Contents of This course
Chapter 1: Introduction
Chapter 2: Life Cycle of Product
Chapter 3: Elements of CIM
Chapter 4: Material Transportation System
Chapter 5: Computer Aided Process Planning
Chapter 6: Product Data Management
Chapter 7: Quality Management and Fault Diagnosis
Chapter 8: Just-in-Time Manufacturing, Lean Manufacturing, and
Agile Manufacturing.
Dr. Van-Phong Vu-Department of Automatic Control
Chapter 4: Material
Transportation System
Dr. Van-Phong Vu-Department of Automatic Control
Contents of Chapter 4
4.1 Overview of Material Handling
4.2 Material Transport Equipment
4.3 Analysis of Material Transport Systems
Dr. Van-Phong Vu-Department of Automatic Control
4.1 Overview
Dr. Van-Phong Vu-Department of Automatic Control
4.1 Overview
Material handling: the movement, protection, storage and control
of materials and products throughout the process of manufacture
and distribution, consumption and disposal.
The handling of materials must be performed safely, efficiently, at
low cost, in a timely manner, accurately (the right materials in the
right quantities to the right locations), and without damage to the
materials
Logistics: the acquisition, movement, storage, and distribution of
materials and products, as well as the planning and control of these
operations in order to satisfy customer demand
Dr. Van-Phong Vu-Department of Automatic Control
4.1 Overview
Logistics
operations
External Internal
Logistics Logistics
External logistics is concerned with transportation and related
activities that occur outside of a facility
Internal logistics, more popularly known as mate rial handling,
involves the movement and storage of materials inside a given
facility
Dr. Van-Phong Vu-Department of Automatic Control
4.1 Overview
Material Handling Equipment
Transport Equipment: Industrial trucks, (2) automated guided
vehicles, (3) rail-guided vehicles, (4) conveyors, and (5) hoists
and cranes.
Positioning Equipment: loading and unloading parts from a
production machine in a work cell.
industrial robots
parts feeders in automated assembly
Dr. Van-Phong Vu-Department of Automatic Control
4.1 Overview
Material Handling Equipment
Unit Load Formation Equipment:
(1) containers used to hold individual items during handling and
(2) equipment used to load and package the containers.
Dr. Van-Phong Vu-Department of Automatic Control
4.1 Overview
Material Handling Equipment
Storage equipment
(1) conventional storage methods: bulk storage, rack systems,
shelving and bins, and drawer storage
(2) automated storage systems.
Identification and Control equipment
RFID (for radio frequency identification)
Bar codes
Dr. Van-Phong Vu-Department of Automatic Control
4.2 Design Considerations in Material handling
Material Characteristics
Design of the material handling system must take these factors into
account.
Dr. Van-Phong Vu-Department of Automatic Control
4.2 Design Considerations in Material handling
Flow rate, routing, and scheduling.
(1) quantities and flow rates of materials to be moved: affects
the type of handling system that should be installed
(2) routing factors: pickup and drop-off locations, move
distances,
(3) scheduling of the moves: the timing of each individual
delivery
Dr. Van-Phong Vu-Department of Automatic Control
4.2 Design Considerations in Material handling
Plant Layout
The material handling system is an important factor in plant
layout design.
A new facility is being planned, the handling system should be
considered part of the layout
Dr. Van-Phong Vu-Department of Automatic Control
4.2 Design Considerations in Material handling
Unit Load principle
The container that holds or supports the materials to be moved.
The unit load may consist of only one part, a container loaded
with multiple parts, or a pallet loaded with multiple containers of
parts
containers, pallets are probably the most widely used
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
4.3.1 Industrial trucks: non-powered and powered
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
Industrial trucks: non-powered and powered
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
4.3.2 Automated Guided Vehicles: An automated guided vehicle
system (AGVS) is a material handling system that uses in-
dependently operated, self-propelled vehicles guided along defined
pathways
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
4.3.2 Automated Guided Vehicles:
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
4.3.2 Automated Guided Vehicles:
Vehicle Guidance Technologies.
(1) imbedded guide wires
Dây mang dòng điện được chôn
Dưới đất tạo từ trường.
Ưu điểm: chi phí thấp, mạnh mẽ
Khuyết điểm: không linh hoạt
dễ bị ảnh hưởng của kim loại trong lòng đất.
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
Automated Guided Vehicles:
(2) paint strips: vehicle uses an optical sensor capable of tracking the
paint.
The strips can be taped, sprayed, or painted on the floor
Advantages: low cost, flexibility
Disadvantages: sensitive with dust, light, the paint strip deteriorates
with time
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
Automated Guided Vehicles:
(3) Magnetic tape: installed on the floor surface to define the pathways.
Unlike imbedded wire guidance, which emits an active powered signal,
magnetic tape is a passive guidance technology.
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
Automated Guided Vehicles:
Vehicle Guidance Technologies.
(4) Laser-guided vehicles (LGVs): use a combination of dead reckoning and
reflective beacons located throughout the plant that can be identified by on-
board laser scanners.
Dead reckoning: the capability of a vehicle to follow a given route in the
absence of a defined pathway in the floor. the process of calculating one's current
position by using a previously determined position.
The location of the laser-guided vehicle must be periodically veri- fied by
comparing the calculated position with one or more known positions
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
Automated Guided Vehicles:
These beacons can be sensed by the laser scanner on the vehicle
Based on the positions of the beacons, the on-board navigation computer uses
triangulation to update the positions calculated by dead reckoning,
(5) Inertial guidance: involves the use of on-board gyroscopes
and/or other motion sensors to determine the position of the vehicle
by detecting changes in its speed and acceleration
Advantage of laser-guided vehicle technology and inertial
navigation over fixed pathways (guide wires, paint strips, and
magnetic tape) is its flexibility.
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
4.3.2 Automated Guided Vehicles:
Vehicle Management:
Purpose: operate efficiently and avoid collision.
Two methods: on-board vehicle sensing and zone control,
On-board vehicle sensing Zone control
• one or more sensors on each • AGVS layout is divided into separate
vehicle to detect the presence zones
of other vehicles and obstacles • No vehicle is permitted to enter a zone
ahead on the guide path. that is already occupied by another vehicle
• Sensor technologies include
optical and ultrasonic devices
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
4.3.2 Automated Guided Vehicles:
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
4.3.2 Automated Guided Vehicles:
Vehicle Safety.
AGV is that its traveling speed is slower than the normal walking pace
of a human minimize the danger.
Most guidance systems is automatic stopping of the vehicle if it strays
more than a short distance, typically 50–150 mm (2–6 in).
Obstacle detection sensor located on each vehicle.
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
4.3.3 Rail-Guided Vehicles
Material transport equipment consists of motorized vehicles that
are guided by a fixed rail system
Rail system consists of either one rail, called a monorail, or two
parallel rails.
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
4.3.4 Conveyor
Roller conveyors Skate-wheel conveyors.
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
4.3.4 Conveyor
belt (flat) conveyor in-floor towline conveyor .
Dr. Van-Phong Vu-Department of Automatic Control
overhead trolley conveyor.
4.3 Material Transport Equipment
4.3.5 Cranes and Hoists
A hoist is a mechanical device used to raise and lower loads.
Dr. Van-Phong Vu-Department of Automatic Control
4.3 Material Transport Equipment
4.3.5 Cranes and Hoists
Cranes include a variety of material handling equipment designed for
lifting and moving heavy loads using one or more overhead beams for
support
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
The time for a typical delivery cycle in the operation of a vehicle-
based transport system consists:
(1) loading at the pickup station,
(2) travel time to the drop-off station
(3) unloading at the drop-off station
(4) empty travel time of the vehicle between deliveries
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Cycle time
Tc = delivery cycle time, min/del
TL = time to load at load station
Ld = distance the vehicle travels between load and unload
station, m (ft)
vc = carrier velocity, m/min
TU = time to unload at unload station, min
Le = distance the vehicle travels empty until the start of the next
delivery cycle, m
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Availability A is a reliability factor defined as the pro- portion of total shift
time that the vehicle is operational and not broken down or being repaired.
traffic factor Ft is defined as a parameter for estimating the effect of these
losses on system performance
by the traffic factor include waiting at intersections, blocking of vehicles (as in an
AGVS), and waiting in a queue at load/unload stations.
Traffic factor for an AGVS range between 0.85 and 1.0
Worker efficiency is defined as the actual work rate of the human operator
relative to the work rate expected under standard or normal performance.
Let Ew symbolize worker efficiency.
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
The available time per hour per vehicle can now be ex- pressed as 60
min adjusted by A, Ft, and Ew
AT = available time, min/hr per vehicle
A = availability
Ft = traffic factor
Ew = worker efficiency
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
The rate of deliveries per vehicle is given by
Rdv = hourly delivery rate per vehicle, deliveries/hr per
vehicle
Tc = delivery cycle time, min/del
AT = the available time in 1 hour, adjusted for time losses,
min/hr
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Workload is defined as the total amount of work, expressed in terms of
time, that must be accomplished by the material transport system in 1 hr
WL = workload, min/hr
Rf = specified flow rate of total deliveries per hour for the
system, deliveries/hr
Tc = delivery cycle time, min/del.
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Number of vehicles required to accomplish this workload can be
written as
nc = number of carriers (vehicles) required,
WL = workload, min/hr
AT = available time per vehicle, min/hr per vehicle
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Conveyor Analysis
(1) single direction conveyors,
(2) continuous loop conveyors,
(3) recirculating conveyors.
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Conveyor Analysis
(1) single direction conveyors,
Time required to move materials from load station to unload station
Td = delivery time, min; Ld = length of conveyor between load and unload sta- tions,
m (ft), and vc = conveyor velocity, m/min
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Conveyor Analysis
(1) single direction conveyors,
Flow rate of materials on the conveyor
Rf = material flow rate, parts/min; RL = loading rate, parts/min;
sc = center to center spacing of materials on the conveyor, m/part
(ft/part); and TL = loading time, min/part
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Conveyor Analysis
(1) single direction conveyors,
time required to unload the conveyor must be equal to or less
than the reciprocal of material flow rat
Unit Load Principle: transporting np parts in a container
np = number of parts per container
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Conveyor Analysis
(1) single direction conveyors,
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Conveyor Analysis
(1) single direction conveyors,
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Conveyor Analysis
(2) continuous loop conveyors
Total length of the conveyor
The length of the delivery loop is Ld, and the length of the return loop is Le
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Conveyor Analysis
(2) continuous loop conveyors
total time required to travel the complete loop
Td = delivery time on the forward loop
number of carriers in the loop
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Conveyor Analysis
(2) continuous loop conveyors
Each carrier is capable of holding parts on the delivery loop, and
it holds no parts on the return trip
nc = number of carriers;
The maximum flow rate between load and un- load stations
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Conveyor Analysis
(3) recirculating conveyors.
Conveyor systems that allow parts or products to remain on the
return loop for one or more revolutions are called recirculating
conveyors .
Two problems:
(1) the possibility that no empty carriers are immediately available
at the loading station when needed
(2) the possibility that no loaded carriers are immediately
available at the unloading station when needed
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Conveyor Analysis
(3) recirculating conveyors.
Three basic principles must be obeyed in designing such a
conveyor system (Kwo principle)
Speed Rule:
RL = required loading rate, pc/min; and RU = the corresponding
unloading rate.
TL = time required to load a carrier, min/carrier; and TU = time
required to unload a carrier
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Conveyor Analysis
(3) recirculating conveyors.
Capacity Constraint: The flow rate capacity of the conveyor
system
Uniformity Principle: This principle states that parts (loads)
should be uniformly distributed throughout the length of the
conveyor
there will be no sections of the conveyor in which every
carrier is full while other sections are virtually empty
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Conveyor Analysis
(3) recirculating conveyors.
Dr. Van-Phong Vu-Department of Automatic Control
4.4 Analysis of Material Transportation system
Conveyor Analysis
(3) recirculating conveyors.
Dr. Van-Phong Vu-Department of Automatic Control
