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Chapter 2Chapter 2
Material HandlingMaterial Handling

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IntroductionIntroduction
 Definition – the movement, storage, protection and
control of material (MHIA).
 The purpose is to handle safely, efficiently, at low
cost, on time, accurately, and without damage to the
material.
 Advantages – safer operating condition, lower cost,
better utilization and better performance of material
handling systems.

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ExamplesExamples
 Movement – industrial trucks and robots.
 Storage – rack, drawer, bins.
 Protection – wooden pallet, pallet box, tote box.
 Control – bar codes, magnetic stripes, radio
frequency tags.

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Position of MHPosition of MH
Automation and control technologies in the production
system

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Equipments of MHEquipments of MH
Categories of the equipment includes:
1. Transport.
2. Storage.
3. Unitizing.
4. Identification.

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TransportTransport
Used to move material inside a factory.
1. Industrial trucks – non-powered and powered.
2. Automated guided vehicles – battery-powered and
automatically steered.
3. Rail guided vehicle – self-propelled and
independently operating.
4. Conveyors – move material over fixed paths in
large quantities.
5. Cranes and hoists – horizontal travel and vertical
lifting for heavy loads. Manually or powered
operating.

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Industrial TrucksIndustrial Trucks
 The non-powered types are often referred as hand
trucks because they are pushed or pulled by human
workers
 Quantities of material moved and distances are
relatively low
 Classified as either two-wheel or multiple-wheel
 Examples of non-powered industrial are shown in
Figure 1

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F o u r w h e e l d o lly
Two-wheel truck
Four wheel
dolly
Hand-operated low-
lift pallet truck
Figure 1

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 Powered truck are self-propelled to relieve the
worker of manually having to move the truck
 Three common types are used in factories and
warehouse are walkie trucks, fork lift truck and
towing tractor

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Walkie truck
Fork lift
truck
Towing tractor

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Automated Guided VehicleAutomated Guided Vehicle
SystemsSystems
 An automated guided vehicle system (AGVS) is a
material handling system that uses independently
operated, self-propelled vehicles guided along
defined pathways
 The pathways for AGVS is unobtrusive
 An AGVS is appropriate where different materials
are moved from various load points to various
unload points
 Suitable for automating material handling in batch
production and mixed production

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Three types of AGV : (a) driveless automated guided train,
(b) AGV pallet truck, (c) Unit load carrier

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Monorails and other rail guidedMonorails and other rail guided
vehiclesvehicles
 Monorail is the motorized vehicles
that are guided by a fixed rail
system
 Are typically suspended overhead
from the ceiling
 Rail guided vehicles pick up
electrical power from an electrified
rail
 Electrified overhead monorails are
used to move large components
and subassemblies in its
manufacturing operations

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Conveyor SystemConveyor System
 Conveyors are used material must be moved in
relatively large quantities between specific locations
over a fixed path
 The fixed path is implemented by a track system,
which may be in-the-floor, above-the-floor or
overhead
 Divide into two categories :
(1) powered
(2) non-powered
 Examples of powered conveyors are shown in
Figure 3 and Figure 4

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Roller
conveyor
Belt (flat)
conveyorSkate wheel
conveyor
Figure 3

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Overhead trolley conveyor
Cart-on-track conveyor
In-floor towline conveyor
Figure 4

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Cranes and HoistCranes and Hoist
 Cranes are used for horizontal movement of
materials in a facility, and hoists are used for vertical
lifting.
 A hoist is a mechanical device that can be used to
raise and lower loads
 Cranes include a variety of material handling
equipment designed for lifting and moving heavy
loads using one or more overhead beams for
support
 Types of cranes : bridge cranes, gantry cranes and
jib cranes

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Jib crane with hoist
(a) Bridge crane
(b) Gantry crane
A hoist

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StorageStorage
 To store materials for a period of time.
 To permit access when required.
 Storage performance is measured according to the
capacity, density, accessibility and throughput.
 There are bulk storage, rack systems, bins, drawer
storage and automated storage systems.

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High density bulk storage provides low
accessibility and bulk storage with loads
arranged to form rows and blocks for improved
accessibility

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Pallet rack system for storage of unit loads on pallet

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Drawer storage

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A u n it lo a d a u t o m a t e d s t o r a g e / r e t r ie v a l s y s t e m

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A horizontal storage carousel

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UnitizingUnitizing
 Containers used to hold individual items for
protection.
 Equipment used to load and package the containers.
 Examples: wooden pallet, pallet box and tote box.

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IdentificationIdentification
 To collect the data in material handling
automatically.
 There are three basic components: encoder data,
machine reader and decoder.
 Examples of technologies: bar codes, magnetic
stripes, radio frequency tags and machine vision.

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Stationary moving beam bar code scanner located along
a moving conveyor

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Material Handling SystemMaterial Handling System
There are some considerations before design the
system as follows:
1. Material characteristics.
2. Flow rate, routing, and scheduling.
3. Plan layout.

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Principle of MHPrinciple of MH
 The purpose is to be applicable in the analysis,
design and operation of MH system.
1. Planning
2. Standard
3. Work
4. Ergonomic
5. Unit load
6. Space utilization
7 System
8. Automation
9. Environment
10. Life cycle cost

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AUTOMATIC DATAAUTOMATIC DATA
CAPTURECAPTURE
 Automatic data capture (ADC) also known as
automatic identification and data capture (AIDC).
 Refers to the technologies that provide direct entry
of data into a computer or other microprocessor
controlled system without using a keyboard.
 Used to collect data in material handling and
manufacturing applications

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 Material handling :
 shipping and receiving, storage, sortation and
order picking
 Manufacturing :
 Monitoring the status of order processing, work-
in-process and worker attendance.

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Component of ADC
Consists of three component :
Encoded data
 A code is a set of symbols or signals
representing alphanumeric characters
 When data are encoded, the characters are
translated into a machine-readable code
 A label or tag containing the encoded data is
attached to the item that is to be later identified

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Machine reader or scanner
 This device reads the encoded data, converting
them to alternative form, usually an electrical
analog signal
Decoder
 This component transforms the electrical signal
into digital data and finally back into original
alphanumeric characters

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Categories of ADC
Can be divided into six :
Optical
 Use high-contrast graphical symbols that can be
interpreted by an optical scanner
 Include bar codes, optical character recognition
and machine vision
Magnetic
 Encode data magnetically, similar to recording
tape
 Include magnetic stripe and magnetic ink
character recognition

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Electromagnetic : Radio frequency
Smart card
 Refers to small plastic cards (the size of credit
card) imbedded with microchips capable of
containing large amounts of information
Touch techniques : Touch screen and button
memory
Biometric
 To identify humans or interpret vocal commands of
human
 Include voice recognition, fingerprint analysis and
retinal eye scans

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Most widely used in industry :
1. Bar codes
2. Radio frequency
3. Magnetic stripe
4. Optical character recognition
5. Machine vision