Material handling is the art and science of moving, storing, protecting, and controlling material

1. AUTOMATED MATERIAL
HANDLING
PRESENTATION
BY
M RAKESH
1MS13MCM04
MSRIT

2. CONTENT OF PRESENTATION
 Material handling
 Material handling equipment
 Automation in Material handling
 Automated guided vehicles (AGV)
 Conveyors
 AGV example
 Simulation
 Limitations

4. WHAT IS MATERIAL HANDLING
 Material handling is the art and science of moving,
storing, protecting, and controlling material
–Moving: Required to create time and place utility.
The value of having the material at the right time and
the right place.
–Storing: Provides a buffer between operations,
facilitates the efficient use of people and machines.
–Protecting: Includes the packaging, packing against
damage and theft.
–Controlling: Physical Orientation, sequence and
space between material.

5. CATEGORIES OF
MATERIAL HANDLING EQUIPMENT
1. Material transport equipment - to move
materials inside a factory, warehouse, or other
facility
2. Storage - to store materials and provide access
to those materials when required
3. Unitizing equipment - refers to
(1) containers to hold materials, and
(2) equipment used to load and package the
containers
4. Identification and tracking systems - to identify
and keep track of the materials being moved and
stored

6. MATERIAL TRANSPORT EQUIPMENT
 Industrial trucks
 AGVs
 Robots
 Monorails and other rail guided vehicles
 Conveyors
 Cranes and hoists

7. AUTOMATION IN
MATERIAL HANDLING

8. WHY USE AUTOMATION IN MATERIAL
HANDLING
1. To increase labor productivity
2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or remove routine manual and clerical
tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish what cannot be done manually

9. AUTOMATED GUIDED
VEHICLES

10. 1. AUTOMATED GUIDED VEHICLE
 What is AGV ?
Material handling system that uses independently
operated, Self-propelled vehicles, Guided along
defined pathways.
 Increase efficiency and reduce costs by helping to
automate a manufacturing facility or warehouse.
 AGVs are employed in nearly every industry,
including, paper, metals, newspaper and general
manufacturing.
 They follow guidance circuits connecting various
workstations in the warehouse

11. COMPONENTS OF AGV
 Vehicle
 Guided path
 Control unit
 Computer interface

12. AGV TYPES
 Driver less trains
 Pallet trucks
 Unit load carriers

13. DRIVER LESS TRAINS
 Consists of towing vehicle, which is the AGV that pulls.
 One or more trailers forming a train.
 Heavy payloads.
 Large distances like in a warehouse.
 With or without intermediate pick-up and drop-off points along its
path.

14. DRIVER LESS TRAIN

15. PALLET TRUCKS

16. PALLET TRUCKS

17. UNIT LOAD CARRIER
 These are used to move unit loads from one
station to another.
 Light load AGVs, up to 250 kg or less.

18. UNIT LOAD CARRIER

19. VEHICLE GUIDANCE TECHNOLOGY
 Imbedded guide wires
 Paint strips (Optical navigation system)
 Self guided vehicles (Laser triangulation navigation
system)

20. 1. IMBEDDED GUIDE WIRES
•Faster and safer
•More accurate
•Less costly
•Simpler and less programming
required

21. 2. PAINT STRIPS (OPTICAL NAVIGATION SYSTEM)
 Chemical or tape strip is fixed or
painted to the floor which contain
fluorescent particles that reflect
UV light source from vehicle
 Vehicle has an onboard sensor
which allows it to detect the path.
 Not typically used in plants or
warehouses because floor line
needs to be cleaned or reapplied
as it deteriorates with time.
 Useful in environment where guide
wires in the floor surface is not
practical.

22. 3. SELF GUIDED
(LASER TRIANGULATION NAVIGATION SYSTEM)
 Most popular method of AGV navigation.
 Operate without continuously defined pathways.
 Use combination of dead reckoning (capability
of a vehicle to follow a given route in the absence
of a defined pathway) and beacons located
throughout the plant, which can be identified by
on board sensors.
 Continuously verify position by comparing the
calculated position with one or more known
position

23. CONVEYORS

24. CONVEYOR SYSTEMS
Large family of material transport equipment
designed to move materials over fixed paths,
usually in large quantities or volumes
1. Non - powered
 Materials moved by human workers or by gravity
2. Powered
 Power mechanism for transporting materials is
contained in the fixed path, using chains, belts, rollers
or other mechanical devices

25. CONVEYOR TYPES
1. Roller
2. Skate - wheel
3. Belt
4. In- floor towline

26. 1. ROLLER CONVEYOR
 Pathway consists of a
series of rollers that are
perpendicular to
direction of travel
 Loads must possess a
flat bottom to span
several rollers
 Powered rollers rotate
to drive the loads
forward

27. 2. SKATE-WHEEL CONVEYOR
 Similar in operation to
roller conveyor but use
skate wheels instead of
rollers
 Lighter weight and
unpowered
 Sometimes built as
portable units that can
be used for loading and
unloading truck trailers
in shipping and
receiving

28. 3. BELT CONVEYOR
 Continuous loop with
forward path to move
loads
 Belt is made of
reinforced elastomer
 Support slider or rollers
used to support
forward loop
 Two common forms:
 Flat belt (shown)
 V-shaped for bulk
materials

29. 4. IN-FLOOR TOW-LINE CONVEYOR
 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 the carts to
be disengaged from
towline for loading and
unloading

30. AGV MATERIAL HANDLING ANALYSIS
 Equations:
 del cycle time Tc = TL + TU + Ld / vc + Le / ve (min)
 available time AT = 60 A Tf E (min/hr/veh)
 rate of del per vehicle Rdv = AT / Tc (num
del/hr/veh)
 work by handling system per hr WL = Rf Tc (min/hr)
 num of vehicles for workload nc = WL/AT = Rf / Rdv
(num of veh for work load)

31. AGV EXAMPLE
Given the AGV layout in the figure and the info listed,
determine the number of vehicles required for a
delivery (flow) rate of 40 del/hr.
Info:
Loading time = 0.75 min Unloading time = 0.5 min
Vehicle speed = 50 m/min Availability = 0.95
Traffic factor = 0.9 (from fig) =>Ld = 110 m ; Le = 80 m
E = 1
Solution:
Ideal cycle time/del/veh = Tc = 0.75 + 0.5 + 110/50 + 80/50 = 5.05 min
Compute workload = WL = (40) (5.05) = 202 min/hr
Available time = AT = (60) (0.95) (0.90) (1.0) = 51.3 min/hr/veh
Num of vehicles = nc = 202/51.3 = 3.94 veh => 4 vehicles!

32. SIMULATION
 Simulation is the only method that can accurately
predict the system’s performance when using a
specific number of specific vehicles in the system
 Video

33. LIMITATIONS OF AUTOMATED
MATERIAL HANDLING SYSTEMS
 Additional investment
 Lack of flexibility
 Vulnerability to downtime whenever there is
breakdown
 Additional maintenance staff and cost
 Cost of auxiliary equipment.
 Space and other requirements

35. DISQUS