Efficient Material Handling Principles for Facilities Planning

1. IENG 471 - Lecture 14 Material Handling IENG 471 Facilities Planning

2. Assignments • Current Assignment: • HW 6: • Work in teams of TWO students • Turn in one set of solutions on EP paper, with a cover page • Next Assignment • HW 7: • Work in teams of FOUR students • Turn in ONE spreadsheet for all team members • Put “IENG 471 HW 7” in subject line • Attach Excel spreadsheet • First tab of spreadsheet has ALL student names & solutions • 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 IENG 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 IENG 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 IENG 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, … IENG 471 Facilities Planning

6. 10 Material Handling Principles • Planning Principle • Defined in advance of implementation, covering: • What • When • Where • Whom • How • Standardization Principle • Reducing the variation in methods and equipment employed • Work Principle • Measured inFlow X Distance • Ergonomic Principle • Adapting the work to fit the abilities of the worker • Unit Load Principle • The load that can be moved as a single entity regardless of the number of component units IENG 471 Facilities Planning

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

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

9. 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 IENG 471 Facilities Planning

10. 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 IENG 471 Facilities Planning

11. 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 Full Size Container 1/4 1/8 1/16 1/16 1/2 IENG 471 Facilities Planning

12. 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 IENG 471 Facilities Planning

13. Pallets (Types & Stacking Patterns) IENG 471 Facilities Planning

14. Pallets • Aisle Width Requirements for Common Pallet Handling Equipment: IENG 471 Facilities Planning

15. 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: • http://www.mhia.org/et/ET_MHI_CICMHE_Home.cfm IENG 471 Facilities Planning

16. Questions & Issues IENG 471 Facilities Planning