Elements of logistics and supply chain management

Topic: Materials Handling System Prof: ajit Rajwade sir

Group members
SWAPNIL GAWADE VIKAS GIRI DIPTI GUJARATHI ABHISHEK GUPTA 29 30 31 32

INDEX
INTRODUCTION OBJECTIVES TYPES OF MATERIALS HANDLING EQUPIMENTS PRINCIPLES OF MATERIAL HANDLING SELECTION MATERIALS HANDLING EQUPIMENTS THERE ARE THREE MATHODS\ SYSTEMS IN PLANTS MOVEMENT OF MATERIALS CASE STUDY

Introduction
Material Handling is the field concerned with solving the pragmatic problems involving the movement, storage, control and protection of materials, goods and products throughout the processes of cleaning, preparation, manufacturing, distribution, consumption and disposal of all related materials, goods and their packaging. The focus of studies of Material Handling course work is on the methods, mechanical equipment, systems and related controls used to achieve these functions. Around 15-20% of cost is spent on material handling cost

Flexible Manufacturing
The material handling system (MHS) is a fundamental part of a Flexible manufacturing system since it interconnects the different processes supplying and taking out raw material, work pieces, sub-products, parts and final products. Due to the automated nature of the whole production process, the MHS must respond in concert with timeliness for all requirements of the processes and systems. The MHS is composed of warehouses, buffers, conveyors, transportation vehicles or systems, part sorters, feeders and manipulators.

Stages of material handling system

Material are transported from supplier to the plant Unloaded inputs are moved to storage spaces & stocked Stored inputs are moved to manufacturing locations Semi finished products are moved from one location to another within the plant or from plant to another outside processing units Finished goods are moved to warehouses for packing \stacking Finished goods are dispatched to customer

Objectives of material handling

Increase the storage capacity of warehouse: Reduction of no of time product handle: Development of effective work condition: Reduction of movement involving manual labor's: Improvement of logistics services: Reduction of cost:

Types of Materials handling Equipments

FIXED PATH

VARIABLE PATH INDUSRTRIL TRUCKS

FIXED DESTINATION CONVEYORS ELEVATORS HOISTS

VARIABLE DESTINATION CRANES AUTOMATED GUIDED VEHICLE INDUSTRIAL ROBOTS

Storage and handling equipment is a category within the material handling industry. The equipment that falls under this description is usually nonautomated storage equipment. Products such as pallet racking, shelving and carts, among others, belong to storage and handling. Many of these products are often referred to as "catalog" items because they generally have globally accepted standards and are often sold as stock materials out of Material handling catalogs.

On-rails transfer cart is a kind of material handling equipment. It moves on the rails and can transfer heavy cargoes or equipment with the weight 1-300t between the workshops or warehouses in the factory. It is widely used in the line of metallurgy, coal, heavy manufacturing, automotive assembly, etc. Its power can be AC or DC. DC Power has rail transmit power and battery power, while AC power includes cable power and slippery touch line power. In addition, there is the manual rail transfer cart or towed rail transfer cart, also called motorized transfer trolley.

 Conveyors
Conveyors are another form of material handling. Conveyors can be used in a multitude of ways from warehouses to airport baggage handling systems. Some types of conveyors are unibilt, power and free, chain, towline and roller conveyor.

Cantilevered Crane Loading Platform

Cantilevered crane loading platforms are temporary platforms attached to the face of multi-storey buildings or structures to allow materials and equipment to be directly loaded on or shifted off floor levels by cranes during construction or demolition. They may be fixed or rolling and a variety of designs are used including fully fabricated and demountable types. The platforms are supported on needles (cantilevered beams) anchored to the supporting structure.

Industrial elevators Are the types of cranes that lift materials usually between floors of buildings.

Cranes Are devices mounted on overhead rails or ground level wheels or rails. They lift, swing and transport large and heavy materials.

Hoists Are devices, which moves materials vertically and horizontally in a limited area. Industrial Trucks These device are used for moving mixed or uniform loads in between over variables paths.

Pipelines Are close tubes that transports liquids means of pumps or gravity

Industrials robots A robot is a mechanism that has movable arm like projection with a gripper on the end that can perform a variety of functions with a control that can be reprogrammed and hence they are very flexible.

Principles of material handling

Planning Material handling system should be design after analyzing needs of origizanation The objectives of the company should be cleared in advance Standardization the system for material handling should be standardice the company should set a system for handling which will be flexible and time saving Work principle the work principle should be set in such away that reduces the efforts of workers in carrying materials one place and another the material should be handling considering the safety and should protect product from damage

 Ergonomics principle it is a science that seeks to adopted work or working condition suite the abilities of the workers material handling & equipment should be human friendly Unit load principle a unit load is one that can be stored or moved as a single unit at one time. the size of cartons or package should be uniform which helps in handling propose Space utilization The space of facility location should be used at optimal capacity

 Systems all the system related to the handling of material should be clearly defined in advance proper system will result in less confusion & congestion in work Automation the company should invent the automation system which reduces human efforts & results in fast completion of work. the automation system results in producing quality products Environment the material handling system should be set keeping in mind its adverse effect on environment the system should not create any damage to environment. Life cycle cost the cost of material handling should be analyzed in advance & should favor the organization the cost of material handling should prove beneficial &

Selection material handling equipments

Suitable for the type of material :some material handling equipments are suitable for heavy load while some are suitable for individual load. Direction of movement: some material handling equipments can move materials only in horizontal direction, other can move only in vertical direction Speed of movement: some material handling speed are fixed speed while some other speed can be changed

Continue
Path followed: some material handling equipment follows a fixed path can be varied Power requirement for the operation of the equipments: material handling equipments have power driven Supervision required: some equipments requires close supervision while do not requires

Methods or system of plant movement of materials

1) Manual labour
In this method the work load is solely dependents on the labours. The labours has to carry the materials from one place to another. This method is time consuming. The risk factor of damaging the goods is more. This method is order & economical for firm

2) Mechanized transport This method involves both manual efforts and mechanize work. The work is mostly done by machine. It reduces the human efforts in the process. Equipments such as fork lift truck, how tractors ,order picker trucks, cranes, convers are used.

3) Automation The method substitute the human requirements in process by electricity. Computerized system is an aspect of Automated system. Automated system increase the productivity & will lead to standardization of work in less time.

Case study on hitachi material handling

Hitachi, Ltd. is a world leader in the development of advanced materials and technologies. Utilizing extensive knowledge of plasma technologies, ion and electron beam technologies, and environmental systems, Hitachi, Ltd. manufactures high quality equipment for use in semiconductor device manufacturing facilities. From its North American Headquarters in Dallas Texas, the Hitachi America, Ltd. Semiconductor Equipment Group (SEG) distributes replacement parts to customers throughout the United States, Ireland and the Middle East. Growth in semiconductor equipment sales and the introduction of new product lines combined to strain the companys existing distribution facility. With increasing inventory, new product lines to support, and accelerating throughput requirements, Senior Operations Manager Tony Ficken knew he needed to improve his distribution operations.

 The impact Because of increasing demand for services, Ficken knew he needed to transform the way his distribution facility operated from the ground up. Hitachi America, Ltd. SEG determined Hitachi simplifies, cuts shipping time with carousel & warehouse management system that a new larger distribution center was required to keep pace with future demand. The company also realized that in addition to more space, it needed to improve distribution processes efficiency and increase control over the operation. I realized that the system and equipment in the old facility wouldnt work in the new warehouse, Ficken said.

 The desired solution

We dance a fine line of supply and demand, Ficken said. Because of the demanding nature of its business, the company needs to maintain near-perfect accuracy levels. Hitachi America, Ltd. SEG puts a premium on accuracy. The new distribution center had to be more efficient than Hitachi America, LTD is previous facility. With an increasing demand for its services and a need to minimize the number of people involved in shipping an order, Hitachi America, Ltd. needed the new operations to do more in less time, with less effort and fewer people. Another goal of Fickens was to remove the manual process to handling inventory orders.I want to remove as much touching of the order as possible, said Ficken. I dont want inventory touched if it doesnt have to be touched.Hitachi needed increased security in the new facility. Access to inventory had to be limited and that meant a solution that automated manual processes.

Case Study Refrige reinvents business process workflow in 12 weeks with the Out Systems Platform
The leader in the carbonated beverage industry in Portugal and one of the biggest bottlers in Europe, Refrige produces 220 million liters of soft drinks each year, but faced a severe operational bottleneck when it came to handling promotional and marketing materials around new products, especially as production volume increased. Seven different departments needed to provide input into the administrative process and all data required manual validation by Refriges IT team, which then had to be input into two separate monolithic systems; a fresh take on the product and promotional material handling process was needed, so Refrige turned to the Out Systems Platform and Out Systems' Partner, Hyfas. In only 12 weeks, a completely new enterprise workflow process was developed and rolled-out company-wide, thanks to the fast and reliable change enabled by the OutSystems Platform; the automated process now took less than a week to execute, whereas previously it took upwards of four to five weeks. Refriges IT team is now much more nimble, able to dramatically shorten response time from a week to one day and are confident that they can remain aligned to the constantly changing needs of the company, thanks to the flexible and change-ready nature of the OutSystems Platform.

Solution
The new application workflow developed by Hyfas using the Out Systems Platform has become a core process for the companys activity. The platform has demonstrated that it is extremely scalable and flexible to keep up with the evolution and business changes, and changes can be done in a short time-span. Material creating in several stages of production; Seven different security and authorization levels, for each of the involved departments; End-to-end management of the whole product and promotion material creation workflow process; Automated workflow with built in e-mail notification system; Integration with existing ERP systems including Basis and SAP; Customized dashboard for all users, according to their specific information needs regarding the stage of the process they are supporting; Centralized the overall management of the product and promotion material handling process; Application back-office providing a centralized change management console for process customization without the need to go through the development team; Extended SAP functionality by adding several fields to the promotion materials data model for comments and references per item; Provided overall view to the product and promotional materials process status to management; Built-in audit management.

Modern materials handling solution installed at Eraring power plant, Australia

The situation Eraring Power Plant, owned by Eraring Energy, is located near the town of Dora Creek, Australia. The plant started operation in 1981 with its first 660 MW boiler. By 1984 the plants four 660 MW boilers were in operation. In 2005 Eraring Energy decided to move forward with their Coal Combustion Product (CCP) Project that would ensure viability of the plant until at least 2032. This would include

solution
Clyde Bergemann Materials Handling (CBMH) in partnership with Clyde Bergemann Senior Thermal (CBST) in Sydney, Australia worked closely to address the plants technical and commercial requirements. Dense-phase conveying based on the well established ash vessel technology was implemented to cater for the handling requirements from the existing fabric filters. Coarse and fine ash is conveyed to intermediate booster stations or directly to the final silos for further utilisation. On demand fine fly ash is transported to the stations existing customer for utilisation in the concrete and cement industries. Alternatively, mixed ash can be diverted via the stainless steel storage silos to the ash pond 3 km away utilising dense slurry conveying technology which uses high pressure piston diaphragm pumps with low volumes of water to transport the wet ash over long distances.

Case study on BLAIR CORPORATION

Need: Blair Corporation needed more than 80 mobile stations integrated with its new high speed sorting and conveying system. Solution: After producing a prototype workstation from an initial concept drawing, Blairs Fulfillment Project Team-which included experienced packing operators from the fulfillment floor-traveled to Production Basics manufacturing facility to evaluate the station with the product engineering department. Blairs team went through an actual fulfillment process for the purpose of evaluating the ergonomic features, determining how practical the workstation was for the tasks, discovering which features were most useful, providing feedback for improvements. The final product materialized as a fully custom packaging and fulfillment workstation integrated with ergonomic and organizational features:

 Hand crank worksurface height accommodates multiple operators and shifts. The heavy gauge steel construction and stainless steel worksurface was designed to withstand Blairs demanding packaging schedule. V-grooved casters sit upon floor tracks to easily move station to merchandise drop shoots with minimal physical effort. Organizational accessories such as shelves with adjustable dividers help sort catalogs and literature inserts, and a bin rail suspends standard plastic bins for easy storage of small office and incidental supplies. To keep the worksurface uncluttered, a tape machine platform stores tape within operator reach, yet out of the way of packaged boxes and merchandise. A unique surface cutout gulps trash and collects it underneath the work area.

Case study NOKIA

Need: Nokia wanted to create a 'pack-line' that would streamline the fulfillment process for their primary cell phone fulfillment center in North America. Operator tasks along this line include testing, cleaning, packaging, weighing and shipping cell phones to a distribution center. Solution: 50 custom flow rack and assembly cell stations with flow rack shelving that included integrated plastic skate wheels that supported Nokias light products. A shallow work surface reduced operator reach and made it easy for operators to access products and supplies traveling on the flow rack.

PSI ENGINEERING CASE STUDY

Material Handling Automation Case Study | PDFS | PSI Engineering Before PDFS System
The order fulfillment and material handling was a manual process at the company. Product orders were physically scanned by the packager. An invoice was printed and inserted into the shipping bag along with the marketing materials (magazines, postcards etc) and the garment. The packager would physically seal the bag by hand, then print and attach the shipping label. The finished bag was then placed back on the conveyor line and sent to the shipping department. Each person could pack between 50-60 orders per hour.

After Implementing PDFS System

The dynamic Product and Document Fulfillment System (PDFS) completely automated the distribution process of their individual customer orders. The system only requires one operator and has an output of 1000 orders per hour (net). Huge labor savings and efficiency gains were realized by PSIs customer.

Case Study on SKECHERS USA

SKECHERS USA, Inc., is an award-winning global leader in the lifestyle footwear industry. They design, develop and market lifestyle footwear for men, women and children of all ages. With more than 3,000 styles, SKECHERS meets the needs of male and female consumers across every age and demographic. With such a large range in styles and sizes, its imperative to have a good handle on logistics within their DC. Thats why they called Wynright when it came time to build their 1.8 million square foot DC in Rancho Belago, CA.

Challenge
Between 1997 and 2007, SKECHERS added distribution centers on an as-needed basis, resulting in the high cost of inconsistent equipment, systems, and seasonal labor needs. Each building had different equipment, and each handled a different piece of the order fulfillment process. The additional handling required to move product between buildings for order fulfillment added considerable time and cost to the fulfillment process. Even with these multiple facilities, they lacked the space required to satisfy their growth forecast. SKECHERS, USA sought Wynrights help to unify the inventory management and distribution of nearly 70,000 SKUs from five smaller locations into a new 1.82 million square-foot distribution center. The new center needed to resolve issues dealing with manual handling, multiple touches, product flow and storage, and carton sequencing.

Solution
Wynrights design solution incorporated a 12-aisle miniload AS/RS system with 58,000 square feet of storage space and nearly 106,000 storage positions, and a 44-aisle miniload AS/RS system with 150,000 square feet of space and more than 257,000 storage positions. These two mini-load automated storage and retrieval systems can accommodate random master carton and repack box sizes. A new residual process was developed to reduce manual handling and multiple touches of residual product. With the new automated system, only product needed is decased, product only requires one touch, and manual handling was nearly eliminated. Bottlenecks caused by surges under the old system were eliminated with the new system.

 Value added services such as tagging, or adding promotional items to cartons are plentiful in the SKECHERS, USA operation. Work stations, fed by MDR conveyor, were added to streamline the VAS process. The new system monitors VAS infeed vs. capacity and reroutes to storage as needed. The automated storage of overflow cartons eliminated the need to stack cartons on the floor. Plus, overflow cartons get retrieved in priority sequence, so sequencing issues were also eliminated. Wynright redesigned the Pack and Hold process, eradicating all non value-added touches which eliminated the need for manual handling of cartons and pallets and extensive staging. The new process, driven by picking and sorter efficiency, reduced dock space requirements and improved response time to truck loading requirements. Wynright also designed and erected a 135,000-square-foot mezzanine that won the 2011 design award from the Steel Joist Institute.

Case Study: Clyde Materials Handling

Background
Clyde Materials Handling Ltd. (CMH), based in Doncaster, is recognized as a global materials handling solutions provider with offices and manufacturing facilities in the UK, USA, Brazil, China and South Africa. It offers levels of service from equipment supply through to total turn-key solutions inclusive of design, installation, commissioning and training. CMH was growing rapidly on the back of global market penetration and innovative designs. The projected growth and the international nature of future business meant that the existing information systems, based on an ageing, unsupported MRP system and numerous Excel spreadsheets, would need changing.

Case
AHC was commissioned by CMH to undertake a systems evaluation and selection process after the company had decided internally that the present systems could not support it's future plans. In parallel with the systems specification and selection project, we also helped the senior team develop a 3 year strategy and 1 year action plan, through facilitating a series of strategy workshops. This fed into the system project by confirming the needs in terms of key business processes and decision-making information.

Solution
"When Clyde Materials Handling embarked upon the task of selecting our new ERP business system, it soon became apparent that whilst we knew a lot about our own business, we were not so sure which system best suited our business needs. As newcomers to this field, it quickly became apparent that some ERP solution providers appeared more suitable than others, but which one met our needs closest?" "At this point we decided that we needed help with the selection process, but what we didn't want was someone telling us "this is the one for you". The decision had to be ours and we had to own the decision once it was made. We looked around the industry and eventually came up with 3 consultants with the right credentials. All promised similar outcomes but using different methodologies." "We settled on AHC and the SELECTOR route, because this methodology reviews the whole business and its future plans, not just its present needs. The process was one of informed choice allowing Clyde to understand the important features of the new business system which will facilitate growth. We found the whole experience very rewarding in that we achieved all the criteria and objectives we had set ourselves prior to making the commitment to order." Brian J Wright, Joint Managing Director, Clyde Materials Handling

biblography
Books which are used to make the presentations are Elements of logistics and supply chain management Publisher :RPh Vishal Mehta Mihir Mehta