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Materials handling in flexible manufacturing systems
1. Introduction
The term material handling is used in defining an integrated
system that involves activities like moving, storing, handling,
and the control of materials using grav-
ity, manual, or machine power. Moving materials is work and
requires time and space. To move a material, it is important to
focus on analyzing the path of movement
regardless of the material's size, shape, weight, and condition.
Storage is a good way of creating a buffer to materials from one
operation to another. It is key to the
efficiency of people and machines in the provision of an
efficient material organization. In designing a material system,
the following should be considered; size,
weight, condition, and ability to a stack of materials. This is
required in all types of designs. Thinking about building design
for example it is important to consider the
floor loading, condition of the floor, and spacing of columns
among others. Materials should be protected from all forms of
deterioration. Protection of materials cov-
ers packaging, safeguarding from theft, and protection against
mishandling. Information about the use of a machine should be
provided to all authorized people to

prevent situations of machine mishandling. It is important to
have both physical and status control. Controls should also
cover misappropriate use and misplacement
of materials. The sequence and space of material movement are
defined as physical control. In status control, one needs to know
the physical location of mater-
ial, origin, destination, ownership, and material schedule.
However, it is difficult to maintain control of materials because
it is affected by things like organizational cul-
ture and the character of people handling the functions
associated with the material. To ensure that an organization has
a flexible manufacturing system, it is import-
ant to focus on material handling. A material can spend 80% of
its time on the floor of a shop waiting or in transportation
activities that do not add value to an organ-
ization. It is therefore important to have efficient material
handling to avoid situations of congestion, shorten the delivery
time, reduce the number of hours a
machine is idle and non-available, or accumulate materials at
workstations. It is important to focus on safe material handling
to reduce wastage, breakage, situ-
ations of loss, scrapes, and fixes. 1. Material handling
principles
In material handling, some principles give fundamentals of
practices for material handling and give guidance to designers
of all material handling systems. The
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following list shows the applicable principles in material
handling; 2.1 Planning principle
Planning is important in material handling. The result of
material handling is inclined to set performance objectives and
performing specific functions. It is important
to plan and define material functions and the modes of
operations. Key questions include; what, when, where, how, and
who. 2.2 Standardization principle
This is key to the flexibility of handling materials. In all
possible situations handling methods should be standardized.

Limits set should assist in achieving all set per-
formance objectives with flexibility, modularity, and
considering the future changes of the materials. 2.3 Ergonomic
principle
This is inclined to respecting the capabilities of humanity in the
design of material handling tasks and equipment. This should is
key to attaining safe and effective op-
erations. The design process should consider making equipment
that does away with repetitive and manual labor which can
strain people. This is a good way of in-
creasing the effectiveness of material handling. 2.4 Flexibility
principle
This is associated with the use of material with the ability to
perform a variety of tasks and can be exposed to different
conditions of operations. 2.5 Simplifica-
tion
This is a principle that reduces and eliminates unnecessary
movements and equipment. 2.6 Gravity
The use of gravity in moving material should be considered in
all possible situations. 2.7 Layout
All viable systems should have a well-selected system of
configuration with well know the operating sequence. 2.8 Cost
The expenses associated with material handling should be
considered. Cost-effective alternatives should be considered.
2.9 Maintenance
In material handling, it is important to keep a schedule of
preventive maintenance. 2.10 Unit load principle

The load that can be stored or moved at a time is known as a
unit load. This can include things like a pallet or a container. A
unit size should always have the ap-
propriate size and be in a way helping organizations achieve the
flow of material and objectives of an organizational inventory
system at different stages of the supply
chain. 2.11 Principle of space utilization
Material handling should consider effective and efficient use of
available space. Transport of material within a facility should
consider overhead space utilization.
2.12 System principle
The movement of material and storage should be well-
coordinated and integrated.
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This should not limit the operating system responsible for
receiving, selection, transportation, and returns handling. This
should also consider the organizational sup-
ply chain with manufacturers, suppliers, distributors, and
consumers. 2.13 Principle of automation
In improving the efficiency of material handling, it is important
to mechanize/ automate operations to increase effectiveness,
consistency, and predictability. 2.14
Principle of Environment
Impacts on the environment and energy consumption should be
considered when designing equipment and material handling
systems. 2.15 Principle of
life cycle cost
The life cycle of machine handling should have a proper
analysis of its economy. This should consider investment
capital, installation, material/machine setup
and equipment programming, any training needed, testing of
system and acceptance, the associated operations and
maintenance, repair, reuse value, and at the end
ultimate disposal. 3.Material Transport Equipment
Equipment has been classified by the International materials
management society as; conveyors, cranes, elevators, and
hoists. There are positioning con-

trol, and weighing equipment, Vehicles for industries, railroad
cars, marine carriers, aircraft, containers, and support. Details
of material transport equipment are
provided as below; 3.1 Conveyor Systems
In cases where there is very frequent movement of material
between two specific points, it is important to use a conveyor.
The conveyor system is combined with
modern identification and recognition system and plays a
critical role in an organizational production line. The common
types of conveyors used include; rollers,
skate-wheel conveyors, in-floor towline conveyors, and
overhead trolley conveyors. 3.1.1 Roller conveyor
This is a conveyor whose part is made up of a series of rollers
perpendicular to the direction in which the load travels. The
load in this type of conveyor should
have a flat bottom to be able to span several rollers. Rollers can
be powered or non-powered. Powering a roller conveyor helps
in driving the loads forward.
Fig. 1. Roller conveyor 3.1.2 Skate-wheel conveyor
This has a similar operation as the roller conveyor. The
difference is that it uses skate wheels instead of rollers which
are lighter and non-powered. They
can be built as portable units for loading and unloading truck
trailers.
Fig. 2. Skate-wheel conveyor 3.1.3 Conveyor belt

This is a continuous loop that is made to have a forward path of
moving loads. The characteristic belt is made up of an
elastomeric support slider or even rollers
supporting the loop. They can be of two types; Flat belts and V-
shaped for very heavy materials.
Fig. 3. Belt conveyor 3.1.4 In-Floor two-line conveyor
This is a cart that is four-wheel powered by a moving chain or
cable in trenches in the floor. Carts are made to use steel pins
that project below the level of the floor
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and engage a chain in tow.
Fig. 4. In-floor two-line conveyor.
3.1.5 Overhead Trolley conveyor It is a wheeled carriage that
runs on an overhead track. This track is used in suspending
loads. Trolleys are connected and
moved by the chain or cable forming a complete loop.
Fig. 5. Over-head trolley conveyor
3.1.6 Cart-on Track conveyor
This is made up of a cart that rides on a track that is above the
floor level and using a spinning tube to drive it. A drive wheel
is used in controlling the forward

motion.
Fig. 6. Cart-on-track conveyor. 3.2 Cranes and Hoists
Transfer of materials with heavyweight requires the use of a
crane for the intermittent flow of material. Loads moved by
cranes have varying shapes and weights.
Craned can be operated manually, electrically, or
pneumatically. A crane uses a hoist making up a combination of
both. They can be used in providing vertical
and horizontal transport.
Fig. 7. (a) Sketch of the hoist (b) diagram to illustrate
mechanical advantage 3.2.1 Bridge Crane
This is a crane that consists of one or two horizontal
girder/beams which are suspended on a fixed rail on both ends
and connected to a structure of a building.
They have used the fabrication of heavy machinery because of
their ability to carry loads not exceeding 100 tons.
Fig. 8. Bridge crane 3.2.2 Half-gantry crane
The difference between this and bridge crane is that this crane
has one or two vertical support elements providing support to a
horizontal girder.
Fig. 9. Half gantry crane
3.2.3 Jib Crane
This kind of crane has a rotating arm and a hoist running across
its length. The arm revolves on a fixed axis held by a grounded

mounted post. They are convenient in
lifting areas which characteristic circular arcs.
Fig. 10. Jib Crane
3.2.4 Stacker Crane
This is very similar to a bridge crane. This crane uses a mast
with forks. It can also use platforms for handling the unit loads.
This crane is used in storing and re-
trieving unit loads in raised store racks. 1. Automated Retrieval
and storage equipment
This can be in form of shelves, racks, drawers, or bins. Racks
are the most common storage equipment used. Racks have
different configurations depending on
the facility and mode of operations.
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1. Automated guided vehicles (AGV) This system of handling
material uses independently operated self-driven vehicles which
move on guided pathways.
This system of material handling is automated. Key parts of the
system include; the drive, steering power, and computer control.
5.1 Types of AGV
5.1.1 Driverless Automated Guided Train
This type of AGV was introduced in 1954. It is used in moving
heavy payloads over distances in warehouses and factories
without stopping along the route.
Fig. 11. Driverless automated guided vehicle 5.1.2 AGV pallet
truck
They are applied in moving palletized loads in predetermined
routes. Workers back vehicles into loaded pallet which is then
elevated from the floor.

Fig. 12. AGV pallet truck 5.1.3 Unit Load carrier
In moving unit loads from one station to another this carrier is
used. They are equipped for automatic loading/unloading of
pallets.
Fig. 13. Unit load carrier 5.1.4 Light load AGV
This can be used for light loads. They are commonly applied in
electronics assembly and offices. 5.1.5 Assembly AGV
In assembly platforms like in the automotive industry, this can
be used. They are used to transport parts in an assembly station.
5.1.6 Forklift AGV
This could pick up and drop off palletized loads. Can be used to
pick loads at floor level or on stands. 5.1.7 Rail-Guided
vehicles
They are made to be self-propped vehicles moving on a fixed
rail. They have an independent operation and maybe overhead
monorail or on-floor- parallel fixed rails.
Fig. 14. Rail guided vehicle 5.2 Management of AGVS system
This should consider the following parameters; guide-path
layout, AGVs required, and operational/transportation control.
5.2.1 Guide-path layout
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This defines the vehicle movement path. This dictates the pick-
up and drop-off points, areas of maintenance, and intersections.
The guide paths can be uni-
directional, bi-directional, multi-guided, or even mixed guided
paths. 5.2.2 Number of AGVs required
The maximum number of AGVs in a system should be properly
estimated. This is a good move towards reducing congestion and
idle times in a working station.
5.2.3 Operational and transportation control
This consists of vehicle dispatching, traffic control, and routing
vehicles. Once a demand rises for an AGV a choice should be
made on the vehicle to be dispatched.
Proper AGV utilization results in justification of the utilization
economy. 1. Industrial robots
These are useful material handling devices that are automated.
They are programmed to perform various tasks like moving
materials, parts, tools m or devices
by variable programmed motions. They operate at a certain
degree of freedom and are automatically controlled. 6.1 Robot
Components
The basic components of an industrial robot are listed as
below;- 6.1.1 Manipulator
This is a mechanical unit that provides characteristic motion
similar to the human arm and hand. 6.1.2 End effector
This is attached with the end of the wrist in a robot. It is used to
enable a robot to undertake a particular task. The end effector
may be equipped with the

following; gripper, hooks, vacuum cups, spray gun, or
attachments used for welding purposes. 6.1.3 Control system
This gives commands to the robot. It is used in data storage and
manipulates the robot. 6.1.4 Power supply
Used in supplying power to the control system. 6.2 Robot types
The classification of robots is Cartesian, cylindrical, and polar.
6.2.1 Pick and place robots
This is a fixed sequence robot that is programmed for specific
operation with movements from point to another. 6.2.2 Playback
robot
This is a robot with the ability to learn the work and motion of
operation activities and repeats them as guided by the operator.
6.2.3 Numerically controlled ro-
bot
This type of robot is programmed and works as a numerical
control machine. 6.2.4 Intelligent robot
This robot can perform tasks done by human beings. It is
equipped with sensors and has tactile capabilities. 6.3
Applications of robots in material handling
The main applications of robots in material handling include; 1.
They are used in industries in loading/unloading materials. 1.
Transfer of material from one con-
veyor to the other. 1. In palletizing and de-palletizing materials
that are taken from conveyor and loaded into a pallet. 1. They
are used in an automotive as-

sembly where repetitive work is needed. 1. The use of
intelligent robots is used in automatically picking the right
workpiece without the interference of the operator.
7. References M.P. Groover. “Automation, Production systems
and computer integrated manufacturing” Second edition.
Pearson-Prentice Hall, 2008. K.
Sareen and C. Grewal.”CAD/CAM: Theory and concepts” S.
Chand & Co. 2009. C. R. Alavala. “ CAD/CAM: Concepts and
applications” Prentice-Hall, 2008. P. N.
Rao. “ CAD/CAM: Principles and applications” McGraw -Hill,
2004. C. R. Asfahl. “Robots and manufacturing automation”
Second edition, John-Wiley and
sons.1992. M. P. Groover and E. W. Zimmers. Jr. “ CAD/CAM:
Computer added design and manufacturing” Pearson-Prentice
Hall, 2009. G. Chryssol-
ouris, “Manufacturing systems: Theory and Practice
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The term material handling is used in defining an integrated
system that involves activit-
ies like moving, storing, handling, and the control of materials
using gravity, manual, or
machine power. Moving materials is work and requires time and
space.
Original source
Material handling can be defined as an integrated system
involving such activities as mov-
ing, handling, storing and controlling of materials by means of
gravity, manual effort or
power activated machinery Moving materials utilize time and
space
3
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size, weight, condition, and ability to a stack of materials.
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the size, weight, condition and stack ability of materials
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In status control, one needs to know the physical location of
material, origin, destination,
ownership, and material schedule.

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Status control is the real time awareness of the location,
amount, destination, origin,
ownership and schedule of material
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It is therefore important to have efficient material handling to
avoid situations of conges-
tion, shorten the delivery time, reduce the number of hours a
machine is idle and non-
available, or accumulate materials at workstations.
Original source
Material handling efficiency is necessary to reduce traffic
congestion, ensure timely deliv-
ery, and reduce machine idle time due to non-availability or
accumulation of materials at
workstations
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It is important to focus on safe material handling to reduce
wastage, breakage, situations
of loss, scrapes, and fixes.
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Safe handling of materials is important in a plant as it reduces

wastage, breakage, loss
and scrapes etc
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Material handling principles
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of material handling principles
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In material handling, some principles give fundamentals of
practices for material hand-
ling and give guidance to designers of all material handling
systems.
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The material handling principles provide fundamentals of
material handling practices and
provide guidance to material handling system designers
2
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2.2 Standardization principle
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[email protected]%@@@#@!!~$$ 2.2 Standardization principle
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2.3 Ergonomic principle
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2.4 Flexibility principle
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2.5 Simplification
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2.5 Simplification

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2.6 Gravity
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2.6 Gravity
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2.7 Layout
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2.7 Layout
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2.8 Cost
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2.8 Cost
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2.9 Maintenance
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2.9 Maintenance
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2.10 Unit load principle
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The load that can be stored or moved at a time is known as a
unit load.
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A unit load is one that can be stored or moved as a single
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2.11 Principle of space utilization
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2.11 Space utilization principle
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2.12 System principle The movement of material and storage
should be well-coordinated
and integrated.
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2.12 System principle Material movement and storage activities
should be fully integrated
to form a coordinated, operational system

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2.13 Principle of automation
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2.13 Automation principle
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2.14 Principle of Environment
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2.14 Environmental principle
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Impacts on the environment and energy consumption should be
considered when
designing equipment and material handling systems.
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Environment Environmental impact and energy consumption
should be considered while
designing or choosing alternative equipment and material
handling systems
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2.15 Principle of life cycle cost
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2.15 Life cycle cost principle

1
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This should consider investment capital, installation,
material/machine setup and equip-
ment programming, any training needed, testing of system and
acceptance, the associ-
ated operations and maintenance, repair, reuse value, and at the
end ultimate disposal.
Original source
Life cycle costs include capital investment, installation, setup
and equipment program-
ming, training, system testing and acceptance, operating (labor,
utilities, etc.), mainten-
ance and repair, reuse value, and ultimate disposal
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3.Material Transport Equipment
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Material Transport Equipment
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Equipment has been classified by the International materials
management society as;

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International Materials Management Society has classified
equipment as (1)
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conveyors, cranes, elevators, and hoists.
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Cranes and Hoists
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Details of material transport equipment are provided as below;
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details of material transport equipment
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3.1 Conveyor Systems
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The common types of conveyors used include;
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Some of common types of conveyors are
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3.1.1 Roller conveyor
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3.1.1 Roller Conveyor
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This is a conveyor whose part is made up of a series of rollers
perpendicular to the direc-
tion in which the load travels.
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The path of a roller conveyor is made up of a series of rollers
that run perpendicular to
the direction of motion
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Rollers can be powered or non-powered.
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Conveyors can be either powered or non-powered
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Roller conveyor 3.1.2 Skate-wheel conveyor
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3.1.2 Skate-Wheel Conveyor
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This has a similar operation as the roller conveyor. The
difference is that it uses skate
wheels instead of rollers which are lighter and non-powered.
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are similar in operation to roller conveyor but use skate wheels
instead of rollers and are
generally lighter weight and non-powered
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They can be built as portable units for loading and unloading
truck trailers.
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Sometimes, these are built as portable units that can be used for
loading and unloading
truck trailers in shipping and receiving
2

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Skate-wheel conveyor 3.1.3 Conveyor belt
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3.1.3 Belt Conveyor
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This is a continuous loop that is made to have a forward path of
moving loads. The char-
acteristic belt is made up of an elastomeric support slider or
even rollers supporting the
loop.
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Is a continuous loop with forward path to move loads in which
the belt is made of rein-
forced elastomeric support slider or rollers used to support
2
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Belt conveyor 3.1.4 In-Floor two-line conveyor This is a cart
that is four-wheel powered by
a moving chain or cable in trenches in the floor. Carts are made
to use steel pins that pro-
ject below the level of the floor and engage a chain in tow.
Original source

3.1.4 In-Floor Tow-Line Conveyor These are four-wheel carts
powered by moving chains
or cables in trenches in the floor Carts use steel pins (or
grippers) to project below floor
level and engage the chain (or pulley) for towing
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In-floor two-line conveyor.
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In-floor two-line conveyor
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3.1.5 Overhead Trolley conveyor It is a wheeled carriage that
runs on an overhead track.
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3.1.5 Overhead Trolley Conveyor A trolley is a wheeled
carriage running on an overhead
track from which loads can be suspended
1
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Trolleys are connected and moved by the chain or cable forming
a complete loop.
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Trolleys are connected and moved by a chain or cable that
forms a complete loop and are
often used to move parts and assemblies between major
production areas
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Over-head trolley conveyor
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Over-head trolley conveyor
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3.1.6 Cart-on Track conveyor
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3.1.6 Cart-On-Track Conveyor
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A drive wheel is used in controlling the forward motion.
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The forward motion of cart is controlled by a drive wheel
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Cart-on-track conveyor.
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· Cart-on-track conveyor
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3.2 Cranes and Hoists
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Craned can be operated manually, electrically, or
pneumatically.
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They can be operated manually, electrically, or pneumatically
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(a) Sketch of the hoist (b) diagram to illustrate mechanical
advantage 3.2.1 Bridge Crane
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(a) Sketch of the hoist (b) diagram to illustrate mechanical
advantage

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This is a crane that consists of one or two horizontal
girder/beams which are suspended
on a fixed rail on both ends and connected to a structure of a
building. They have used
the fabrication of heavy machinery because of their ability to
carry loads not exceeding

100 tons.
Original source
A bridge crane consists of one or two horizontal girders or
beams suspended between
fixed rail on either end which are connected to the structure of
the building They have
the ability to carry loads up to 100 tons
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Bridge crane 3.2.2 Half-gantry crane The difference between
this and bridge crane is that
this crane has one or two vertical support elements providing
support to a horizontal
girder.
Original source
3.2.2 Half-gantry crane Half gantry crane is distinguished from
bridge crane by the pres-
ence of one or two vertical supporting elements which support
horizontal girder
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Half gantry crane
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Half gantry crane

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3.2.3 Jib Crane
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3.2.3 Jib Crane
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3.2.4 Stacker Crane
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3.2.4 Stacker Crane
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This crane uses a mast with forks.
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The stacker crane uses a mast with forks or a platform to
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Automated Retrieval and storage equipment

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Automated Retrieval and storage equipment
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This can be in form of shelves, racks, drawers, or bins.
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Storage equipments can be in the form of racks, shelves, bins
and drawers
1
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Automated guided vehicles (AGV) This system of handling
material uses independently
operated self-driven vehicles which move on guided pathways.
Original source
Automated Guided Vehicles An Automated Guided Vehicle
System (AGVS) is a material
handling system that uses independently operated, self-
propelled vehicles guided along
defined pathways in the facility floor

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This system of material handling is automated.
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Automated material handling
2

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5.1 Types of AGV 5.1.1 Driverless Automated Guided Train
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5.1 Types of AGV 5.1.1 Driverless Automated Guided Train
6
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It is used in moving heavy payloads over distances in
warehouses and factories without
stopping along the route.
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Common application is moving heavy payloads over long
distances in warehouses and
factories without intermediate stops along the route Automated
guided pellet trucks
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Driverless automated guided vehicle 5.1.2 AGV pallet truck
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5.1.2 AGV Pallet Truck
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They are applied in moving palletized loads in predetermined
routes.
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Palletized loads are transported along predetermined routes
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Workers back vehicles into loaded pallet which is then elevated
from the floor.
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pallet is then elevated from floor
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AGV pallet truck 5.1.3 Unit Load carrier
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5.1.3 Unit Load Carrier
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In moving unit loads from one station to another this carrier is
used.

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This type of AGVS is used to move unit loads from one station
to another station
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They are equipped for automatic loading/unloading of pallets.
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often equipped for automatic loading/unloading of pallets
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Unit load carrier 5.1.4 Light load AGV
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5.1.4 Light load AGV
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5.1.5 Assembly AGV
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5.1.5 Assembly AGV
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5.1.6 Forklift AGV
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5.1.6 Forklift AGV

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This could pick up and drop off palletized loads.
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Used to pick up and drop off palletized loads both at floor
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Can be used to pick loads at floor level or on stands.
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It can pick up and drop off palletized loads both at floor level
and on stands
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5.1.7 Rail-Guided vehicles
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5.1.7 Rail-Guided Vehicles
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Rail guided vehicle 5.2 Management of AGVS system
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5.2 AGVS System Management
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guide-path layout, AGVs required, and
operational/transportation control.
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Guide-path layout Number of AGVs required Operational and
transportation control
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This defines the vehicle movement path.
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defines the possible vehicle movement path
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This dictates the pick-up and drop-off points, areas of
maintenance, and intersections.
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Pick-up and drop-off points, maintenance areas, and
intersections represent the route
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5.2.2 Number of AGVs required
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5.2.3 Operational and transportation control This consists of
vehicle dispatching, traffic
control, and routing vehicles. Once a demand rises for an AGV
a choice should be made
on the vehicle to be dispatched.
Original source
5.2.3 Operational and Transportation Control The operation and
transportation consists
of vehicle dispatching, vehicle routing and traffic control issues
Once a demand arises for
an AGV, a choice needs to be made regarding the vehicle to be
dispatched among the
pool of vehicles available
2

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These are useful material handling devices that are automated.
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Industrial robots are very useful material handling devices in an
automated environment
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6.1 Robot Components
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6.1 Robot components
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The basic components of an industrial robot are listed as
below;- 6.1.1 Manipulator
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6.1 Robot components The following are basic components of
an industrial robot
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This is a mechanical unit that provides characteristic motion

similar to the human arm
and hand.
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It is a mechanical unit that provides motions similar to those of
human arm and hand
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6.1.2 End effector
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6.1.2 End effector
2
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This is attached with the end of the wrist in a robot.
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It is attached with the end of wrist in a robot
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The end effector may be equipped with the following;
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Depending on the type of work, end effector may be equipped
with any of the following
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6.1.3 Control system

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6.1.4 Power supply
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6.1.4 Power supply
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6.2 Robot types
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6.2 Robot Types
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6.2.1 Pick and place robots
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6.2.1 Pick and place robot
10

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This is a fixed sequence robot that is programmed for specific
operation with movements
from point to another.
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It is also called fixed sequence robot and is programmed for a
specific operation
3
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6.2.2 Playback robot
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3
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6.2.3 Numerically controlled robot
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This type of robot is programmed and works as a numerical
control machine.
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It is a programmable type of robot and works same as the
numerical control machines
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6.2.4 Intelligent robot
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2
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6.3 Applications of robots in material handling The main
applications of robots in material
handling include;
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6.3 Robot applications in Material handling Major applications
in material handling
include

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Transfer of material from one conveyor to the other.
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These are used to transfer the material from one conveyor to
another
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In palletizing and de-palletizing materials that are taken from
conveyor and loaded into a
pallet.
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· These are used in palletizing and de-palletizing so that
components and materials are
taken from the conveyor and loaded into a pallet in the proper
pattern and sequence,
and vice versa
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References M.P.
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References M.P
2
Student paper
“Automation, Production systems and computer integrated
manufacturing” Second edi-
tion. Pearson-Prentice Hall, 2008.
Original source
“Automation, Production systems and computer integrated
manufacturing” Second edi-
tion Pearson-Prentice Hall, 2008

2
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Sareen and C. Grewal.”CAD/CAM: Theory and concepts” S.
Original source
Sareen and C Grewal.”CAD/CAM Theory and concepts” S
2
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Concepts and applications” Prentice-Hall, 2008.
Original source
Concepts and applications” Prentice-Hall, 2008
2
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Principles and applications” McGraw-Hill, 2004.
Original source
Principles and applications” McGraw-Hill, 2004
2
Student paper
“Robots and manufacturing automation” Second edition, John-

Wiley and sons.1992.
Original source
“Robots and manufacturing automation” Second edition, John-
Wiley and sons.1992
2
Student paper
Groover and E.
Original source
Groover and E
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Hall, 2009.
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Hall, 2009
2
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Chryssolouris, “Manufacturing systems:
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Chryssolouris, “Manufacturing systems
3
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Theory and Practice
Original source
Theory and Practice” Springer-
Materials handling in lexible manufacturing systems 121
Materials handling in lexible manufacturing systems
Dr. Tauseef Aized

X
Materials handling in flexible
manufacturing systems
Dr. Tauseef Aized
Professor, Department of Mechanical, Mechatrnics and
Manufacturing Engineering, KSK
Campus, University of Engineering and Technology, Lahore,
Pakistan
1. Introduction
Material handling can be defined as an integrated system
involving such activities as
moving, handling, storing and controlling of materials by means
of gravity, manual effort or
power activated machinery. Moving materials utilize time and
space. Any movement of
materials requires that the size, shape, weight and condition of
the material, as well as the
path and frequency of the move be analyzed. Storing materials
provide a buffer between
operations. It facilitates the efficient use of people and
machines and provides an efficient
organization of materials. The considerations for material
system design include the size,
weight, condition and stack ability of materials; the required
throughput; and building
constraints such as floor loading, floor condition, column
spacing etc. The protection of
materials include both packaging and protecting against damage

and theft of material as
well as the use of safeguards on the information system to
include protection against the
material being mishandled, misplaced, misappropriated and
processed in a wrong
sequence. Controlling material includes both physical control as
well as status of material
control. Physical control is the orientation of sequence and
space between material
movements. Status control is the real time awareness of the
location, amount, destination,
origin, ownership and schedule of material. Maintaining the
correct degree of control is a
challenge because the right amount of control depends upon the
culture of the organization
and the people who manage and perform material handling
functions.
Material handling is an important area of concern in flexible
manufacturing systems because
more than 80 % of time that material spends on a shop floor is
spent either in waiting or in
transportation, although both these activities are non-value
added activities. Efficient
material handling is needed for less congestion, timely delivery
and reduced idle time of
machines due to non-availability or accumulation of materials at
workstations. Safe
handling of materials is important in a plant as it reduces
wastage, breakage, loss and
scrapes etc.
6
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Future Manufacturing Systems122
2. Principles of material handlings
provide guidance to material handling system designers. The
following is a brief description
of material handling principles.
2.1 Planning principle
All material handling should be the result of a deliberate plan
where the needs, performance
objectives and functional specification of the proposed methods
are completely defined at
the outset. In its simplest form a material handing plan defines
the material (what) and the
moves (when and where); together they define the method (how
and who).
Standardize handling methods and equipments wherever
possible. Material handling
methods, equipment, controls and software should be
standardized within the limits of
achieving overall performance objectives and without
sacrificing needed flexibility,
modularity and throughout anticipation of changing future
requirements.

Human capabilities and limitations must be recognized and
respected in the design of
material handling tasks and equipment to ensure safe and
effective operations. Equipments
should be selected that eliminates repetitive and strenuous
manual labor and which
effectively interacts with human operators and users.
Use methods and equipments that can perform a variety of tasks
under varying operating
conditions.
2.5 Simplification
Simplify material handling by eliminating, reducing or
combining unnecessary movements
and equipments.
2.6 Gravity
Utilize gravity to move material wherever possible.
2.7 Layout
Prepare an operation sequence and equipment layout for all
viable system solutions and
then select the best possible configuration.
2.8 Cost
Compare the economic justification of alternate solutions with
equipment and methods on
the basis of economic effectiveness as measured by expenses
per unit handled.

2.9 Maintenance
Prepare a plan for preventive maintenance and scheduled repairs
on all material handling
equipments.
A unit load is one that can be stored or moved as a single entity
at one time, such as a pallet,
container or tote, regardless of the number of individual items
that make up the load. Unit
loads shall be appropriately sized and configured in a way
which achieves the material flow
and inventory objectives at each stage in the supply chain.
Effective and efficient use must be made of all available space.
In work areas, cluttered and
unorganized spaces and blocked aisles should be eliminated.
When transporting loads
within a facility, the use of overhead space should be
considered as an option.
Material movement and storage activities should be fully
integrated to form a coordinated,
operational system which spans receiving, inspection, storage,
production, assembly,
packaging, unitizing, order selection, shipping, transportation
and the handling of returns.
Systems integration should encompass the entire supply chain
including reverse logistics. It
should include suppliers, manufacturers, distributors and

customers.
Material handling operations should be mechanized and/or
automated where feasible to
improve operational efficiency, increase responsiveness, and
improve consistency and
predictability.
Environmental impact and energy consumption should be
considered as criteria when
designing or selecting alternative equipment and material
handling systems.
A thorough economic analysis should account for the entire life
cycle of all material
handling equipment and resulting systems. Life cycle costs
include capital investment,
installation, setup and equipment programming, training, system
testing and acceptance,
operating (labor, utilities, etc.), maintenance and repair, reuse
value, and ultimate disposal
3. Material Transport Equipment
equipment as (1) conveyor, (2)
cranes, elevators, and hoists, (3) positioning, weighing, and
control equipment, (4) industrial
vehicles, (5) motor vehicles, (6) railroad cars, (7) marine

carriers, (8) aircraft, and (9)
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2. Principles of material handlings
provide guidance to material handling system designers. The
following is a brief description
of material handling principles.
2.1 Planning principle
All material handling should be the result of a deliberate plan
where the needs, performance
objectives and functional specification of the proposed methods
are completely defined at
the outset. In its simplest form a material handing plan defines
the material (what) and the
moves (when and where); together they define the method (how
and who).
Standardize handling methods and equipments wherever
possible. Material handling
methods, equipment, controls and software should be
standardized within the limits of
achieving overall performance objectives and without
sacrificing needed flexibility,
modularity and throughout anticipation of changing future

requirements.
Human capabilities and limitations must be recognized and
respected in the design of
material handling tasks and equipment to ensure safe and
effective operations. Equipments
should be selected that eliminates repetitive and strenuous
manual labor and which
effectively interacts with human operators and users.
Use methods and equipments that can perform a variety of tasks
under varying operating
conditions.
2.5 Simplification
Simplify material handling by eliminating, reducing or
combining unnecessary movements
and equipments.
2.6 Gravity
Utilize gravity to move material wherever possible.
2.7 Layout
Prepare an operation sequence and equipment layout for all
viable system solutions and
then select the best possible configuration.
2.8 Cost

Compare the economic justification of alternate solutions with
equipment and methods on
the basis of economic effectiveness as measured by expenses
per unit handled.
2.9 Maintenance
Prepare a plan for preventive maintenance and scheduled repairs
on all material handling
equipments.
A unit load is one that can be stored or moved as a single entity
at one time, such as a pallet,
container or tote, regardless of the number of individual items
that make up the load. Unit
loads shall be appropriately sized and configured in a way
which achieves the material flow
and inventory objectives at each stage in the supply chain.
Effective and efficient use must be made of all available space.
In work areas, cluttered and
unorganized spaces and blocked aisles should be eliminated.
When transporting loads
within a facility, the use of overhead space should be
considered as an option.
Material movement and storage activities should be fully
integrated to form a coordinated,
operational system which spans receiving, inspection, storage,
production, assembly,
packaging, unitizing, order selection, shipping, transportation

and the handling of returns.
Systems integration should encompass the entire supply chain
including reverse logistics. It
should include suppliers, manufacturers, distributors and
customers.
Material handling operations should be mechanized and/or
automated where feasible to
improve operational efficiency, increase responsiveness, and
improve consistency and
predictability.
Environmental impact and energy consumption should be
considered as criteria when
designing or selecting alternative equipment and material
handling systems.
A thorough economic analysis should account for the entire life
cycle of all material
handling equipment and resulting systems. Life cycle costs
include capital investment,
installation, setup and equipment programming, training, system
testing and acceptance,
operating (labor, utilities, etc.), maintenance and repair, reuse
value, and ultimate disposal
3. Material Transport Equipment

equipment as (1) conveyor, (2)
cranes, elevators, and hoists, (3) positioning, weighing, and
control equipment, (4) industrial
vehicles, (5) motor vehicles, (6) railroad cars, (7) marine
carriers, (8) aircraft, and (9)
www.intechopen.com
containers and supports. The following provides the details of
material transport
equipments.
A Conveyor is used when a material is moved very frequently
between specific points and
the path between points is fixed. Conveyors combined with
modern identification and
recognition systems like bar code technologies have played a
significant role in the
transportation and sorting of a large variety of products in
modern warehouses. Some of the
common types of conveyors are:
te- wheel conveyor
- floor towline conveyor
-on-track conveyor

In roller conveyors, the pathway consists of a series of rollers
that are perpendicular to the
direction of travel. Loads must possess a flat bottom to span
several rollers which can be
either powered or non-powered. Powered rollers rotate to drive
the loads forward in roller
conveyor. The following figure shows a roller conveyor.
Fig. 1. Roller conveyor
Skate-wheel conveyors are similar in operation to roller
conveyor but use skate wheels
instead of rollers and are generally lighter weight and non-
powered. Sometimes, these are
built as portable units that can be used for loading and
unloading truck trailers in shipping
and receiving. Figure 2 shows a skate-wheel roller.
Fig. 2. Skate-wheel conveyor
3.1.3 Belt Conveyor
A belt conveyor is a continuous loop with forward path to move
loads in which the belt is
made of reinforced elastomeric support slider or rollers used to
support forward loop. There
are two common forms:
-shaped for bulk materials

Fig. 3. Belt conveyor
3.1.4 In-Floor Tow-Line Conveyor
These are four-wheel carts powered by moving chains or cables
in trenches in the floor.
Carts use steel pins (or grippers) to project below floor level
and engage the chain (or
pulley) for towing. This allows carts to be disengaged from
towline for loading and
unloading purpose as is shown in Figure 4.
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containers and supports. The following provides the details of
material transport
equipments.
A Conveyor is used when a material is moved very frequently
between specific points and
the path between points is fixed. Conveyors combined with
modern identification and
recognition systems like bar code technologies have played a
significant role in the
transportation and sorting of a large variety of products in
modern warehouses. Some of the

common types of conveyors are:
- wheel conveyor
- floor towline conveyor
-on-track conveyor
In roller conveyors, the pathway consists of a series of rollers
that are perpendicular to the
direction of travel. Loads must possess a flat bottom to span
several rollers which can be
either powered or non-powered. Powered rollers rotate to drive
the loads forward in roller
conveyor. The following figure shows a roller conveyor.
Fig. 1. Roller conveyor
Skate-wheel conveyors are similar in operation to roller
conveyor but use skate wheels
instead of rollers and are generally lighter weight and non-
powered. Sometimes, these are
built as portable units that can be used for loading and
unloading truck trailers in shipping
and receiving. Figure 2 shows a skate-wheel roller.
Fig. 2. Skate-wheel conveyor

3.1.3 Belt Conveyor
A belt conveyor is a continuous loop with forward path to move
loads in which the belt is
made of reinforced elastomeric support slider or rollers used to
support forward loop. There
are two common forms:
-shaped for bulk materials
Fig. 3. Belt conveyor
3.1.4 In-Floor Tow-Line Conveyor
These are four-wheel carts powered by moving chains or cables
in trenches in the floor.
Carts use steel pins (or grippers) to project below floor level
and engage the chain (or
pulley) for towing. This allows carts to be disengaged from
towline for loading and
unloading purpose as is shown in Figure 4.
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3.1.5 Overhead Trolley Conveyor
A trolley is a wheeled carriage running on an overhead track
from which loads can be
suspended. Trolleys are connected and moved by a chain or
cable that forms a complete
loop and are often used to move parts and assemblies between
major production areas.
Figure 5 shows an overhead trolley conveyor.
Carts ride on a track above floor level and are driven by a
spinning tube. The forward
motion of cart is controlled by a drive wheel whose angle can
be changed from zero (idle) to
45 degrees (forward). It is shown in the following figure.
Fig. 6. Cart-on-track coveyor.
Cranes are normally used for transferring materials with some
considerable size and weight
and for intermittent flow of material. In general, loads handled
by cranes are more varied
with respect to their shape and weight than those handled by a
conveyor. Hoists are
frequently attached to cranes for vertical translation that is,
lifting and lowering of loads.
They can be operated manually, electrically, or pneumatically.
Cranes usually include hoists

so that the crane-and-hoist combination provides
This class of material handling equipments can typically lift &
move a material up to 100
tons. A hoist consists of one or more fixed pulley & one or
more rotatable pulley & a hook to
attach load with it. The number of pulleys in hoist determines
its mechanical advantage
which is the ratio of load lifted & deriving force. Hoist with
mechanical advantage of four
are shown below:
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3.1.5 Overhead Trolley Conveyor
A trolley is a wheeled carriage running on an overhead track
from which loads can be
suspended. Trolleys are connected and moved by a chain or
cable that forms a complete
loop and are often used to move parts and assemblies between
major production areas.
Figure 5 shows an overhead trolley conveyor.

Carts ride on a track above floor level and are driven by a
spinning tube. The forward
motion of cart is controlled by a drive wheel whose angle can
be changed from zero (idle) to
45 degrees (forward). It is shown in the following figure.
Fig. 6. Cart-on-track coveyor.
Cranes are normally used for transferring materials with some
considerable size and weight
and for intermittent flow of material. In general, loads handled
by cranes are more varied
with respect to their shape and weight than those handled by a
conveyor. Hoists are
frequently attached to cranes for vertical translation that is,
lifting and lowering of loads.
They can be operated manually, electrically, or pneumatically.
Cranes usually include hoists
so that the crane-and-hoist combination provides
This class of material handling equipments can typically lift &
move a material up to 100
tons. A hoist consists of one or more fixed pulley & one or
more rotatable pulley & a hook to
attach load with it. The number of pulleys in hoist determines
its mechanical advantage

which is the ratio of load lifted & deriving force. Hoist with
mechanical advantage of four
are shown below:
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Fig. 7. (a) Sketch of the hoist (b) diagram to
illustrate mechanical advantage
There are different types of cranes that are used in industrial
applications. Some of these are
discussed below.
3.2.1 Bridge Crane
A bridge crane consist of one or two horizontal girder or beam
suspended between fixed rail
on either end which are connected to the structure of building.
The hoist trolley can be
moved along the length of bridge & bridge can be moved the
length of rail in building.
These two capabilities provide motion along X-axis & Y-axis
whereas hoist can provide
motion in the z-axis. Their application includes heavy
machinery fabrication. They have
ability to carry load up to 100 tons.
Fig. 8. Bridge crane

3.2.2 Half-gantry crane
Half gantry crane is distinguished from bridge crane by the
presence of one or two vertical
supporting elements which support horizontal girder. Gantry
cranes may be half or
double.Half gantry has one supporting vertical element whereas
double gantry crane has
two vertical supporting legs.
3.2.3 Jib Crane
Jib cranes consist of a rotating arm with a hoist that runs along
its length. The arm usually
revolves on an axis which can be a fixed, ground-mounted post,
or can be a wall or ceiling-
mounted pin.
Fig. 10. Jib Crane
Wall-bracket mounted jib cranes are usually the least expensive
jib cranes, but they require
the most headroom and exert more force on their mounting wall.
Cantilever jib cranes place
the arm at the top, allowing for maximum lift when used in
situations with limited
headroom. They also exert less force on the wall on which
they're mounted. Tie rod jib
cranes make use of a tie rod between the arm and the mounting
area. More inexpensive jib

cranes feature manually operated chain hoists, while
sophisticated cranes use an electric
chain hoist. Jib cranes are used when the desired lifting area
resides within a (semi-
)circular arc.
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Fig. 7. (a) Sketch of the hoist (b) diagram to
illustrate mechanical advantage
There are different types of cranes that are used in industrial
applications. Some of these are
discussed below.
3.2.1 Bridge Crane
A bridge crane consist of one or two horizontal girder or beam
suspended between fixed rail
on either end which are connected to the structure of building.
The hoist trolley can be
moved along the length of bridge & bridge can be moved the
length of rail in building.
These two capabilities provide motion along X-axis & Y-axis
whereas hoist can provide
motion in the z-axis. Their application includes heavy
machinery fabrication. They have
ability to carry load up to 100 tons.

Fig. 8. Bridge crane
3.2.2 Half-gantry crane
Half gantry crane is distinguished from bridge crane by the
presence of one or two vertical
supporting elements which support horizontal girder. Gantry
cranes may be half or
double.Half gantry has one supporting vertical element whereas
double gantry crane has
two vertical supporting legs.
3.2.3 Jib Crane
Jib cranes consist of a rotating arm with a hoist that runs along
its length. The arm usually
revolves on an axis which can be a fixed, ground-mounted post,
or can be a wall or ceiling-
mounted pin.
Fig. 10. Jib Crane
Wall-bracket mounted jib cranes are usually the least expensive
jib cranes, but they require
the most headroom and exert more force on their mounting wall.
Cantilever jib cranes place
the arm at the top, allowing for maximum lift when used in
situations with limited
headroom. They also exert less force on the wall on which
they're mounted. Tie rod jib

cranes make use of a tie rod between the arm and the mounting
area. More inexpensive jib
cranes feature manually operated chain hoists, while
sophisticated cranes use an electric
chain hoist. Jib cranes are used when the desired lifting area
resides within a (semi-
)circular arc.
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3.2.4 Stacker Crane
It is similar to a bridge crane. The major difference is that,
instead of using a hoist, the
stacker crane uses a mast with forks or a platform to handle unit
loads. Stacker cranes are
generally used for storing and retrieving unit loads in storage
racks, especially in high-rise
applications.
4. Automated Retrieval and storage equipments
and drawers. Among these,
storage rack is probably the most common form of storage
equipment. There are numerous
variants and configurations of storage racks, which include
single-deep, double-deep rack,
cantilever rack etc. and configurations that are designed to
facilitate specific storage and
retrieval operations drive-through, flow-through etc. More
sophisticated retrieval and

storage system combine the use of storage equipment, storing
and retrieval machines and
control that are manifested in a modern automated storage/
retrieval system.
5. Automated Guided Vehicles
An Automated Guided Vehicle System (AGVS) is a material
handling system that uses
independently operated, self-propelled vehicles guided along
defined pathways in the
facility floor. It is an automated material handling system which
moves along predefined
and preprogrammed path along an aisle from one station to
another. The main parts of an
AGV include structure, drive system, steering mechanism,
power source (battery) and
onboard computer for control.
5.1 Types of AGV
The following are common types of AGVs.
These are the first type of AGVS to be introduced around
1954.Its typical application is
moving heavy payloads over long distances in warehouses and
factories without
intermediate stops along the route
Fig. 11. Driverless automated guided vehicle

These are used to move palletized loads along predetermined
routes. Vehicle is backed into
loaded pallet by worker; pallet is then elevated from floor.
Worker drives pallet truck to
AGV guide path and programs destination.
Fig. 12. AGV pallet truck
These are used to move unit loads from station to station and
are often equipped for
automatic loading/unloading of pallets using roller conveyors,
moving belts, or mechanized
lift platforms.
www.intechopen.com
3.2.4 Stacker Crane
It is similar to a bridge crane. The major difference is that,
instead of using a hoist, the
stacker crane uses a mast with forks or a platform to handle unit
loads. Stacker cranes are
generally used for storing and retrieving unit loads in storage
racks, especially in high-rise
applications.
4. Automated Retrieval and storage equipments

and drawers. Among these,
storage rack is probably the most common form of storage
equipment. There are numerous
variants and configurations of storage racks, which include
single-deep, double-deep rack,
cantilever rack etc. and configurations that are designed to
facilitate specific storage and
retrieval operations drive-through, flow-through etc. More
sophisticated retrieval and
storage system combine the use of storage equipment, storing
and retrieval machines and
control that are manifested in a modern automated storage/
retrieval system.
5. Automated Guided Vehicles
An Automated Guided Vehicle System (AGVS) is a material
handling system that uses
independently operated, self-propelled vehicles guided along
defined pathways in the
facility floor. It is an automated material handling system which
moves along predefined
and preprogrammed path along an aisle from one station to
another. The main parts of an
AGV include structure, drive system, steering mechanism,
power source (battery) and
onboard computer for control.
5.1 Types of AGV
The following are common types of AGVs.

These are the first type of AGVS to be introduced around
1954.Its typical application is
moving heavy payloads over long distances in warehouses and
factories without
intermediate stops along the route
Fig. 11. Driverless automated guided vehicle
These are used to move palletized loads along predetermined
routes. Vehicle is backed into
loaded pallet by worker; pallet is then elevated from floor.
Worker drives pallet truck to
AGV guide path and programs destination.
Fig. 12. AGV pallet truck
These are used to move unit loads from station to station and
are often equipped for
automatic loading/unloading of pallets using roller conveyors,
moving belts, or mechanized
lift platforms.
www.intechopen.com

Fig. 13. Unit load carrier
It can be applied for smaller loads. These are typically used in
electronics assembly and
office environments as mail and snack carriers.
5.1.5 Assembly AGV
These are used as assembly platforms, for example car chassis,
engines etc., by carrying
products and transport them through assembly stations.
5.1.6 Forklift AGV
It has the ability to pick up and drop off palletized loads both at
floor level and on stands.
Generally, these fork lift AGVs have sensors on forks for pallet
interfacing.
These are self-propelled vehicles that ride on a fixed-rail
system. These vehicles operate
independently and are driven by electric motors that pick up
power from an electrified rail.
Fixed rail system may be:
i. Overhead monorail - suspended overhead from the ceiling
ii. On-floor - parallel fixed rails, tracks generally protrude up
from the floor

Fig. 14. Rail guided vehicle
AGVS is a complex system and a number of parameters need to
be considered which
include:
Guide-path layout
Number of AGVs required
Operational and transportation control
The guide-path layout defines the possible vehicle movement
path. Links and nodes that
represent the action points such as pick-up and drop-off points,
maintenance areas and
intersections represent the path. The guide-path can be divided
into four types:
1. Unidirectional single lane guide-path
2. Bi-directional single lane guide-path
3. Multiple lanes
4. Mixed guide-path.
Generally bidirectional single lane is considered the most cost
effective and widely used
layout.
It is important to estimate the optimum number of AGVs
required for a system as too many
AGVs will congest the traffic while too few means larger idle
time for workstations in a
system. Generally, the number of AGVs required is the sum of
the total loaded and empty

travel time and waiting time of the AGVs divided by the time an
AGV is available.
5.2.3 Operational and Transportation Control
The operation and transportation consists of vehicle
dispatching, vehicle routing and traffic
control issues. Once a demand arises for an AGV, a choice
needs to be made regarding the
vehicle to be dispatched among the pool of vehicles available.
In an event when several
workstations need servicing, a choice is to be made as to which
workstation is to be
serviced. The selection criteria can be applied for assigning the
vehicles or workstations
based on one or a combination of the following:
A random vehicle
Longest idle vehicle
Nearest vehicle
Farthest vehicle
Least utilized vehicle
Random workstation
Nearest workstation
Farthest workstation
Maximum queue size
Minimum remaining queue size
First come fist served
Unit load arrival time, due time or priority.
In order to dispatch an AGV to any workstation, it is necessary
to find the shortest feasible
path from the existing position. While selecting the shortest
path it is necessary to consider
www.intechopen.com

Fig. 13. Unit load carrier
It can be applied for smaller loads. These are typically used in
electronics assembly and
office environments as mail and snack carriers.
5.1.5 Assembly AGV
These are used as assembly platforms, for example car chassis,
engines etc., by carrying
products and transport them through assembly stations.
5.1.6 Forklift AGV
It has the ability to pick up and drop off palletized loads both at
floor level and on stands.
Generally, these fork lift AGVs have sensors on forks for pallet
interfacing.
These are self-propelled vehicles that ride on a fixed-rail
system. These vehicles operate
independently and are driven by electric motors that pick up
power from an electrified rail.
Fixed rail system may be:
i. Overhead monorail - suspended overhead from the ceiling
ii. On-floor - parallel fixed rails, tracks generally protrude up
from the floor

Fig. 14. Rail guided vehicle
AGVS is a complex system and a number of parameters need to
be considered which
include:
Guide-path layout
Number of AGVs required
Operational and transportation control
The guide-path layout defines the possible vehicle movement
path. Links and nodes that
represent the action points such as pick-up and drop-off points,
maintenance areas and
intersections represent the path. The guide-path can be divided
into four types:
1. Unidirectional single lane guide-path
2. Bi-directional single lane guide-path
3. Multiple lanes
4. Mixed guide-path.
Generally bidirectional single lane is considered the most cost
effective and widely used
layout.
It is important to estimate the optimum number of AGVs
required for a system as too many
AGVs will congest the traffic while too few means larger idle

time for workstations in a
system. Generally, the number of AGVs required is the sum of
the total loaded and empty
travel time and waiting time of the AGVs divided by the time an
AGV is available.
5.2.3 Operational and Transportation Control
The operation and transportation consists of vehicle
dispatching, vehicle routing and traffic
control issues. Once a demand arises for an AGV, a choice
needs to be made regarding the
vehicle to be dispatched among the pool of vehicles available.
In an event when several
workstations need servicing, a choice is to be made as to which
workstation is to be
serviced. The selection criteria can be applied for assigning the
vehicles or workstations
based on one or a combination of the following:
A random vehicle
Longest idle vehicle
Nearest vehicle
Farthest vehicle
Least utilized vehicle
Random workstation
Nearest workstation
Farthest workstation
Maximum queue size
Minimum remaining queue size
First come fist served
Unit load arrival time, due time or priority.
In order to dispatch an AGV to any workstation, it is necessary
to find the shortest feasible
path from the existing position. While selecting the shortest
path it is necessary to consider

www.intechopen.com
only those paths which are free and not occupied by vehicles. It
may also be necessary to
consider the future positions of the vehicles in the route in
addition to their current occupied
positions. In identifying the traffic control systems for AGVs
movement, the approaches that
can be used are forward sensing control, zone sensing control
and combinatorial control. In
forward sensing control, an AGV is equipped with obstruction
detecting sensors that can
identify another AGV in front of it and slow down or stop. This
helps in improving the AGV
utilization due to closer allowable distance between vehicles.
However, this approach may
not be able to detect the obstacles at intersections and around
corners. This is generally
useful for long and straight path which is divided into zones.
Once an AGV enters a zone, it
becomes unavailable for other AGVs which may introduce
system inefficiency. The main
advantages derived from the use of AGVs in manufacturing
environment are:
Dispatching, tracking and monitoring under real time control
which help in planned
delivery.
Better resource utilization as AGVs can be economically
justified.
Increased control over material flow and movement
Reduced product damage and routing flexibility
Increased throughput because of dependable on-time delivery.

6. Industrial Robots
Industrial robots are very useful material handling devices in an
automated environment.
An industrial robot is a reprogrammable multifunctional
manipulator designed to move
materials, parts, tools, or other devices by means of variable
programmed motions and to
perform a variety of other tasks. It is also defined as a machine
formed by a mechanism
including several degrees of freedom often having the
appearance of one or several arms
ending in a wrist capable of holding a job, tool and inspection
device. It is automatically
controlled, reprogrammable, multipurpose manipulative
machine with several
reprogrammable axes which is either fixed in place or mobile
for use in industrial
automation applications.
The following are basic components of an industrial robot.
6.1.1 Manipulator
human arm and hand. The
end of wrist can reach a point in space having a specific set of
coordinates in specific
orientation.
6.1.2 End effector

It is attached with the end of wrist in a robot. It is a special
purpose tooling which enables
the robot to perform a particular job. Depending on the type of
work, end effector may be
equipped with any of the following:
a) Grippers, hooks, vacuum cups, and adhesive fingers for
material handling
b) Spray guns for painting
c) Attachments for different kinds of welding processes.
It is a brain of a robot which gives commands for the
movements of the robot. It stores the
data to initiate and terminate movements of the manipulator. It
interfaces with the
computers and other equipments such as manufacturing cells or
assembly operations.
6.1.4 Power supply
It supplies the power to the controller and manipulator. Each
motion of manipulator is
controlled and regulated by actuators that use an electrical,
pneumatic or hydraulic power.
6.2 Robot Types
Robots are generally classified as Cartesian or rectilinear,
cylindrical, polar or spherical
jointed arms. They are also classified, from material handling
point of view, as under:

specific operation. Its
movements are from point to point and cycle is repeated. These
robots are simple and
inexpensive and are used to pick and place materials.
This robot learns the work and motions from operator who leads
the playback robot and its
end effector through the desired path. The robot memorizes and
records the path and
sequence of motions and can repeat them continuously without
any further action or
guidance by the operator.
numerical control machines. The
robot is servo controlled by digital data and its sequence of
movements can be changed with
relative ease.
It is capable of performing some of the functions and tasks
carried out by humans and is
equipped with a variety of sensors with usual and tactile
capabilities. It can perform tasks
such as moving among a variety of machines on a shop floor
avoiding collisions. It can
recognize, select and properly grip the correct work piece.
6.3 Robot applications in Material handling
The major applications in material handling include:

1. Industrial robots are used to load/ unload materials during
operations.
2. These are used to transfer the material from one conveyor to
another.
3. These are used in palletizing and de-palletizing in such a way
that parts/ materials are
taken from conveyor and are loaded on to a pallet in a desired
pattern and sequence
and vice-versa.
4. These are very effective in automated assembly where
repetitive work is required.
www.intechopen.com
only those paths which are free and not occupied by vehicles. It
may also be necessary to
consider the future positions of the vehicles in the route in
addition to their current occupied
positions. In identifying the traffic control systems for AGVs
movement, the approaches that
can be used are forward sensing control, zone sensing control
and combinatorial control. In
forward sensing control, an AGV is equipped with obstruction
detecting sensors that can
identify another AGV in front of it and slow down or stop. This
helps in improving the AGV
utilization due to closer allowable distance between vehicles.
However, this approach may
not be able to detect the obstacles at intersections and around
corners. This is generally

useful for long and straight path which is divided into zones.
Once an AGV enters a zone, it
becomes unavailable for other AGVs which may introduce
system inefficiency. The main
advantages derived from the use of AGVs in manufacturing
environment are:
Dispatching, tracking and monitoring under real time control
which help in planned
delivery.
Better resource utilization as AGVs can be economically
justified.
Increased control over material flow and movement
Reduced product damage and routing flexibility
Increased throughput because of dependable on-time delivery.
6. Industrial Robots
Industrial robots are very useful material handling devi ces in an
automated environment.
An industrial robot is a reprogrammable multifunctional
manipulator designed to move
materials, parts, tools, or other devices by means of variable
programmed motions and to
perform a variety of other tasks. It is also defined as a machine
formed by a mechanism
including several degrees of freedom often having the
appearance of one or several arms
ending in a wrist capable of holding a job, tool and inspection
device. It is automatically
controlled, reprogrammable, multipurpose manipulative
machine with several
reprogrammable axes which is either fixed in place or mobile
for use in industrial
automation applications.

The following are basic components of an industrial robot.
6.1.1 Manipulator
human arm and hand. The
end of wrist can reach a point in space having a specific set of
coordinates in specific
orientation.
6.1.2 End effector
It is attached with the end of wrist in a robot. It is a special
purpose tooling which enables
the robot to perform a particular job. Depending on the type of
work, end effector may be
equipped with any of the following:
a) Grippers, hooks, vacuum cups, and adhesive fingers for
material handling
b) Spray guns for painting
c) Attachments for different kinds of welding processes.
It is a brain of a robot which gives commands for the
movements of the robot. It stores the
data to initiate and terminate movements of the manipulator. It
interfaces with the
computers and other equipments such as manufacturing cells or
assembly operations.
6.1.4 Power supply
It supplies the power to the controller and manipulator. Each

motion of manipulator is
controlled and regulated by actuators that use an electrical,
pneumatic or hydraulic power.
6.2 Robot Types
Robots are generally classified as Cartesian or rectilinear,
cylindrical, polar or spherical
jointed arms. They are also classified, from material handling
point of view, as under:
specific operation. Its
movements are from point to point and cycle is repeated. These
robots are simple and
inexpensive and are used to pick and place materials.
This robot learns the work and motions from operator who leads
the playback robot and its
end effector through the desired path. The robot memorizes and
records the path and
sequence of motions and can repeat them continuously without
any further action or
guidance by the operator.
numerical control machines. The
robot is servo controlled by digital data and its sequence of
movements can be changed with
relative ease.

It is capable of performing some of the functions and tasks
carried out by humans and is
equipped with a variety of sensors with usual and tactile
capabilities. It can perform tasks
such as moving among a variety of machines on a shop floor
avoiding collisions. It can
recognize, select and properly grip the correct work piece.
6.3 Robot applications in Material handling
The major applications in material handling include:
1. Industrial robots are used to load/ unload materials during
operations.
2. These are used to transfer the material from one conveyor to
another.
3. These are used in palletizing and de-palletizing in such a way
that parts/ materials are
taken from conveyor and are loaded on to a pallet in a desired
pattern and sequence
and vice-versa.
4. These are very effective in automated assembly where
repetitive work is required.
www.intechopen.com
5. Intelligent robots can be used to automatically pick the right
work piece without

interference of operator and hence improves quality and pace of
work.
7. References
M.P. Groover. “Automation, Production systems and computer
integrated manufacturing”
Second edition. Pearson-Prentice Hall, 2008.
K. Sareen and C. Grewal.”CAD/CAM: Theory and concepts” S.
Chand & Co. 2009.
C. R. Alavala. “ CAD/CAM: Concepts and applications”
Prentice-Hall, 2008.
P. N. Rao. “ CAD/CAM: Principles and applications” McGraw -
Hill, 2004.
C. R. Asfahl. “Robots and manufacturing automation” Second
edition, John-Wiley and
sons.1992.
M. P. Groover and E. W. Zimmers. Jr. “ CAD/CAM: Computer
added design and
manufacturing” Pearson-Prentice Hall, 2009.
G. Chryssolouris, “Manufacturing systems: Theory and
Practice” Springer-Verlag,1992.
www.intechopen.com
Future Manufacturing Systems
Edited by Tauseef Aized
ISBN 978-953-307-128-2
Hard cover, 268 pages

Publisher Sciyo
Published online 17, August, 2010
Published in print edition August, 2010
InTech Europe
University Campus STeP Ri
Slavka Krautzeka 83/A
51000 Rijeka, Croatia
Phone: +385 (51) 770 447
Fax: +385 (51) 686 166
www.intechopen.com
InTech China
Unit 405, Office Block, Hotel Equatorial Shanghai
No.65, Yan An Road (West), Shanghai, 200040, China
Phone: +86-21-62489820
Fax: +86-21-62489821
This book is a collection of articles aimed at finding new ways
of manufacturing systems developments. The
articles included in this volume comprise of current and new
directions of manufacturing systems which I
believe can lead to the development of more comprehensive and
efficient future manufacturing systems.
People from diverse background like academia, industry,
research and others can take advantage of this
volume and can shape future directions of manufacturing
systems.
How to reference
In order to correctly reference this scholarly work, feel free to
copy and paste the following:
Tauseef Aized (2010). Material Handling in Flexible
Manufacturing System, Future Manufacturing Systems,

Tauseef Aized (Ed.), ISBN: 978-953-307-128-2, InTech,
Available from:
http://www.intechopen.com/books/future-manufacturing-
systems/material-handling-in-flexible-manufacturing-
system

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