Industrial Automation

2. Material Handling
“ the movement, storage, protection & control of material
through out the manufacturing and distribution process
including their consumption and disposal ”
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 2

3. Material Handling System
Handling of material should be performed
 Safely
Efficiently
At low cost
In timely manner
Accurately ( right material in the right quantities to the
right location in right time )
 Without Damage
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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4. Material Handling System
 Cost of material handling is a significant portion of
total production cost
 Estimate average around 20-25% of total
manufacturing labor cost (in USA)
The proportion of total cost varies , depending on
the type of production and
degree of automation in the material handling function
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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5. Material Handling System
 Material handling is an important activity within the
larger system.
 LOGISTICS : concerned with
 Acquisition
 Movement
 Storage
 Distribution of materials and products
As well as planning and control of these operations in
order to satisfy customer demand.
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 5

6. LOGISTICS
 External Logistics
 Concern with transportation and related activities that occur
outside of a facility.
 Involve movement of material between different geographical
locations.
 Examples?????
 Internal Logistics
 Popularly known as material handling,
 Involve movement and storage of materials inside a given
facility.
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 6

7. Mr. Rahul Bhardwaj, Assistant Professor, MED, BUEST
External Logistics
7

8. Internal Logistics
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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9. Categories of
Material Handling Equipment
 Material Transport Equipment
 Storage system
Unitizing Equipment
Identification and Tracking Systems
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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10. Material Handling Equipment
 Used to move materials inside a factory, warehouse, or
other facility
Five main types of equipment are:
1. Industrial Trucks
2. Automated Guided Vehicles
3. Rail guided vehicles
4. Conveyors &
5. Hoists and cranes
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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11. Storage System
 Work in process and finished products likely to spend
some time in ware house or distribution center before
being delivered to the final customer.
Conventional storage methods ( bulk storage, rack
systems, shelving, bins and drawer storage )
 Automated storage systems ( AS/RS system and
Carousel Systems )
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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12. Unitizing Equipment
 Containers used to hold individual items during
handling and equipment used to load and package the
containers. Containers include pallets, boxes, baskets,
barrels, pails, and drums
 Containers include pallets, boxes, baskets, barrels and
drums etc.
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 12

13. Design Considerations in Material
Handling
Material handling equipment is usually assembled into a system. The system
must be specified and configured to satisfy the requirement of a particular
application.
The following factors influence the design of the material handling system.
1. Material Characteristics:
Category Measures
Physical state Solid, gas, fluid
Size Volume, length, width, height
Weight Weight per piece, weight per volume
Shape Long and flat, round, square
Condition Hot, wet, dirty
Risk of damage Fragile, brittle
Safety risk Explosive, flammable, toxic, corrosive
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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14. Design Considerations in Material
Handling
2. Flow Rate, Routing and
Scheduling:
Flow rate means the amount of material to
be moved per unit time. (pcs/hr, loads/hr,
tons/hr, ft3 /day)
If a large amount of material is to be
handled, then a dedicated system is to
be used.
If a quantity is small but different
types of material are to be handled,
then material handling system must be
designed such.
Routing factors include pick up and
drop off locations, move distances,
routing variations and conditions along
the route.
Handling cost is directly related to the
distance of the move.
Scheduling relates to timing of each
individual delivery.
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST
• Prompt delivery when required
• Use of buffer stocks to mitigate
against late deliveries
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15. Design Considerations in Material
Handling
3. Plant Layout
Process layout Hand trucks and fork lift trucks are
commonly used. These days application
of AGVS is growing in such applications.
Product layout Conveyor systems are mostly used in this
type of layout
Fixed Position
Layout
Cranes, hoists and trucks are commonly
used.
When a new facility is being planned, the design
of the handling system should be considered part
of the layout
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 15

16. Design Considerations in Material
Handling
A unit load is simply the mass that is to be moved or handled at one
time. It can be a one part, a container loaded with multiple parts or
pallet loaded with multiple containers of parts
3. Unit Load Principle
The reasons for using unit load principle are:
 Multiple items can be handled simultaneously.
 Required numbers of trips are reduced.
 Loading and unloading time is reduced.
 Product damage is reduced.
 Lower cost and higher operating efficiency.Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 16

17. Unit Load Containers
(a) Wooden pallet, (b) pallet box, (c) tote box
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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18. MATERIAL TRANSPORT
EQUIPMENT
There are five categories of material transport equipment commonly used
 Industrial Trucks
 AGVS
 Monorails and other rail-guided vehicles
 Conveyors
 Cranes and hoists
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 18

19. Summary and Features of these
five categories of Material
Handling Equipment
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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20. Industrial Trucks
Divided into two categories
 Nonpowered
 Powered
Also referred to as hand trucks as they
are pushed or pulled by human workers.
Quantities moved are low and distance
moved is small.
They are self-propelled to relieve
the worker of having to move the
truck manually.
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 20

21. Nonpowered
TWO WHEEL HAND TRUCK HAND OPERATED LOW LIFT PALLET TRUCKS
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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FOUR-WHEEL DOLLY
21

22. Powered
WALKIE TRUCK
FORKLIFT TRUCK
TOWING TRACTOR
They are battery operated. Speed is limited to 5 km/hr
Have cab for the worker to sit in and drive. Load carrying capacity is 450 kg to
4500 kg. Are IC engines or electric motor driven.
Used for moving large amount of material between major collection and
distribution areas. Are IC engines or electric motor driven.
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 22

23. Powered Trucks: Walkie Truck
 Wheeled forks insert into pallet openings
 No provision for riding; truck is steered by worker
using control handle at front of vehicle
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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24. Powered Trucks: Forklift Truck
 Widely used in factories
and warehouses because
pallet loads are so
common
 Capacities from 450 kg
(1000 lb) up to 4500 kg
(10,000 lb)
 Power sources include
on-board batteries and
internal combustion
motors
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 24

25. Powered Trucks: Towing Tractor
 Designed to pull one or more trailing carts in factories and
warehouses, as well as for airport baggage handling
 Powered by on-board batteries or IC engines
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 25

26. AGVS (AUTOMATED GUIDED
VEHICLE)
AGVS is a material handling system that uses independently operated, self-
propelled vehicles guided along defined pathways.
They are powered by on-board batteries.
AGVS is appropriate where different materials are moved from various load
points to various unload points.
Types of AGVS:
Driverless trains - Pallet trucks - Unit load carriers
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 26

27. Automated Guided Vehicles:
Driverless Automated Guided Train
 First type of AGVS to
be introduced
around 1954
 Common application
is moving heavy
payloads over long
distances in
warehouses and
factories without
intermediate stops
along the route
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 27

28. Automated Guided Vehicles:
AGV Pallet Truck
 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
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 28

29. Automated Guided Vehicles:
Unit Load Carrier
 Used to move unit loads from station to station
 Often equipped for automatic loading/unloading of
pallets and tote pans using roller conveyors, moving
belts, or mechanized lift platforms
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 29

30. AGVS (AUTOMATED GUIDED
VEHICLE)
Driverless trains
Pallet trucks
Unit load carriers
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 30

31. AGVS (AUTOMATED GUIDED
VEHICLE)
 Vehicle Guidance Technology:
 The guidance system is the method by which AGVS
pathways are defined and vehicles are controlled to follow
the pathways.
 There are three technologies that are used:
 Imbedded guide wires.
 Paint Strips.
 Self-guided vehicles. (dead reckoning and beacons)
Dead reckoning is used to move the vehicle between beacons and the actual
position of beacons provide data to update the computer’s map.
The advantage of SGV is its flexibility.Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 31

32. Vehicle Guidance Using Guide
Wire
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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33. Monorails and other rail guided
Vehicles
 This system consists of either one rail (called
monorails) or two parallel rails.
 Monorails are normally suspended overhead from the
ceiling.
 Presence of fixed rail pathways distinguishes it from
AGVS.
 These work with electrical power unlike AGVS which
were powered by their on-board batteries.
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 33

34. Overhead Monorail
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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35. Conveyors
Used when material must be moved in relatively large quantities between specific
locations over a fixed path, which may be in the floor, above the floor or overhead.
Conveyors can be either powered or non-powered.
Powered conveyors
are moved with a
mechanism using
chains, belts, rotating
rolls etc. They are
usually used in
automated material
transport system.
In non-powered
conveyors, materials
are moved either
manually by humans
who push the loads
along the fixed path or
by gravity from one
elevation to lower
elevation.
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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36. Types of Conveyors
Roller Conveyors
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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37. Types of Conveyors
Skate-wheel conveyors
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38. Types of Conveyors
Belt conveyors
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39. Types of Conveyors
Chain conveyors
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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40. Types of Conveyors
Overhead trolley conveyor
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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41. Types of Conveyors
In-floor towline conveyors
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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41

42. Cart-On-Track Conveyor
 Carts ride on a track
above floor level
 Carts are driven by a
spinning tube
 Forward motion of
cart is controlled by a
drive wheel whose
angle can be changed
from zero (idle) to 45
degrees (forward)
Mr. Rahul Bhardwaj, Assistant Professor, MED,
BUEST 42

43. Hoist
Hoist with
mechanical
advantage of four:
(a) sketch of the
hoist
(b) diagram to
illustrate mechanical
advantage
(a) (b)
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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44. Bridge Crane
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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45. Gantry Crane
A half-gantry crane
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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46. Jib Crane
Mr. Rahul Bhardwaj, Assistant Professor, MED,
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