KIOT

Plant Layout and Facility Design

Course code: Greg 4181
Target group: 4th year GED
Chapter six
Material Handling
By: Endashaw Yohannes
Kombolcha/Ethiopia
January, 2020

08/21/2020 1
HIERARCHY OF FACILITY PLANNING

Facility
Facility Systems
Location
Design

Facility
Planning
Facility Layout
Design Design

Handling System
Design
Material handling in garment industry

Material handling: is the means used for transporting work (like

Fabrics, cuttings, bundles, finished garments and general items)
from one place to another, storing materials and protecting
material from damage, are called material handling system.

It may be an equipment, device or procedures.

 Concerns of Material Handling
(i) Movement.

o Involves mechanical or manual movements of materials

o Movement of materials may be horizontal, vertical or combination

of both.

Primary concern of materials handling engineer is to find out

1. Most efficient manner as to how raw materials reach operator

and how finished or processed articles are removed from the
work station.

2. How parts, materials, and finished products must be moved from

location to location.
 Concerns of Material Handling cont..
(ii) Time.

Materials must arrive at its place at right time.

Materials handling must ensure that no production process or customer (internal as

well as external) need is hampered due to late or early arrival of material at each
location.

(iii) Quantity.

Materials handling must ensure that each location continually receives the right
quantity of materials (parts, raw material or semi-finished/processed item).

(iv) Space.

o Space requirements are influenced by the materials handling flow pattern.

o Space is required for storage of raw materials, parts and semi-finished or

finished products.
 The Ten Principles
of Material Handling

The Key to Greater Productivity, Customer Service

and Profitability
 PLANNING PRINCIPLE

Definition: A plan is a prescribed course of action that is

defined in advance of implementation.
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).
 PLANNING PRINCIPLE
KEY POINTS

The material handling plan should reflect the

strategic objectives of the organization as
well as the more immediate needs.

The plan should document existing methods

and problems, physical and economic
constraints, and future requirements and
goals.
 PLANNING PRINCIPLE
KEY POINTS

The plan should promote concurrent

engineering of product, process design,
process layout, and material handling
methods, as opposed to independent and
sequential design practices.
 STANDARDIZATION PRINCIPLE

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 throughput.
 STANDARDIZATION
PRINCIPLE

Definition: Standardization means less

variety and customization in the methods
and equipment employed.
STANDARDIZATION PRINCIPLE
Key Points

The planner should select methods and

equipment that can perform a variety of tasks
under a variety of operating conditions and in
anticipation of changing future requirements.

Standardization applies to sizes of containers

and other load forming components as well as
operating procedures and equipment.
 WORK PRINCIPLE

Material handling work should be minimized

without sacrificing productivity or the level of
service required of the operation.
Definition: The measure of work is material
handling flow (volume, weight or count per
unit of time) multiplied by the distance moved.
 WORK PRINCIPLE
Key Points

Simplifying processes by reducing, combining,

shortening or eliminating unnecessary moves
will reduce work.

Consider each pickup and set-down, or placing

material in and out of storage, as distinct
moves and components of the distance moved.
The shortest distance between two points is a
straight line.
 ERGONOMIC PRINCIPLE

Human capabilities and limitations must be

recognized and respected in the design of
material handling tasks and equipment to ensure
safe and effective operations.
 ERGONOMIC PRINCIPLE

Definition: Ergonomics is the science that

seeks to adapt work or working conditions
to suit the abilities of the worker.
 ERGONOMIC PRINCIPLE
Key Points

Equipment should be selected that eliminates

repetitive and strenuous manual labor and
which effectively interacts with human
operators and users.
The ergonomic principle embraces both
physical and mental tasks.
The material handling workplace and the
equipment employed to assist in that work
must be designed so they are safe for people.
 UNIT LOAD PRINCIPLE

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.
 UNIT LOAD PRINCIPLE

Definition: 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 LOAD PRINCIPLE
Key Points

Less effort and work is required to collect and

move many individual items as a single load
than to move many items one at a time.
Load size and composition may change as
material and product moves through stages of
manufacturing and the resulting distribution
channels.
Large unit loads are common both pre and
post manufacturing in the form of raw
materials and finished goods.
 UNIT LOAD PRINCIPLE
Key Points

During manufacturing, smaller unit loads,

including as few as one item, yield less in-
process inventory and shorter item
throughput times.
Smaller unit loads are consistent with
manufacturing strategies that embrace
operating objectives such as flexibility,
continuous flow and just-in-time delivery.
 UNIT LOAD PRINCIPLE
Key Points

Unit loads composed of a mix of different

items are consistent with just-in-time and/or
customized supply strategies so long as item
selectivity is not compromised.
 SPACE UTILIZATION

Effective and efficient use must be made of

all available space.
 SPACE UTILIZATION

Definition: Space in material handling is

three dimensional and therefore is counted
as cubic space.
 SPACE UTILIZATION
Key Points

In work areas, cluttered and unorganized

spaces and blocked aisles should be
eliminated.

In storage areas, the objective of

maximizing storage density must be
balanced against accessibility and
selectivity.

When transporting loads within a facility

the use of overhead space should be
considered as an option.
 SYSTEM PRINCIPLE

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.
 SYSTEM PRINCIPLE

Definition: A system is a collection of

interacting and/or interdependent entities
that form a unified whole.
 SYSTEM PRINCIPLE
Key Points

Systems integration should encompass the

entire supply chain including reverse
logistics. It should include suppliers,
manufacturers, distributors and customers.

Inventory levels should be minimized at all

stages of production and distribution while
respecting considerations of process
variability and customer service.
 SYSTEM PRINCIPLE
Key Points

Information flow and physical material flow

should be integrated and treated as
concurrent activities.

Methods should be provided for easily

identifying materials and products, for
determining their location and status
within facilities and within the supply
chain and for controlling their movement.
 SYSTEM PRINCIPLE
Key Points

Customer requirements and expectations

regarding quantity, quality, and on-time
delivery should be met without exception.
 AUTOMATION PRINCIPLE

Material handling operations should be

mechanized and/or automated where
feasible to
• Improve operational efficiency,
• Increase responsiveness,
• Improve consistency and predictability,
decrease operating costs and
• To eliminate repetitive or potentially unsafe
manual labor.
 AUTOMATION PRINCIPLE

Definition: Automation is a technology

concerned with the application of electro-
mechanical devices, electronics and
computer-based systems to operate and
control production and service activities.
It suggests the linking of multiple mechanical
operations to create a system that can be
controlled by programmed instructions.
 AUTOMATION PRINCIPLE
Key Points

Pre-existing processes and methods should

be simplified and/or re-engineered before
any efforts at installing mechanized or
automated systems.

Computerized material handling systems

should be considered where appropriate for
effective integration of material flow and
information management.
 AUTOMATION PRINCIPLE
Key Points

All items expected to be handled

automatically must have features that
accommodate mechanized and automated
handling.

Treat all interface issues as critical to

successful automation, including equipment
to equipment, equipment to load, equipment
to operator, and control communications.
ENVIRONMENTAL PRINCIPLE

Environmental impact and energy

consumption should be considered as criteria
when designing or selecting alternative
equipment and material handling systems.
ENVIRONMENTAL PRINCIPLE

Definition: Environmental consciousness

stems from a desire not to waste natural
resources and to predict and eliminate the
possible negative effects of our daily actions
on the environment.
ENVIRONMENTAL PRINCIPLE
Key Points

Containers, pallets and other products used

to form and protect unit loads should be
designed for reusability when possible
and/or biodegradability as appropriate.

Systems design should accommodate the

handling of spent dunnage, empty
containers and other by-products of
material handling.
ENVIRONMENTAL PRINCIPLE
Key Points

Materials specified as hazardous have

special needs with regard to spill
protection, combustibility and other risks.
LIFE CYCLE COST PRINCIPLE

A thorough economic analysis should

account for the entire life cycle of all
material handling equipment and resulting
systems.
 LIFE CYCLE COST PRINCIPLE
Definition:
Life cycle costs include all cash flows that will occur
between the time the first dollar is spent to plan or
procure a new piece of equipment, or to put in place a
new method, until that method and/or equipment is
totally replaced.
 LIFE CYCLE PRINCIPLE
Key Points

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.
A plan for preventive and predictive maintenance
should be prepared for the equipment, and the
estimated cost of maintenance and spare parts should
be included in the economic analysis.
 LIFE CYCLE PRINCIPLE
Key Points

A long-range plan for replacement of the equipment

when it becomes obsolete should be prepared.
Although measurable cost is a primary factor, it is
certainly not the only factor in selecting among
alternatives.
Other factors of a strategic nature to the organization
and which form the basis for competition in the
market place should be considered and quantified
whenever possible.
 MATERIAL HANDLING SYSTEM PLANNING
o Materials handling system should be properly designed (planned)
for implementing the planned materials flow.

o For this purpose sufficient information's and data should be

collected.

o Suitably designed handling system helps in planning a layout.

 SYSTEM CONCEPT

o A system is a set of elements, such as people, things, and concepts,

that are related to achieve a mutual goal.

o A subsystem is a part of a larger system with which we are

concerned, and all systems are parts of a larger system.

o A 'system' always exists within an environment which provides

resources as input into the system, and that accepts outputs of the
system.

o A 'system' is always doing something.

o For example human body is a 'system', while a rock is not a system

(because it does not do anything).
A SIMPLIFIED SYSTEM
 SYSTEM AND INFORMATION
The system will work at optimum level when timely and relevant
information's are received as feed-back, and timely decisions are
taken and implemented.
PRINCIPAL FACTORS CONSIDERED IN MATERIALS HANDLING PROBLEMS

1. Products: There is large variety of materials handling equipment,

selection of which depends upon products and process of their

manufacture.

It is necessary to study the product and process very carefully before

selecting a type and size of equipment.

2. Layout: layout and materials handling are not separable problems,

and hence are considered together.

In any design of new buildings or the rearrangement or reconstruction

of old buildings, it is essential that layout and materials handling be

considered jointly.
PRINCIPAL FACTORS CONSIDERED IN MATERIALS HANDLING PROBLEMS CONT…

3. Building Construction.

First problem of building construction is in respect to the number of

floors i.e. considering the question of vertical transportation if the

building is more than one storey.

Second problem related to building is concerned with the loading that

the floors can withstand safely.

 MATERIAL HANDLING EQUIPMENT

MHE can be classified into the following five major

categories:
Transport Equipment:
Equipment used to move material from one location to another
(e.g., between workplaces, between a loading dock and a
storage area, etc.).
Material can also be transported manually using no equipment.
 MATERIAL HANDLING EQUIPMENT

Positioning Equipment.
Equipment used to handle material at a single location so that it is in
the correct position for subsequent handling, machining, transport,
or storage.
Material can also be positioned manually using no equipment.
Unit Load Formation Equipment.
Equipment used to restrict materials so that they maintain their
integrity when handled as a single load during transport and for
storage.
If materials are self-restraining (e.g., a single part or interlocking
parts), then they can be formed into a unit load with no equipment.
 MATERIAL HANDLING EQUIPMENT

Storage Equipment. Equipment used for holding or buffering materials

over a period of time.
If materials are block stacked directly on the floor, then no storage
equipment is required.
Identification and Control Equipment.
Equipment used to collect and communicate the information that is
used to coordinate the flow of materials within a facility and between
a facility and its suppliers and customers.
The identification of materials and associated control can be
performed manually with no specialized equipment.
TRANSPORT EQUIPMENT
The major subcategories of transport equipment are:
Conveyors. Equipment used to move materials over a fixed path
between specific points.
Cranes. Equipment used to move materials over variable paths
within a restricted area.
Industrial Trucks. Equipment used to move materials over
variable paths, with no restrictions on the area covered by the
movement (i.e., unrestricted area).
No Equipment. Material can also be transported manually using
no equipment.
 TRANSPORT EQUIPMENT - CONVEYORS

Conveyors are used:

1. When material is to be moved frequently between
specific points
2. To move materials over a fixed path
3. When there is a sufficient flow volume to justify the
fixed conveyor investment
Conveyors can be classified in different ways:
1. Type of product being handled: unit load or bulk
load
2. Location of the conveyor: overhead, on-floor, or
in-floor
 TRANSPORT EQUIPMENT - HORIZONTAL MOVEMENT
CONVEYORS

Flat Belt Conveyor

Chain Conveyor
Live (Powered) Roller
Conveyor
TRANSPORT EQUIPMENT – DIAGONAL
MOVEMENT CONVEYORS

SlantConveyor

Gravity Roller
Conveyor

Magnetic Belt Conveyor

 TRANSPORT EQUIPMENT - VERTICAL
MOVEMENT CONVEYORS

Reciprocating Vertical Conveyor

Vertical Lift Conveyor

TRANSPORT EQUIPMENT - GROUND
TOW( WIRE GUIDED) CONVEYORS

Trolley Conveyor
TRANSPORT EQUIPMENT – OVERHEAD CONVEYORS

Power-and-Free Conveyor

Monorail
TRANSPORT EQUIPMENT - CRANES

Stacker
Jib Crane Crane

Gantry Crane
Bridge Crane
TRANSPORT EQUIPMENT – HAND
TRUCKS

Two-Wheeled Hand Truck Floor Hand Truck

 ELECTRIC
TRANSPORT EQUIPMENT –
MOTOR HAND TRUCKS
Manual Pallet Jack

Manual Walkie Stacker

Powered Pallet Jack

TRANSPORT EQUIPMENT – POWERED
INDUSTRIAL TRUCKS

Narrow-Aisle (NA) Straddle Truck

Sit-Down Counterbalanced Lift Truck

TRANSPORT EQUIPMENT – AUTOMATIC
GUIDED VEHICLE (AGV)

Tow AGV

Unit Load AGV

Assembly AGV
 Positioning Equipment
As compared to manual handling, the use of positioning
equipment can provide the following benefits

• raise the productivity of each worker when the frequency of

handling is high,
• improve product quality and limit damage to materials and
equipment when the item handled is heavy or awkward to hold
and damage is likely through human error or inattention, and
• reduce fatigue and injuries when the environment is hazardous or
inaccessible.
 POSITIONING EQUIPMENT

Articulated Jib Crane

Manipulator
Vacuum Manipulator

Industrial Robot
 MATERIAL HANDLING EQUIPMENT
UNIT LOAD FORMATION EQUIPMENT

Advantages of unit loads:

• More items can be handled at the same time, thereby
reducing the number of trips required and, potentially,
reducing handling costs, loading and unloading times, and
product damage.
• Enables the use of standardized material handling equipment.
Disadvantages of unit loads:
• Time spent forming and breaking down the unit load.
• Cost of containers/pallets and other load restraining materials
used in the unit load
• Empty containers/pallets may need to be returned to their
point of origin.
UNIT LOAD EQUIPMENT

Pallets
Tote Pans
UNIT LOAD EQUIPMENT

Pallet Boxes

Intermodal Containers

Skid Boxes
 UNIT LOAD FORMATION
EQUIPMENT

Manual Palletizing
Robotic Pick and Place Palletizers

Shrink-Wrap/Stretch-Wrap
STORAGE EQUIPMENT

Drive-Through Rack

Selective Pallet Rack

 STORAGE EQUIPMENT

Drive-In Rack

Flow-Through Rack
STORAGE EQUIPMENT

Shelves / Bins / Drawers

Storage Carousel
STORAGE EQUIPMENT

Sliding Rack
MATERIAL HANDLING EQUIPMENT
IDENTIFICATION AND CONTROL EQUIPMENT

• Manual (no equipment)

• Bar codes
• Radio frequency (RF) tag
• Machine vision
• Electronic data interchange (EDI)/Internet
 MATERIAL HANDLING EQUIPMENT
IDENTIFICATION AND CONTROL EQUIPMENT

Manual (No Equipment)

¨ The identification of materials and associated

communication can be performed manually with no
specialized equipment
¨ Although it is sometimes possible to manually coordinate
the operation of a material handling system, it becomes
more difficult to do so as the speed, size, and complexity
of the system increases
 MATERIAL HANDLING EQUIPMENT
IDENTIFICATION AND CONTROL EQUIPMENT

Bar Codes

¨ Unique bar/space patterns represent various

alphanumeric characters

¨ Bar code system consists of bar code label, bar

code scanner, and bar code printer
 MATERIAL HANDLING EQUIPMENT
IDENTIFICATION AND CONTROL EQUIPMENT

Radio Frequency (RF) Tag

 Data encoded on chip encased in a tag
 Non-contact: can be read when the tag is within 30
ft. of an antenna
 Tags can either be attached to a container, or
permanently or temporarily to an item
 RF tags have greater data storage capability than
bar codes
 MATERIAL HANDLING EQUIPMENT
IDENTIFICATION AND CONTROL EQUIPMENT

Machine Vision

 Does not require explicit encoding of data since

objects can be identified by their physical
appearance

 Non-contact, but typically requires structured

lighting

 More flexible than other identification equipment,

MATERIAL HANDLING EQUIPMENT
IDENTIFICATION AND CONTROL EQUIPMENT

Electronic Data Interchange (EDI)/Internet

 Electronic data interchange (EDI) provides

standards for inter-corporate transfer of purchase
orders, invoices, shipping notices, and other
frequently used business documents

 Prior to the Internet, EDI required expensive

dedicated value added networks (VANs)

 EDI is critical for implementing JIT manufacturing

Material Handling Equipment
Safety and Ergonomics – Job Design

Paying special attention to:

Heavy Frequent lifting Awkward lifting

lifting
Material Handling Equipment
Safety and Ergonomics – Job Design

PRINCIPLES FOR REDUCING HEAVY LIFTING

Reduce the weight
Use mechanical assistance
Slide instead of lift
Team lifting
 Material Handling Equipment
Safety and Ergonomics – Job Design
PRINCIPLES FOR REDUCING FREQUENT
LIFTING
oUse mechanical assistance
oAvoid unnecessary lifting
oUse mobile storage
Material Handling Equipment
Safety and Ergonomics – Job Design
PRINCIPLES FOR REDUCING AWKWARD LIFTING -
REACHING
Remove obstacles
Slide closer
Reduce shelf depth
Reduce package size
Use mechanical assistance
Team lifting
 Material Handling Equipment
Safety and Ergonomics – Job Design

PRINCIPLES FOR REDUCING AWKWARD

LIFTING - BENDING
Use mechanical assistance to raise the load
Add handles
Arrange storage
Avoid unnecessary lifting
Material Handling Equipment
Safety and Ergonomics – Job Design

PRINCIPLES FOR REDUCING AWKWARD

LIFTING – REACHING ABOVE SHOULDERS
oArrange storage
oUse mechanical assistance
oUse a rolling stair or “safety ladder”
THE END
Thank you