(Textbook Chapter 5)
Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

• Material Handling accounts for:
– 25% of all employees,
– 55% of all factory space,
– 87% of production time
– 15-70% of the total cost of a manufactured product
• 3-5% of all material handled becomes damaged
– “Totally eliminate”
– However, handling less is not the answer.
Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

• Material handling is a means by which:
– Total manufacturing costs are reduced through
• Reduced inventory
• Improved safety
• Reduced pilferage
• Improved material control.
– Manufacturing quality is improved by:
• Reducing inventory
• Reducing damage
– Any production strategy is executed.
Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

•
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.
Status: Real-time awareness of the location, amount, destination, origin, ownership, and schedule of material.
Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

9. Environmental
10. Life Cycle Cost
1. Planning
2. Standardization
8. Automation
MH
3. Work principle
7. System
6. Space Utilization
5. Unit load
Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003
4. Ergonomic

No pre-kitting of work
System not capable of change or expansion
Idle production equipment due to material shortage
Automatic data collection system not used
Material piled directly on floor
MH
Backtracking of material
In-plant containers not standardized
Misdirected material
Excessive demurrage
Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003
Operators travel excessively for materials and supplies

1. Define the objectives and scope for the material handling system.
2. Analyze the requirements for moving, storing, protecting, and controlling material.
3- Generate alternative designs for meeting material handling system requirements.
4. Evaluate alternative material handling system designs.
5. Select the preferred design for moving, storing, protecting, and controlling material.
6. Implement the preferred design, including the selection of suppliers, training of personnel, installation, debug and startup of equipment, and periodic audits of system performance.
Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

NADLER’s IDEALS approach:
1.
Aim for the theoretical ideal system.
2.
Conceptualize the ultimate ideal system.
3.
Design the technologically workable ideal system.
4.
Install the recommended system.
Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

The What Question
1. What are the types of material to be moved?
2. What are their characteristics?
3. What are the amounts moved and stored?
The Where Question
• Where is the material coming from? Where should it come from?
• Where is the material delivered? Where should it be delivered?
• Where is the material stored? Where should it be stored?
• Where can material handling tasks be eliminated, combined or simplified?
• Where can you apply mechanization or automation?
The When Question
1. When is material needed? When should it be moved?
2. When is it time to mechanize or automate?
3. When should we conduct a material handling performance audit?
The How Question
1. How is the material moved or stored? How should material be moved or stored? What are the alternative ways of moving or storing the material?
2. How much inventory should be maintained?
3- How is the material tracked? How should the material be tracked?
4. How should the problem be analyzed?
The Who Question
1. Who should be handling material? What are the required skills to perform the material handling tasks?
2. Who should be trained to service and maintain the material handling system?
3. Who should be involved in designing the system?
The Which Question
1. Which material handling operations are necessary?
2. Which type of material handling equipment, if any, should be considered?
3. Which material handling system is cost effective?
4. Which alternative is preferred?
Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

“ picked up and moved between two locations as a single mass”
Example:
1. a single item picked up and moved manually between two locations
2. Two tote pans with identical components picked up moved by a dolly from one machine to another
3. One pallet load of nonuniform-size cartons with different products picked up and moved by a lift truck from the packaging area to the shipping dock
4. One full load of products delivered by a trucktrailer from a warehouse to a customer store If the trailer is half full, it is still one unit load.
Larger unit load:
+ fewer moves
- bigger and heavier equipment
wider aisles
higher floor load capacities
increased work-in-process inventory
Smaller unit load:
+ reduced work-in-process inventory
+simple material handling methods (i.e., push carts)
+reduced completion time (How??)
more moves
increased material handling time
“Achieving single unit production requires the materail handling time to be shorter than the unit processing time.”
Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

1. Containers and Unitizing Equipment
• Containers
• Unitizers
2. Material Transport Equipment
• Conveyors
• Industrial Vehicles
• Monorails, Hoists, and Cranes
3. Storage and Retrieval Equipment
• Unit Load Storage and Retrieval
• Unit Load Storage Equipment
• Unit Load Retrieval Equipment
• Small Load Storage and Retrieval
4. Automatic Data Collection and Communication Equipment
• Automatic Identification and Recognition
• Automatic Paperless Communication
Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003

18. Cost
17. Layout
16. System Flow
19. Maintenance
20. Obsolescence
15. Computerization
14. Safety
MH
13. Gravity
12. Simplification 10. Mechanization
11. Flexibility
9. Ecology
Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003
1. Orientation
2. Planning
3. Systems
4. Unit load principle
5. Space utilization
6. Standardization
7. Ergonomic
8. Energy

Shared by Ryan Patton, Irving ISD
Dr. Muzaffer Kapanoğlu - Decision Support Systems © 2003