Material Handling System

Automated Material Handling Systems (AMHS) Young Jae Jang (youngjae@mit.edu) MIT December 11, 2006 2.853/2.854

Contents ,[object Object],[object Object],[object Object],[object Object]

Automated Material Handling Systems ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],M1 M2 B

AMHS Engineers ,[object Object],[object Object],[object Object],[object Object],[object Object],Mechanical Engineering Manufacturing Engineering Material Handling System Engineering

Needs for AMHS Role of AMHS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Production Strategy ,[object Object],Advanced Production ,[object Object],[object Object],Flexible Production ,[object Object],Mass Production ,[object Object],Birth of Industry AMHS Strategy Stage

AMHS trends in Semiconductor and LCD industries Lab production Mass production Lean Production Lab production Mass Production Lean Production Semiconductor Chips ,[object Object],[object Object],[object Object],Critical Entity in Manufacturing 1970 1980 1990 2000 2010 LCD

Semiconductor Manufacturing ,[object Object],[object Object],[object Object],[object Object]

AMHS in Semiconductor Fab ,[object Object]

Fleet Size Analysis – Simulations Solution 1 Layout Solution 2 Layout Solution 3 Layout AMHSA Layout

Fleet Size Analysis – Simulations 2/3

Main LCD Production Stages ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Critical production Clean room environment TFT process C/F process Cell stage Module stage Array Stage C/F glass TFT glass Liquid Crystal

Example of a Layout (TFT) ,[object Object],[object Object],[object Object],Photo Depo Etch Clean Test

Automated Guided Vehicle (AGV) ,[object Object],[object Object],[object Object],[object Object],Source: Shinsung ENG

Rail Guided Vehicle (RGV) ,[object Object],[object Object],Source: Shinsung ENG

Cassette – Transfer lot ,[object Object],[object Object],[object Object]

Loading System ,[object Object],[object Object],Source: Shinsung ENG

Design Issues in AMHS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Current Market Situation ,[object Object],[object Object],[object Object],[object Object],[object Object]

Contents ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Case 1 - Buffer Allocations ,[object Object],[object Object],[object Object]

Decomposition Analysis – FAB design ,[object Object]

LCD – OHS System Development ,[object Object]

Problem ,[object Object],[object Object],[object Object],[object Object]

Approach – Analytical Model ,[object Object],Analytical Model ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Inputs Outputs

Approach – Queueing Model ,[object Object], : Arrival rate is given  : Service rate depends on arrival types

Modeling Assumptions ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Time Definitions ,[object Object],[object Object],[object Object],[object Object]

Time Definitions ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Modeling Input-Output ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Transport time ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Dispatching time ,[object Object],[object Object],[object Object],[object Object],[object Object]

Dispatching time ,[object Object],[object Object]

Dispatching time – Nearest Dispatching Rule ,[object Object],[object Object],[object Object],[object Object]

Dispatching time example ,[object Object]

Dispatching time ,[object Object]

Queue waiting time - Tq ,[object Object],[object Object],[object Object],[object Object]

Iterative Method ,[object Object],[object Object],[object Object],[object Object],[object Object]

Solution Algorithm ,[object Object]

Model Verification ,[object Object],1.23% 1.19% 2.99% 0.0 Error AGV utilization Total Travel Dispatch Transport 0.3128 0.2599 0.2567 3 2.494 2.4643 1.5 0.994 0.9643 1.5 1.500 1.5 Heuristics Simulation Analytical 0 0 20 0 4 20 0 0 0 3 10 0 0 20 2 0 20 10 0 1 4 3 2 1 480min Part flow rate 0 1 2 3 4 1 0 1 2 3 2 1 0 1 2 3 2 1 0 1 4 3 2 1 Travel Time

Model Verification ,[object Object],14.09 -2.53% 13.319 13.6566 Total Travel -2.06% - -4.99% 0.042% Error AGV utilization Waiting time Dispatch Transport 0.919 0.870 0.889 18.05 12.365 7.045 6.271 6.584 7.045 7.048 7.045 Heuristics Simulation Analytical 0 0 0 44 0 22 0 25 75 9 0 0 0 0 15 37 12 38 0 8 63 41 0 0 0 0 48 0 39 7 54 0 32 0 52 12 0 65 0 6 22 0 18 27 0 54 25 0 0 5 0 0 16 74 30 0 72 0 65 4 0 0 72 52 25 0 0 52 0 3 0 37 0 26 0 30 20 0 0 2 0 65 0 28 50 0 18 15 0 1 9 8 7 6 5 4 3 2 1 4800min Part flow rate 0 8 10 10 14 12 10 6 2 9 4 0 6 6 6 8 6 6 6 8 2 10 0 12 16 14 12 8 4 7 6 6 4 0 4 6 8 8 8 6 10 6 12 8 0 2 8 8 12 5 8 4 10 6 6 0 6 6 10 4 10 6 12 8 8 2 0 8 10 3 6 6 8 8 8 6 4 0 8 2 6 6 8 8 12 10 8 4 0 1 9 8 7 6 5 4 3 2 1 Travel time

Optimization ,[object Object],[object Object]

Conclusions ,[object Object],[object Object],[object Object],[object Object]

Material Handling System

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