11-Material Handling com

8/8/2019 11-Material Handling com

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Material Handling


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Primary Handling activities

The primary handling objective in a

warehouse is to sort inbound shipments

according to precise customer requirements.

The three handling activities are

receiving, in-storage handling, and

shipping.


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Receiving

Merchandise and materials typically arrive at thewarehouse in larger quantities than when theydepart.

The first handling activity required is unloading thetransportation vehicle.

In most warehouses, unloading is manual.

Limited automated and mechanized methods havebeen developed that are capable of adapting tovarying product characteristics.


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Receiving

Generally, one or two people unload a shipment.

The product is hand-stacked on pallets to form a unit

load for movement efficiency.

In some cases, conveyors are employed to unloadvehicles more rapidly.

Larger types ofmerchandise may beunloaded directly from thecar or truck to be movedinto the warehouse.


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In-storage Handling

In-storage handling consists of all movement within awarehouse facility.

Following product receipt, it is necessary to transfer

merchandise within the warehouse to position it forstorage or order selection.

Finally, when an order is received, it is necessary toaccumulate the required products and to transport

them to a shipping area.

The two types of in-storage handling are transferand selection.


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In-storage Handling

Transfer

There are at least two and sometimes three transfer

movements required within a typical warehouse.

The merchandise is first moved into the building andplaced at a designated storage location.

The inbound movement is handled by forklift trucks

when pallets are used or other mechanical tractionfor larger unit loads.


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Forklift lifting another forklift


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In-storage Handling

Transfer

A second internal movement may be required prior toorder assembly depending on the operatingprocedures of the warehouse.

When products are required for order selection, theyare transferred to an order selection or picking area.

When the merchandise is physically large or bulky,such as a stove or washing machine, this second

movement may be omitted. In the final transfer, the assortment of products

required for a customer shipment is moved from thewarehouse to the shipping dock.


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In-storage Handling

Selection

The selection process groups materials, parts, andproducts into customer orders.

It is typical for one section of the warehouse to beestablished as a selection area to minimize traveldistance.

The typical selection process is coordinated by a

computerized control system.

The primary focus for warehouse automation is theselection process.


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Shipping

Shipping consists of checking and loading ordersonto transportation vehicles.

As in receiving, shipping is manually performed in

most systems.

Shipping with unit loads is becoming increasinglypopular because considerable time can be saved invehicle loading.

A unit load consists of grouped products, while adead-stack or floor-stack load consists of boxesloaded directly from the floor.


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Basic Handling Considerations

Some guidelines for the design of material-handling

systems are:

Equipment for handling and storage should beas standardized as possible.

The system should be designed to provide

maximum continuous product flow.

Handling equipment should be utilized to themaximum extent possible.

In handling equipment selection, the ratio of

deadweight to payload should be minimized.


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Handling systems are classified as mechanized,semi-automated, automated, and information-directed.

A combination of labor and handling equipment isutilized in mechanized systems.

Generally, labor constitutes a high percentage ofoverall cost in mechanized handling.

Automated systems, in contrast, attempt tominimize labor as much as practical by substitutingcapital investment in equipment.


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When selected handling requirements are performedusing automated equipment and the remainder of thehandling is completed on a mechanized basis, thesystem is referred to as semi-automated.

An information-directed system uses computers tomaximize control over mechanized handlingequipment.

Mechanized handling systems are the most common.

However, the use of semi-automated and automatedsystems is rapidly increasing.


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Mechanized Systems

Mechanized systems employ a wide range ofhandling equipment.

The types of equipment most commonly usedare:

Forklift trucks,

Walkie-rider pallet trucks,

Towlines, Tractor-trailer devices,

Conveyors, and

Carousels.


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Forklift Trucks

A pallet or slip sheet forms a platform upon

which loads are stacked.

A slip sheet consists of a thin sheet of

material such as fiber or corrugated paper.

Slip sheets are an inexpensive alternative topallets and are ideal for situations when

product is handled only a few times.


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A sample slip sheet made of plastic

Plastic slip sheet

Packaging industry has

found a lower cost,

environmentally friendly,

recyclable replacement for

expensive, damage prone,

short life wood pallets.

Plastic slip sheets are thin,strong sheets made of

various plastic or rubberized

materials.


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Plastic Slip sheets

Slip sheet technology

depends on special

attachment to standard

lift truck which enables

the lift driver to either

push or pull load of

goods on top of slip

sheet without the need

of wood pallets.Slip sheet under the load


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Choosing the right lift truck

Choosing the best vehicle for your operationwill result in optimal utilization of space andlabor while maintaining a high safety factor.

Factors to consider when selecting a lift truck: Fuel Types

Tire Types

Lift Capacity and Lift Height Aisle Types

Truck Types

Attachments / Options


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Fuel Types

Electric

Electric vehicles are designed for indoor use

only.

Advantages are the absence of fumes andtheir quiet operation.

Gaso

lin

eor

Diesel Outdoor use only.

Heavily used in construction.


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Fuel Types

LPG Liquid Propane

Advantages of using LP include minimal

fumes

the ability to quickly change LP tanks

Fuel-cell Technology

hydrogen fuel cell power sources providing the clean-air benefits of electric


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Tire Types

Cushion Tires are solid tires generally with

no tread pattern designed for use indoors on

smooth solid surfaces.

Pneumatic tires require airand are

designed for use outdoors on uneven andloose surfaces.


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Lift Capacity and Lift Height

The lift capacity of a truck is affected by lift height andload size.

A larger size load moves the center of gravity of thevehicle and thus reduces the lift capacity.

Attachments also affect the capacity of a truck.

If there are any changes made to the truck likeadding an attachment load capacities should berevised.


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Lift Capacity

Why spend so much time on capacity?

Why not just play it safe and get a higher capacitytruck?

The answer is size.

Bigger is not necessarily better in warehousing.

A higher capacity truck will be physically larger andrequire larger aisles.


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Aisle Types

Wide Aisle. Standard forklifts fall into this

category of trucks designed to work in aisles

greater than 11' wide.

NarrowAisle (NA) trucks operate in aisles of

8'to10'

and are generally stand up vehiclessuch as Reach Trucks.


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Aisle Types

Very NarrowAisle (VNA)trucks operate in aisles

less than 6' and often use guidance systems (wire,

rail, or optical) to travel within the aisles.

Types of VNA trucks are OrderSelectors, Swing Mast,

and Turret Trucks

Wide Aisle and Narrow Aisle trucks are designed to

turn in the aisle while Very Narrow Aisle trucks donot

turn within the aisle


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Truck Types

Lift Trucks have come

a long way since first

being introduced in the

early part of the 20thcentury as can be

seen in this early

photo of an Ellwell-

Parker"Tiering

Tructor".

Their original purpose, the efficient movement of

materials, however has not changed.


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Truck Types

1- Standard forklift

The standard forklift, also known as a

counterbalanced lift truck, is the vehicle most people

think of when they think Lift truck or Forklift.

It is available with any of the fuel types and tire types

as well as numerous weight capacities, lift heights

and attachment options.

If you are running a small operation and will only

have one truck, this is probably the vehicle for you.


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STANDARDFORKLIFT

3,000 - 8,000 lb. Capacity

2.0 Liter or 2.5 or 2.7 Liter industrial engines

Gas / LPG / Diesel / Electric Power (with battery)


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Truck Types

1- Standard forklift

The standard forklift is a wide aisle truck whichrequires at least 11' aisles to turn in.

The aisle width is determined by the size of the truck,the turn radius, and the size of the load.

Available options and attachments include side shifts,fork shifts, hydraulic clamps, and slip sheet

attachments, to name a few.

Standard forklifts are usually used for lift heightsunder 20 feet (~ 6 meters).


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Truck Types

2- Reach truck

The reach truck is a narrow aisle truck designed

specifically for racked pallet storage.

It consists of outriggers in front and telescoping forksthat use a hydraulic scissors-type mechanism that

allows you to pick up the load and retract it over the

outriggers.

This reduces the overall truck and load length,

allowing you to turn in a narrower aisle.


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Truck Types

2- Narrow aisle reach truck

Reach trucks are

designed for rackingareas only and do not

work for loading trucks

or quickly moving

loads over distances.

Other Names of reach trucks are: Stand-up reach,

Straddle reach , Double-deep reach


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Truck Types

2- Reach truck

Narrow aisle truck

designed specifically

for racked pallet

storage.

Double-deep version

(shown) loads pallets

2-deep in specialdouble-deep racking.


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Truck Types

2- Reach truck

Operator training on reach trucks tends to take longer

than on other vehicles due to the complexity of the

controls.

Double-deep reach trucks use an extended reach

mechanism which allows you to store pallets too

deep in specially designed double-deep rack.

Reach trucks are available with lift heights up to 30

feet (~ 10 meters).


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Truck Types

3- Motorized pallet truck

OtherNames include: Walkie, Walkie-rider, Rider

They come in "Walkie" versions or "Rider" versions.

As you would expect the walkie is designed for theoperator to walk along with the truck as they moveloads, while the Rider has a small platform which theoperator stands on.

The riders work great for frequent moving of loadsover extended distances within warehouses andmanufacturing operations.


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WALKIE TRUCKS


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Motorized Pallet Truck

(Rider Type)

Low cost and highmaneuver-abilitymake these vehicles

a good choice wherefrequent movement ofloads is required.

Options includedouble pallet lengthforks that allow you tomove 2 pallets in onetrip.


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Truck Types

3- Motorized pallet truck

They are fast and highly maneuverable.

Minimal controls result in short learning curves foroperators.

If you are looking for an inexpensive method formoving loads from point A to point B, a rider may bethe answer.

If you are moving heavy loads short distances andare looking for an employee-friendly option to thepallet jack, check out a walkie.


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Truck Types

4- Order selector

Designed specifically for manual handling of less-than-pallet-load quantities in racking.

It has fixed forks attached to a platform whichelevates the load and the operator to facilitatemanual loading and unloading from racking.

OrderSelectors are very narrow aisle vehicles which

operate in aisles of less than6'

.

Order selectors are available in lift heights up to 40feet however 20 to 30 foot models are more common.


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Order Selector Truck

Elevates the load

and the operator

to facilitate manualloading and

unloading from

racking


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Order Selector Truck

Vehicle is designed

specifically for handloading less-than-

pallet load quantities

into and out of

selective rack.


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Attachments / Options

There is an enormous variety ofattachments and options available for lifttrucks.

While most attachments are designed for useon standard lift trucks, some of them are alsoused on reach trucks and VNA trucks.

Most attachments will change the capacity ofthe lift truck.


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Common types of attachments

2- Fork positionerallows the operator to

adjust the distance between the forks without

getting off of the truck.

Used primarily in high volume operations

where there is a great variety of pallet sizes.

3- Fork pivot allows the forks and carriage to

pivot (rotate).


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Common types of attachments

4- Paperroll clamp. Designed specifically for thehandling of large paper rolls, the paper roll clampclamps around the roll and also allows for a full 360degree rotation.

5- Prongs. AProng is a specialized rod typeattachment used for picking up rolls of materials suchas carpet rolls, wire and cable spools, and rolledsteel, by inserting the prong into the center of thespool.

6- Fork extensions. Fork extensions slide over theexisting forks on the truck to allow you to pick uplonger loads.


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Conveyor Systems

Conveyor systems have been a mainstay ofmaterial handling for over100 years.


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Conveyor Systems

Belt conveyors were moving materials inmanufacturing plants before the forklift was eveninvented.

New configurations and sophistication of controlshave kept conveyor systems in the state-of-the-artcategory with other automated material handlingsystems.

Conveyor is very cost effective and the ease ofexpandability and reconfiguration makes it ideal forgrowing operations.


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Gravity Skate Wheel Conveyor

Gravity flow skate wheelconveyor is a low costoption for conveyinglightweight cartons or

trays.

Used extensively inshipping/receiving andassembly areas, skate

wheel conveyors reducemanual material handling oflightweight items over shortdistances.


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Automated Belt Conveyor

Automated beltconveyer has similarapplications to gravityroller and skate wheel.

Single units can beincorporated into gravityconveyor systems tocreate a simple low cost

semi-automatedsystem.


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Flexible Conveyor

Used extensively inshipping/receivingoperations for package

handling, flexibleconveyor is usuallyanchored at one end tofixed gravity or automatedconveyor allowing theother end to be expanded

and flexed into trailers forloading and unloading.


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Unit Load Conveyor

Unit Load Conveyor

is a heavy duty

version of roller

conveyor used for

handling pallet loads

or larger trays.


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High Volume Trailer Loading

This shows an

application of

conveyor in highvolume trailer

loading/unloading.


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Sortation Systems

Sortation systems are the key to large elaborate

conveyor systems.

The variety of sortation systems is extensive as are their

applications.


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Automated Equipment

While you will need deep pockets for some of

this equipment, the increase in productivity

and storage capacity can provide areasonable ROI in many operations.


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Vertical Carousels

Vertical Carouselsconsist of a series ofhorizontal trays on avertical carousel.

Vertical carousels aremost effective when floorspace is at a minimumand there is ampleoverhead clearance.


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Vertical Carousels

Enclosed vertical carousels offer additional

security and protection for the product stored

in them.

Vertical carousels are frequently used in

laboratories, offices, and specialty

manufacturing operations.


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Automated Storage and Retrieval

System (ASRS)

A system of rows ofrack, each row hasa dedicated retrievalunit that moves

vertically andhorizontally alongthe rack picking andputting away loads.


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Automated Storage and Retrieval

System (ASRS)

ASRS systems are availablein

Mini-load

types which store andtransfer product onsome type of tray or inbins and

Unit-load types(shown) which transferand store pallet loads.


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Automated Guided Vehicle (AGV)

Vehicles that can beprogrammed to automaticallydrive to designated points and

perform preprogrammedfunctions.

Guidance system may consistof a wire embedded in the

floor, special tape, laser andoptical system.


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AutomatedGuided Vehicle

They are most effective where highly

repetitive tasks are performed over extended

distances.

The variety in configurations ofAGVs is

endless, virtually any type of material

handling equipment can be converted to an

AGV.


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AutomatedGuided Vehicle

This is another

version of an AGVthat has added

functionality to raise

and lower the pallet

to different heights.


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Towline (AGV) system

Towline system

is designed for

movement ofmaterials and

products over

paths.


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Towline system

Towed vehicles can be manually engaged or

disengaged anywhere along the route or

automatically activated at pre-selected stations.

Sophisticated controls route vehicles along the

main path and switch them into pre-selected side

routes.

When disengaged, vehicles can manually be

routed through inspection, order checking or

unloading operations.


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DockEquipment

The loading dock is generally considered themost dangerous part of a material handlingoperation.

Every year there are numerous injuries whenlift trucks drive off the edge of a dock or fallbetween the dock and the trailer.

The number one concern when purchasingdock equipment should be safety.


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Standard Pull-chain mechanical

DockLeveler

Dock levelers areused to bridge thegap between thedock and the trailerand adjust for anyheight differences.

The pull-chainmechanical dockleveler is the mostcommon type used.


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Hydraulic DockLeveler

A step up from themechanical dockleveler, the hydraulicdock leveler uses anelectric pump and

hydraulic cylinder toengage/disengage thedock leveler.

This works from a

remote switch which isgenerally mounted onthe wall next to thedock.

Docks with high volume willbenefit from this automation.


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Truck Restraint: ICC Bar Type

The most dangerousaspects of loading andunloading trailers iswhen a driver starts to

pull away from the dockwhile he is still beingloaded.

The ICC Bar type

restraints automaticallyengage the rear guardon the trailer when itbacks into the dock.

After the trailer isloaded/unloaded therestraint is disengaged viaa control panel


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Truck Restraint: Automatic Wheel

Type

Another automated

truck restraint system,

the wheel type systemengages in front of the

rear wheels of the

trailer.


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Elevating Docks

Elevating docks are

used where a raised

dock is not available.

They operate via an

electric pump and ahydraulic lift cylinder.


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Dock Seals

Dock seals come in a

variety of configurations

and are used to preventair, dirt, insects, birds,

and rain/snow from

entering the building

while loading and

unloading trucks.

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