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Tinker AFB Material Handling Study

Tinker AFB Material Handling Study. Randa L. Shehab, Ph.D. Thomas Landers, Ph.D., P.E. John Eichman University of Oklahoma School of Industrial Engineering. Problem Definition. Problems:

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Tinker AFB Material Handling Study

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  1. Tinker AFB Material Handling Study Randa L. Shehab, Ph.D. Thomas Landers, Ph.D., P.E. John Eichman University of Oklahoma School of Industrial Engineering School of Industrial Engineering – University of Oklahoma

  2. Problem Definition • Problems: • The automated conveyor system in use was grossly under-utilized and less efficient methods of transport were being used for material transport. • The inventory tracking system was ineffective. • Objectives: • Evaluate the realistic capacity limits for the automated conveyor system • Minimize material handling time • Improving material tracking School of Industrial Engineering – University of Oklahoma

  3. Methods of Material Movement • Mechanized Material Handling System • Automated conveyor system • Non-Mechanized Modes • Forklifts • Electric carts • Trucks • Hand carried School of Industrial Engineering – University of Oklahoma

  4. Conveyor System • IDTS System • Categorized by two levels • Areas (9) and Zones (656) • Zones • Represented by a 110 array • Each position in array tracks pallet location within the zone School of Industrial Engineering – University of Oklahoma

  5. Capacity of Conveyor System • Control capacity based on conveyor system control logic • Physical capacity based on pallets that can be physically located on conveyor School of Industrial Engineering – University of Oklahoma

  6. Material Flow Problems • Station 53 receives largest portion of conveyed material (6372 pallets/month) • Material for surrounding high volume stations routed through Station 53 • Station operator required to service multiple stations - creates backlog on conveyor School of Industrial Engineering – University of Oklahoma

  7. Maintenance & Upgrade Problems • Limit Switches • Mechanical vs. Electrical • Lack of standardization • Elevators • Vertical Reciprocating vs. Platform • Lack of standardization and old technology School of Industrial Engineering – University of Oklahoma

  8. Tape Maintenance & Upgrade Problems • Rollers • Worn and misaligned • Easy “fix” by non-maintenance personnel is to tape rollers; maintenance personnel will not repair • Preventive Maintenance • Group that overhauled conveyor no longer exists • Bar Code Reader PM plan not implemented School of Industrial Engineering – University of Oklahoma

  9. Control Logic Problems • System cannot recover from tracking errors due to bad reads of pallet ID • Error perpetuates throughout system as pallet passes from zone to zone • Error results in IDTS system losing track of pallets within zones, resulting in an excessive number of pallets being routed to the bad pallets area School of Industrial Engineering – University of Oklahoma

  10. Control Logic Problems • Nine PLC’s record material locations as material travels on the conveyor • Conveyor control computer surveys the PLC’s for information to direct material routing • Delay in information flow from PLC’s to control computer causes routing errors School of Industrial Engineering – University of Oklahoma

  11. Conveyor System Utilization • Conveyor system at 11% utilization • Over two-thirds of material sampled is conveyable • Potential increase in conveyor volume is 356 pallets/month • Reduce manual MH by 196 trips/month School of Industrial Engineering – University of Oklahoma

  12. Material Flow Recommendations • Reconfigure control logic to route through traffic away from Station 53. • Reduce duties of Station 53 operator to avoid conveyor backlogs. • Create displays to supply information on conveyor system pallet jams to conveyor personnel. School of Industrial Engineering – University of Oklahoma

  13. Maintenance and Upgrades Recommendations • Standardize replacement parts for maintenance. There should be specifications for all conveyor parts. • Replace platform elevators with vertical reciprocating elevators. • Design and implement a more thorough preventative maintenance program for conveyor system. School of Industrial Engineering – University of Oklahoma

  14. Control Logic Recommendations • Systematically increase conveyor capacity and study effect. • Reduce the level of tracking performed by conveyor control logic to only material input/output. • Put tracking at PLC level. • Fix control logic so pallets are not lost. School of Industrial Engineering – University of Oklahoma

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