving-beam scanners employ a moving light source to search for codes on moving objects.
Some scanners can read codes accurately on items moving at a speed of 1000 ft/min.
Charged couple device (CCD) scanners are more like a camera. By changing camera lenses and
focal lengths, the device read various bar codes at various distances.
c) Bar code printers
The design and selection of the printers determines the success of the bar code system, since the
quality of the printed code is critical to the acceptance and capacity of the system. There are five
main classes of bar code printers: Laser; Thermal transfer; Serial; Impact; and Ink jet.

2) Optical character recognition (OCR):

OCR systems read and interpret alphanumeric data. Optical characters are human and
machine-readable. OCR systems operate at slower read rates than bar code systems.
3) Radio frequency (RF) tag:
Both the RF tag and the SAW tag encode data on a chip that is encased in a tag. When a
tag is within a range of a special antenna, a tag reader decodes the chip. RF and SAW
tags are typically used for permanent identification of a container, because of tags
durability.
4) Magnetic Stripe (MS):
MS is used to store a large quality of information in a small space. The stripe is readable
through direct or grease, and the data contained in the stripe can be changed. The strip
must be read by contact.
5) Machine vision:
Relies on cameras to take picture of objects and codes and send the pictures to a
computer for interpretation. These systems do not recognize contact with the object or
code.

Devices for automatic, paperless communications with material handling operators include:
Radio frequency data terminal (RDT)
Voice headset
Light and computer Aids
Smart cards

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RDT is a reliable device for inventory and vehicle/driver management. The RDT incorporates a
multicharacter display, full keyboard, and special function keys. It communicates and receives
messages on a selective frequency via antennae and a host computer interface unit. The majority
of RDTs use handheld wands or scanners for data entry, product identification, and location
verification.
1) Voice handset synthesized voice communication and human voice recognition systems.
In order to interact with the computer system a headset with earphones and an attached
microphone is used. RF is used to transmit communications to mobile operators.
2) Lights and computer aids. The objective of use these devices are to reduce the search
time, and a documentation time portions of total order picking time to improve order-
picking accuracy. Systems of this type are available for use with vertical carousels,
miniload AS/RS, and vertical lift modules.
3) Smart card is used to capture information ranging from employee identification, to the
contents of a trailer load of material, to the composition of an order picking tour. The
smart cards are inserted into a smart card reader on each order-picking cart. Is so doing,
the picking tour is illuminated on an electronic map of the warehouse appearing on the
front of the cart.

5.7 Comparisons of Material Handling Equipment

The equipment can be characterized by the area it is intended to serve:
1) Between fixed points over a fixed path
a) Belt conveyor
b) Roller conveyor
c) Chute conveyor
d) Slat conveyor
e) Screw conveyor
f) Chain conveyor
g) Overhead monorail conveyor
h) Trolley conveyor
i) Wheel conveyor
j) Tow conveyor
k) Bucket conveyor
l) Cart-on-track conveyor
m) Pneumatic tube conveyor
2) Over limited areas
a) Hoists
b) Overhead cranes
c) Hydraulic scissors lift
3) Over large areas
a) Handcart/truck
b) Tier platform truck
c) Hand lift truck/pallet jack
d) Power-driven hand truck
e) Power-driven platform truck
f) Forklift truck
g) Narrow-aisle truck

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h) Tractor-trailer train
i) Material lift
j) Drum truck
k) Drum lifter
l) Dolly
m) Automated guided vehicle system
Advantages of Conveyors
1) Their high capacity permits moving a large number of items.
2) Handling combined with other activities such as processing and inspection is possible.
3) They are versatile and can be on the floor or overhead.
4) Temporary storage of loads between workstations is possible (for overhead conveyors in particular).
5) Load transfer is automatic and does not require the assistance of many operators.
6) Straight-line paths or aisles are not required.
7) Utilization of the cube (entire volume of the workplace) is feasible through the use of overhead conveyors.
Disadvantages of Conveyors
1) They follow a fixed path serving only limited areas.
2) Bottlenecks can develop in the system.
3) A breakdown in any part of the conveyor stops the entire line.
4) Since conveyors are fixed in position, they hinder the movement of mobile equipment on the floor.
Advantages of trucks
1) They are not required to follow a fixed path of movement and therefore can be used anywhere on the floor
where space permits.
2) They are capable of loading, unloading, and lifting, in addition to transferring material.
3) Because of their unrestricted mobility, which allows them to serve different areas, trucks can achieve high
utilization.
Disadvantages of Trucks
1) They cannot handle heavy loads.
2) They have limited capacity per trip.
3) Aisles are required: otherwise the trucks will interfere with the work on the floor.
4) Most trucks have to be driven by an operator.
5) Trucks do not allow handling to be combined with processing or inspection as other types of equipment do.

5.8 Material Handling Checklist

The following checklist is very useful in detecting any sign of material handling deficiencies:
1) Is the material handling equipment more than 10 years old?
2) Do you use a wide variety of makes and models that require a high spare parts inventory?
3) Are equipment breakdowns the result of poor preventive maintenance?
4) Do the lift trucks go too far for serving?
5) Are there excessive employee accidents due to manual handling of materials?
6) Are materials weighing more than 50 pounds handled manually?
7) Are there many handling tasks that require or more employees?
8) Are skilled employees wasting time handling materials?
9) Does material become congested at any point?
10) Is production work delayed due to poorly scheduled delivery and removal of materials?
11) Are high demurrage charges experienced?
12) Is material being damaged during handling?
13) Do shop trucks operate empty more than 20% of the time?
14) Does the plant have an excessive number of rehandling points?
15) Is power equipment used on jobs that could be handled by gravity?

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16) Are too many pieces of equipment being used, because their scope of activity is confined?
17) Are many handling operations unnecessary?
18) Are single pieces being handled where unit loads could be used?
19) Are floors and ramps dirty and in need of repair?
20) Is handling equipment being overloaded?
21) Is there unnecessary transfer of material from one container to another?
22) Are inadequate storage areas hampering efficient scheduling of movement?
23) Is it difficult to analyze the system because there are no detailed flow charts?
24) Are indirect labor costs too high?

Some reasons for considering changes in material handling are:

1) Reduce costs.
2) Reduce damage.
3) Increase space and equipment utilization.
4) Increase throughput.
5) Increase productivity.
6) Improve working conditions.

But we have to be careful, otherwise change in material handling system may:

1) Increase capital requirements.
2) Decrease flexibility. Decrease reliability, maintainability, and operability.

5.9 Symptoms of Inefficient Material Handling:

1) Backtracking in material-flow path.
2) Built-in hindrances to flow.
3) Cluttered aisles.
4) Confusion at the dock.
5) Disorganized storage.
6) Excess scrape.
7) Excessive handling of individual pieces.
8) Excessive manual effort.
9) Excessive walking.
10) Failure to use gravity.
11) Fragmented operations.
12) High indirect labor cost.
13) Idle machines.
14) Inefficient use of skilled labor.
15) Lack of cube storage.
16) Lack of parts and supplies.
17) Long hauls.
18) Material piled up on the floor.
19) No standardization.
20) Overcrowding.
21) Poor housekeeping.
22) Poor inventory control.
23) Product damage, repetitive handling, service areas not conveniently located, trucks delayed or tied up, two-
man lifting jobs, on and on!

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Note:
1) By moving, storing, queuing and controlling product Overhead, you may significantly
control or reduce costs. A few benefits of overhead material handling systems are:
a) Improve the working environment and worker safety.
b) Increase Productivity.
c) Reduce and control operational costs and improve profitability.

2) Sortation is the act of merging, identifying, inducting, and separating products to be

conveyed to specific destinations. Their main benefit is in greater throughput with less labor.
A few sortation devices are deflectors; diverters; pop-up belt and chain; pop-up roller; pop-
up skewed wheels; tilting sort devices; and moving slat.

3) Automatic Identification Devices: Moving beam laser scanners are the principle means of
collecting bar coded information along package conveyors. The main advantages of the
scanners are:
a) The scanner provides multiple read attempts, which enables the scanner to read a code that is moving.
b) The code does not have to contact the scanner in order to be read.

Homework Assignment:
1. Briefly describe the circumstances that would lead you to consider each of the following
conveyors in preference to others:
Belt conveyor, roller supported.
Belt conveyor, slider bed supported.
Powered roller conveyor.
Towline conveyor.

2. Robots are being developed with the capability of sensing the orientation of randomly
placed parts on a conveyor such that parts can be picked up and loaded into a machine tool
automatically. What are three other approaches that can be used to overcome the problem
of randomly oriented parts?
3. For each of the following material handling principles,
a) Explain what it means, and
b) Give a specific example of how it can be applied
1) Unit load principle
2) Space utilization principle
4. Distinguish between a two-way and a four-way pallet.

5. Sketch a 40 x 48 pallet and compare it with a 48 x 40 pallet.

6. Develop a set of attributes for company unit load storage systems and unit load
retrieval technologies.

7. Develop a set of attributes for company bar code readers and bar code printers.

8. Develop a set of attributes for comparing automated data collection systems.

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