Ch 10 Material Transport Systems

Sections:
1. Introduction to Material Handling Equipment
2. Material Transport Equipment
3. Analysis of Material Transport Systems

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 Material Handling Defined

“The movement, storage, protection and control of

materials throughout the manufacturing and distribution
process including their consumption and disposal” (The
Material Handling Industry of America)
 Estimated to represent 20-25% of total manufacturing
labor cost in US
 The proportion varies depending on type of
production and degree of automation

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 Material Handling

 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

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 Logistics
Concerned with the acquisition, movement, storage, and
distribution of materials and products to satisfy customer
demand
 Two categories of logistics:
 External logistics - transportation and related
activities that occur outside of a facility (between
different geographical locations)
 Five traditional modes of transportation: rail, truck,
air, ship, and pipeline
 Internal logistics – known as material handling, it
involves movement and storage of material within a
facility
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 External Logistics

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 Categories of
Material Handling Equipment
1. Material transport equipment - to move materials
inside a factory, warehouse, or other facility. Examples of such
equipment are industrial trucks, rail-guided vehicles, conveyors and cranes.

2. Storage - to store materials and provide access to

those materials when required. What are the main categories of
storage methods and equipment? Give examples.

3. Unitizing equipment - refers to (1) containers to hold

individual items during handling (examples include pallets, boxes, baskets,
barrels ) and (2) equipment used to load and package the

containers (examples include palletizers and depalletizers)

4. Identification and tracking systems - to identify and
keep track of the materials being moved and stored
(example: barcodes)
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 Design Considerations
in Material Handling
 Material characteristics
 Flow rate, routing, and scheduling
 Plant layout
 Unit load principle

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 Material Characteristics

 Material characteristics affect type of transport and storage

equipment required
 Physical state- Solid, liquid or gas (example: pipe lines used to move great
volumes of liquid over long distances)

 Size
 Weight
 Shape - long, flat, bulky
 Condition - hot, cold, wet, dirty
 Risk of damage - fragile, brittle
 Safety risk - explosive, flammable, toxic, corrosive

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 Flow Rate, Routing, and Scheduling
 Flow rate - amount of material moved per unit time.
 Examples: pieces/hr, pallet loads/hr, tons/hr
The unit is based on whether the material must be
moved in individual units, as batches, or continuously.
(if large quantity of a particular material must be handled at a certain flow rate, then a
dedicated handling system would be appropriate)

 Routing - includes pick-up and drop-off locations, move

distances, routing variations, conditions along the route.
(Give examples on the conditions along the route)

 Scheduling - timing of each delivery. The handling system should be

responsive to timely pickup and delivery of items, the system should also enable:

 Prompt delivery when required

 Use of buffer stocks to mitigate against late deliveries
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 Plant Layout

 Material handling equipment considerations must be

included in the plant layout design problem. (This could result in utilizing
the most appropriate type of handling system)

 Correlation between layout type and material handling

equipment:
Plant layout type Material handling equipment
Fixed-position Cranes, hoists, industrial trucks
Process Hand trucks, forklift trucks, AGVS
Product Conveyors for product flow
Trucks to deliver parts to stations

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 Unit Load Principle
 A unit load is the mass that is to be moved or otherwise
handled at one time. It may consist of one part, a container loaded with multiple parts,
or a pallet loaded with multiple containers of parts.

 In general, the unit load should be as large as practical

for the material handling system that will move and
store it
 Reasons for using unit loads in material handling:
 Multiple items handled simultaneously
 Required number of trips is reduced
 Loading/unloading times are reduced
 Product damage is decreased
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 Unit Load Containers

(a) Wooden pallet, (b) pallet box, (c) tote box

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 Material Transport Equipment

Five categories:
1. Industrial trucks
2. Automated guided vehicles
3. Monorails and other rail guided vehicles
4. Conveyors
5. Cranes and hoists

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 Industrial Trucks

Two basic categories:

1. Non-powered
 Human workers push or pull loads
2. Powered
 Self-propelled, guided or driven by human
 Common example: forklift truck

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 Nonpowered Industrial Trucks
(Hand Trucks)

(a) Two-wheel hand truck, (b) four-wheel dolly, (c) hand-

operated low-lift pallet truck

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 Powered Trucks:
Walkie Truck

 Wheeled forks insert into pallet openings (speed 5 km/hr)

 No provision for riding; truck is steered by worker using
control handle at front of vehicle
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 Powered Trucks:
Forklift Truck

 Widely used in factories

and warehouses because
pallet loads are so
common
 Capacities from 450 kg
(1000 lb) up to 4500 kg
(10,000 lb)
 Power sources include
on-board batteries and
internal combustion
motors
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 Powered Trucks:
Towing Tractor

 Designed to pull one or more trailing carts in factories and

warehouses, as well as for airport baggage handling
 Powered by on-board batteries or IC engines
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 Automated Guided Vehicles

An Automated Guided Vehicle System (AGVS) is a material

handling (transport) system that uses independently
operated, self-propelled vehicles guided along defined
pathways in the facility floor
 Types of AGV:
 Driverless trains
 Pallet trucks
 Unit load AGVs

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 Automated Guided Vehicles:
Driverless Automated Guided Train
 First type of AGVS to
be introduced around
1954
 Common application
is moving heavy
payloads over long
distances in
warehouses and
factories without
intermediate stops
along the route

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 Automated Guided Vehicles:
AGV Pallet Truck
 Used to move
palletized loads along
predetermined routes
 Vehicle is backed into
loaded pallet by
worker; pallet is then
elevated from floor
 Worker drives pallet
truck to AGV guide
path and programs
destination
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 Automated Guided Vehicles:
Unit Load Carrier

 Used to move unit loads from station to station

 Often equipped for automatic loading/unloading of pallets
and tote pans using roller conveyors, moving belts, or
mechanized lift platforms

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 AGVS Applications

1. Driverless train operations - movement of large quantities

of material over long distances
2. Storage and distribution - movement of pallet loads
between shipping/receiving docks and storage racks
3. Assembly line operations - movement of car bodies and
major subassemblies (motors) through the assembly
stations
4. Flexible manufacturing systems - movement of workparts
between machine tools

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 Vehicle Guidance Technology
 Method by which AGVS pathways are defined and
vehicles are controlled to follow the pathways – There are
three main technologies:
 Imbedded guide wires - guide wires in the floor emit
electromagnetic signal that the vehicles follow. (explain how
the vehicle decides on which path to take when the guide path forks into two or more?)

 Paint strips - optical sensors on-board vehicles track

the white paint strips (explain how this technology works? In which
cases its useful to be used?
 Self-guided vehicles - vehicles use a combination of
 Dead reckoning - vehicle counts wheel turns in given direction
to move without guidance
 Beacons located throughout facility - vehicle uses triangulation
to compute locations
What is the advantage of self-guided vehicle technology over fixed pathways?
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 Vehicle Guidance Using Guide Wire

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 Vehicle Management

Two aspects of vehicle management:

 Traffic control - to minimize interference between vehicles
and prevent collisions
1. Forward sensing (Uses one or more sensors on each vehicle to detect the presence of
other vehicles and obstacles ahead on the guide path)

2. Zone control (the AGVS layout is divided into separate zones, and the operating rule is that no
vehicle is permitted to enter a zone that is already occupied by another vehicle)

 Vehicle dispatching
1. On-board control panel
2. Remote call stations (What is the simplest form of a call station?)
3. Central computer control (where does it usually used?)
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 Zone Control

Zone control to implement blocking system. Zones A, B,

and D are blocked. Zone C is free. Vehicle 2 is blocked
from entering Zone A by vehicle 1. Vehicle 3 is free to
enter Zone C.

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 Vehicle Safety

 Travel velocity of AGV is slower than typical walking

speed of human worker
 Automatic stopping of vehicle if it strays from guide path
 Acquisition distance
 Obstacle detection system in forward direction
 Use of ultrasonic sensors common
 Emergency bumper - brakes vehicle when contact is made
with forward object
 Warning lights (rotating red lights)
 Warning sounds of approaching vehicles
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 Rail-Guided Vehicles

 Self-propelled vehicles that ride on a fixed-rail system

 Vehicles operate independently and are driven by
electric motors that pick up power from an electrified rail
 Fixed rail system
 Overhead monorail - suspended overhead from the
ceiling
 On-floor - parallel fixed rails, tracks generally
protrude up from the floor
 Routing variations are possible: switches, turntables,
and other special track sections

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 Overhead Monorail

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 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

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 Conveyor Types

 Roller
 Skate-wheel
 Belt
 In-floor towline
 Overhead trolley conveyor
 Cart-on-track conveyor

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 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
 Un-powered roller
conveyors also available
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 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
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 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: (Support frame not shown)

 Flat belt (shown)

 V-shaped for bulk
materials
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 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

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 Overhead Trolley Conveyor

 A trolley is a wheeled
carriage running on an
overhead track from which
loads can be suspended
 Trolleys are connected and
moved by a chain or cable
that forms a complete loop
 Often used to move parts
and assemblies between
major production areas
What is power-and-free overhead trolley conveyor?
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 Cart-On-Track Conveyor

 Carts ride on a track

above floor level
 Carts are driven by a
spinning tube
 Forward motion of
cart is controlled by a
drive wheel whose
angle can be
changed from zero
(idle) to 45 degrees
(forward)
What is the main advantage of cart-on-
track ©2008
conveyor?
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 Powered Conveyor
Operations and Features
 Types of motions
1. Continuous - conveyor moves at constant velocity
2. Asynchronous - conveyor moves with stop-and-go
motion, loads usually contained in carriers
 They stop at stations, move between stations
Examples: overhead power-and-free trolley, cart-on-track conveyors
What are the reasons for using asynchronous conveyors?

 Another classification of conveyors:

1. Single direction (used to move material in one direction, and when there is no need to return
containers back to the loading station. Examples: roller, skate-wheel, belt conveyors.)

2. Continuous loop (in this type of conveyors, the empty containers or carriers are
automatically returned from the unload station to the load station. Example: overhead trolley conveyor)

3. Recirculating (allow parts or products to remain on the return loop, used to smooth out the
effects of loading and unloading variations)
 (a) Single-Direction Conveyor and
(b) Continuous Loop Conveyor

(a) Single direction

conveyor

(b) Continuous loop

conveyor

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 Cranes and Hoists

Handling devices for lifting, lowering and transporting

materials, often as heavy loads
 Cranes
 Used for horizontal movement of materials
 Hoists
 Used for vertical lifting of materials
 Cranes usually include hoists so that the crane-and-hoist
combination provides
 Horizontal transport
 Vertical lifting and lowering
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 Hoist

Hoist with mechanical

advantage of four:
(a) sketch of the hoist
(b) diagram to
illustrate mechanical
advantage

(a) (b)

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 Bridge Crane

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 Gantry Crane

A half-gantry crane

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 Jib Crane

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 Analysis of
Material Transport Systems

 Analysis of vehicle-based systems

 From-to network diagrams
 Types of systems: industrial trucks, AGVS, rail-guided
vehicles, and asynchronous conveyor operations
 Conveyor analysis
 Single-direction conveyors
 Closed loop conveyors
 Recirculating conveyor systems

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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Network Diagram Showing Deliveries
between Load/Unload Stations

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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Analysis of
Vehicle Based Systems

 Delivery cycle time (min/del) Tc equals to

Tc = TL + Ld / vc + TU + Le / vo
TL = time to load at load station (min)
Ld = distance the vehicle travels between load and unload stations (m)
vc = vo = carrier velocity
TU = time to unload at unload station (min)
Le = distance the vehicle travels empty until the start of the next cycle (m)

The ideal hourly rate of deliveries per vehicle is 60 min divided by the delivery
cycle time Tc , that is
Rdv(ideal) = 60 / Tc
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Analysis of
Vehicle Based Systems contd.
 However, we have to adjust for any time losses during the
hour; this can be expressed as:
Rdv = 60 A Ft Ew / Tc
Rdv = hourly delivery rate per vehicle (del/hr per vehicle)
A = Availability
Ft = traffic factor (to account for waiting in a queue or at intersections)
Ew = worker efficiency (only for carrier operated by human worker)
 Now, We can calculate number of carriers (vehicles) required to satisfy a
specified total delivery requirement from the following equation:
nc = Rf / Rdv
where nc = number of carriers required, and Rf = total delivery
requirements in the system (del/hr). See example 10.1
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Problem10.5

 An automated guided vehicle system has an average

travel distance per delivery (Ld) = 200 m and an average
empty travel distance (Le) = 150 m. Load and unload times
are each (TL=TU) 24 s and the speed (vc=vo ) of the AGV =
1 m/s. Traffic factor (Ft ) = 0.9. How many vehicles are
needed to satisfy a delivery requirement of (Rf) 30
deliveries/hour? Assume that availability (A) = 0.95.
 Solution: Tc = 24 + 200/1 + 24 + 150/1 = 398 s = 6.63 min
Rdv = 60(0.90)(0.95)/6.63 = 7.73 deliveries/hr per vehicle
nc = 30/7.73 = 3.88  4 vehicles

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Problem 10.1
 A flexible manufacturing system is being planned. It has a ladder layout as
pictured in Figure P10.1 and uses a rail guided vehicle system to move parts
between stations in the layout. All workparts are loaded into the system at
station 1, moved to one of three processing stations (2, 3, or 4), and then
brought back to station 1 for unloading. Once loaded onto its RGV, each
workpart stays onboard the vehicle throughout its time in the FMS. Load and
unload times at station 1 are each 1.0 min. Processing times at other stations
are: 5.0 min at station 2, 7.0 min at station 3, and 9.0 min at station 4. Hourly
production of parts through the system is: 7 parts through station 2, 6 parts
through station 3, and 5 parts through station 4. (a) Develop the network
diagram for this data similar to Figure 10.13. (b) Determine the number of rail
guided vehicles that are needed to meet the requirements of the flexible
manufacturing system, if vehicle speed = 60 m/min and the anticipated traffic
factor = 0.85. Assume reliability = 100%.

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Problem 10.1 solution
 (a) Network diagram:
5/50 7/30
4
5/40 1 2
7/20

6/30 6/40

 Ld = 7(30  20)  6(40  30)  5(50  40) = 67.7 m , Le = 0

7 6 5
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Problem 10.1 solution

 Average handling and processing time =

1.0 + 7(5.0)  6( 7.0)  5( 9.0) + 1.0 = 8.78 min
7 6 5

67.7
 Tc = 8.78 + 60
= 9.91 min

60( 0.85)
 Rdv = 9.91 = 5.15 pc/hr per vehicle

7 6 5
 (b) nc = 515
.
= 18/5.15 = 3.5  4 vehicles

©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Analysis of
Single Direction Conveyer

 Consider the case of a single direction powered conveyor

with one load station at the upstream end and one unload
station at the downstream end

 the time required to move materials from load station to

unload station is given by:
 Analysis of
Single Direction Conveyer…..continued

 The flow rate of materials on the conveyor is determined

by the rate of loading at the load station; given by:

 where 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).
 An additional requirement for loading and unloading is that
the time required to unload the conveyor must be equal to
or less than the loading time Tu. That is,
 Analysis of
Single Direction Conveyer…..continued

 For transporting np parts in a carrier rather than a single

part, Rf can be written as:

 where Rf = material flow rate (parts/min), np = number of

parts in carrier (parts), sc = center to-center spacing of
materials on the conveyor (m/part, ft/part]. and TL =
loading time (min/part).
Analysis of Single Direction Conveyer…..continued
Problem 10/19