Material Handling Equipment - Industrial and Systems Engineering

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MATERIAL HANDLING EQUIPMENTThe Unit Load ConceptA unit load is either a single unit of an item, or multiple units so arranged or restricted that theycan be handled as a single unit and maintain their integrity.Advantages of unit loads:1. More items can be handled at the same time, thereby reducing the number of trips requiredand, potentially, reducing handling costs, loading and unloading times, and productdamage.2. Enables the use of standardized material handling equipment.Figure 1. Unit vs. bulk handling of material. 4Disadvantages of unit loads:1. Time spent forming and breaking down the unit load.2. Cost of containers/pallets and other load restraining materials used in the unit load3. Empty containers/pallets may need to be returned to their point of origin.Basic ways of restraining a unit load:• Self-restraining—one or more units that can maintain their integrity when handled as asingle item (e.g., a single part or interlocking parts)4
1. OVERVIEW OF MATERIAL HANDLING• Platforms—pallets (paper, wood, plastic, metal), skids (metal, plastic)• Sheets—slipsheets (plastic, cardboard, plywood)• Reusable containers—tote pans, pallet boxes, skid boxes, bins, baskets, bulk containers(e.g., barrels), intermodal containers• Disposable containers—cartons, bags, crates• Racks—racks• Load stabilization—strapping, shrink-wrapping, stretch-wrapping, glue, tape, wire, rubberbandsBasic ways of moving a unit load:• Use of a lifting device under the mass of the load (e.g., a pallet and fork truck)• Inserting a lifting element into the body of the load (e.g., a coil of steel)• Squeezing the load between two lifting surfaces (e.g., lifting a light carton between yourhands, or the use of carton clamps on a lift truck)• Suspending the load (e.g., hoist and crane)Unit Load DesignUnit loads can be used both for in-process handling and for distribution (receiving, storing, andshipping).Unit load design involves determining the:1. Type, size, weight, and configuration of the load2. Equipment and method used to handle the load3. Methods of forming (or building) and breaking down the load.Selecting unit load size for in-process handling:• Unit loads should not be larger than the production batch size of parts in process—if theunit load size is larger, then a delay would occur if the load is forced to wait until the nextbatch of the part is scheduled to start production (which might be days or weeks) before itcan be transported.• Large production batches (used to increase the utilization of bottleneck operations) can besplit into smaller transfer batches for handling purposes, where each transfer batchescontains one or more unit loads, and small unit loads can be combined into a larger transferbatch to allow more efficient transport (e.g., several cartons at a time can be transported ona hand truck, although each carton is itself a unit load and could be transported separately);thus:Single part ≤ Unit load size ≤ Transfer batch size ≤ Production batch size• When parts are transferred between adjacent operations, the unit load may be a single part.5
Page 3: 1. OVERVIEW OF MATERIAL HANDLING6.
Page 7 and 8: 2. MAJOR EQUIPMENT CATEGORIES2. Maj
Page 9 and 10: 2. MAJOR EQUIPMENT CATEGORIESTransp
Page 11 and 12: 3. LOAD FORMATION EQUIPMENT3. Skids
Page 13 and 14: 3. LOAD FORMATION EQUIPMENT12. Inte
Page 17 and 18: 3. LOAD FORMATION EQUIPMENTabreast
Page 19 and 20: 3. LOAD FORMATION EQUIPMENTFigure 4
Page 21 and 22: 4. POSITIONING EQUIPMENTLifting Equ
Page 23 and 24: 4. POSITIONING EQUIPMENT8. HoistUse
Page 25 and 26: 5. CONVEYORS5. ConveyorsConveyors a
Page 27 and 28: 5. CONVEYORS3(a) Gravity roller con
Page 29 and 30: 5. CONVEYORS9. Bucket conveyorBulk
Page 31 and 32: 5. CONVEYORSSeries of flexible conv
Page 33 and 34: 5. CONVEYORSindependently and the t
Page 35 and 36: 5. CONVEYORSTilt tray sorters usual
Page 37 and 38: 6. CRANES2. Bridge craneBridge moun
Page 39 and 40: 7. INDUSTRIAL TRUCKS7. Industrial T
Page 41 and 42: 7. INDUSTRIAL TRUCKS1(a) Two-wheele
Page 43 and 44: 7. INDUSTRIAL TRUCKS5(a) Walkie pla
Page 45 and 46: 7. INDUSTRIAL TRUCKS9(a) Operator-d
Page 47 and 48: 7. INDUSTRIAL TRUCKSabsolute positi
Page 49 and 50: 7. INDUSTRIAL TRUCKSPrinciple of Op
Page 51 and 52: 7. INDUSTRIAL TRUCKS0( ) − ( )M
Page 53 and 54: 7. INDUSTRIAL TRUCKS3. Forks: attac
Page 55 and 56:
8. STORAGE EQUIPMENT• Dead-reckon
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8. STORAGE EQUIPMENT3. Drive-in rac
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8. STORAGE EQUIPMENT7. Sliding rack
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8. STORAGE EQUIPMENTOne operator pi
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8. STORAGE EQUIPMENTS/R Machine: An
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9. MH EQUIPMENT SELECTIONTable 12.
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10. REFERENCES10. ReferencesThe fol
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Material Handling Equipment - Industrial and Systems Engineering

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