1 / 32

MATERIAL HANDLING – CONCEPT AND ANALYSIS IN FACILITIES DESIGN

MATERIAL HANDLING – CONCEPT AND ANALYSIS IN FACILITIES DESIGN. INTRODUCTION. Material handling is an integral part of the overall facilities process. Problem arise in wide variety of context. Activities – parts move in the manufacturing system.

moranl
Download Presentation

MATERIAL HANDLING – CONCEPT AND ANALYSIS IN FACILITIES DESIGN

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. MATERIAL HANDLING – CONCEPT AND ANALYSIS IN FACILITIES DESIGN

  2. INTRODUCTION • Material handling is an integral part of the overall facilities process. • Problem arise in wide variety of context. • Activities – parts move in the manufacturing system. • Typically more than 1 best solution to a material handling system design problem.

  3. Material handling is the art and science Moving Storing Protecting Controlling material Material handling providing: Right amount Right material Right condition Right sequence Right orientation Right place Right time Right cost Right method DEFINITION

  4. SCOPE 3 views on the scopes of material handling identities by Apple: CONVENTIONAL CONTEMPORARY PROGRESSIVE

  5. OBJECTIVES • Improve production operations. • Improve indirect to direct labor handling labor handling ratios. • Reduce damage due to material handling. • Maximize space utilization. • Reduce the accident rate.

  6. PLANNING PRINCIPLE STANDARDIZATION PRINCIPLE AUTOMATION PRINCIPLE ERGONOMIC PRINCIPLE UNIT LOAD PRINCIPLE SPACE UTILIZATION WORK PRINCIPLE SYSTEM PRINCIPLE ENVIROMENTAL PRINCIPLE LIFE CYCLE COST PRINCIPLE PRINCIPLES

  7. CRITERIA FOR DESIGNING MATERIAL HANDLING SYSTEM

  8. WHY DEFINING CRITERIA IS IMPORTANT? • Without criteria, designer has no basis for choosing among the alternatives available for his system. • Designer uses selective criteria to evaluate alternatives in system design.

  9. HOW TO MEASURE CRITERIA Operating Cost is RM50 per unit Quantitative. Scaling. Zero-One. Intangible. 10 being the best possible and 0 the worst System meet criteria = 1 , Not meet = 0 System meet criteria = 1 , Not meet = 0 Interpretation by management, staff difficult.

  10. WHAT ARE THEIR CRITERION? (Cost, Customer Service, WIP, Productivity, System Control, Personnel Utilization) • Cost • How much money that you have. • Is the price proper for the system. • Customer Service • Fulfill customer requirement. • On-time delivery, follow-up service and minimum damage.

  11. WHAT ARE THEIR CRITERION? (Cost, Customer Service, WIP, Productivity, System Control, Personnel Utilization) • Work-In-Process • Some major investment for most companies. • WIP inventory = Good material handling!! • Productivity • Input and output consideration. • Aware of possible faults due to inadequate data.

  12. WHAT ARE THEIR CRITERION? (Cost, Customer Service, WIP, Productivity, System Control, Personnel Utilization) • System Control • High-volume material handling increase control over production. • Control the system reduce the number of rush and expedited orders. • Personnel Utilization • Difficulties in hiring and retaining workers for highly skilled job. • Job working condition: noise, dirt, heat, etc

  13. DESIGNING A MATERIAL HANDLING SYSTEM

  14. HOW TO DESIGN MATERIAL HANDLING SYSTEM? Define objective and scope. Analyze the requirements: moving, storing, protecting and controlling Generate alternative design that fulfill system. Evaluate alternative material handling system design. Select the preferred design. Implement the preferred design.

  15. DEVELOPING ALTERNATIVE MATERIAL HANDLING SYSTEM DESIGN

  16. NADLER’S APPROACH: Developing Alternative Material Handling System Designs • Aim for the theoretical ideal system. • Conceptualize the ultimate ideal system. • Design the technologically workable ideal system. • Install the recommended system.

  17. NADLER’S APPROACH: Developing Alternative Material Handling System Designs • Theoretical ideal system: • zero cost, perfect quality, no hazards, no wasted space and no management inefficiencies. • Ultimate ideal system: • achievable system in the future since the technology exists for its development but its application has not been accomplished. • Workable ideal system: • required technology available for system but their installation very costing. • Recommended system: • cost-effective system that will work for successful implementation.

  18. THE MATERIAL HANDLING EQUATION Necessary How Why What When Who Where Move Unnecessary Material Method Factors Source destination Logistics Characteristics Type Factors Unit handled Equipment Man power Factors Type Characteristics Quantity . . .

  19. QUESTIONS IN MATERIAL HANDLING • Why – Why to do this? • What – What types of material to be moved?

  20. QUESTIONS IN MATERIAL HANDLING • Where – Where is the material coming from/to? • When – When is the material needed? • How – How should the material be moved or stored? • Who – Who should be handling material?

  21. DEFINITION Identify problem. Determine scope of problem. Establish objective. Define problem. INVESTIGATION Determine data to collect. Establish work plan & schedule. Collect data. Develop, weigh & analyze data. SOLUTION Develop improvement. Prepare justification. Obtain approval. Revise. INSTALLATION Implementation. Supervision. Follow up. ANALYSIS PROCEDURE

  22. DEFINITION • Identify problem. • Determine scope of problem. • Establish objective — facilitate auditing. • Define problem — parameter within.

  23. INVESTIGATION • Determine data to collect — Basic Data Required Form. • Establish work plan & schedule. • Extend depends upon scope & problem. • Break individually as separate problem. • Plan — What, Who, Where. • Time-scaled schedule. • Collect Data. • Review sources of data. • Data — material, move, method. (schedule, layout, flow pattern, equipment) • Develop, Weigh & Analyze Data. • Classify data — 3M. • Summarized in appropriate form.

  24. SOLUTION • Develop improvement. • Redefine problem – reflect finding. • Investigate, evaluate effect of anticipated changes in: • Capacity or sales volume. • Product design. • Processing • Tooling. • Select possible solution Detailed plan Inviolate MH principle Review repeatedly • Prepare justification. • Compare cost & other method. • Determine capital investment & rate of return. • Review solution in term of problem definition & objective. • Document into final project report. • Obtain Approval. • Revise.

  25. INSTALLATION • Implementation. • Secure & evaluate quotation — delivery date & item of equipment. • Establish manpower requirement & time schedule of installation. • Supervision — Install accordingly. • Follow Up — Corrective action.

  26. UNIT LOAD DESIGN

  27. DEFINITION A number of items, or bulk material, so arranged or restrained that the mass can be picked up and moved as a single object too large for manual handling and which upon being released will retain its initial arrangement for subsequent movement. It is implied that single objects too large for manual handling are also regarded as unit loads. Bright

  28. DEFINITION It can be seen that two major criteria are (1) a large number of units and (2) a size too large for manual handling. However, in the overall material handling and physical distribution activity, these two criteria as well as the balance of the above definition, and the ‘unit size principle’ leave some room for misunderstanding, since it is obvious that either a handful or a carload both bear a relationship to the unit load concept. Apple

  29. DEFINITION A single item, a number of items or bulk material which is arranged and restrained so that the load can be stored and picked up and moved between two locations as a single mass. Tanchoco

  30. LARGE UNIT LOADS VS SMALL UNIT LOADS

  31. Processing time = 1 time unit/piece Material handling time = 2 time units/move Material handling large unit load size The material handling time must be shorter than the unit load processing time small

More Related