AGV forklift, AGV forklift truck - All industrial manufacturers

Carrying capacity: 5 t
Lifting height: 1,500 mm

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Compact forklift with a 5-ton capacity. Thanks to its automatic battery replacement system, the FC50E can be configured to meet the specific needs of any industrial environment, ensuring reliable and sustainable performance ...

Counterbalance AGVs have counterweights at the rear of the vehicle to eliminate the need for support legs around loads (such as with Straddle AGVs). This allows the lift mast to be integrated at the front, ...

Carrying capacity: 2,000, 3,000, 1,500, 4,500, 800 kg
Lifting height: 3,000 mm
Overall width: 1,800, 1,000, 1,600, 820 mm

Auriga CT are counterbalanced vehicles with forks. These vehicles are designed for transporting any type of product. HIGH STABILITY OF THE PRODUCT BEING MOVED POSSIBILITY OF HANDLING PALLETS, HALF PALLETS AND QUARTERS OF A PALLET product ...

Carrying capacity: 1,200 kg - 2,000 kg
Travel speed: 2 m/s

Autonomous Mobile Robot (AMR/ASV) F series vehicles are designed for palletized load handling by forks. This pallet handling system allows itself to have a great versatility when picking and delivering pallets in different positions. Depending ...

Carrying capacity: 4,500, 4,000, 5,500, 5,000 kg
Lifting height: 3,300 mm
Overall width: 1,415, 1,965, 1,460 mm

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These larger engine 4 to 5.5 tonnes powered forklift models are designed for heavy duty applications and are the natural choice for use in ports, construction, freight, and metal and brick operations. With exceptional ...

Carrying capacity: 4,000 kg

... four-way forklifts, the loads to be picked up can also be approached and picked up from the side, as the wheels can be turned 90 degrees, i.e. no more maneuvering in narrow aisles. Even more versatile on the road are ...

Lifting height: 1,500 mm

The FX20 is a compact counterbalance AGV and ideal where closed pallets are required. It is perfect in operations or applications where the fork over or straddle options cannot be used, its small footprint and optimum ...

AGV forklifts are the most common vehicles for moving pallets and or other products in production lines. Equipped with forks, they are able to balance the load and move it with safety and precision.

Carrying capacity: 2,500 kg
Lifting height: 4,500 mm - 10,000 mm
Overall width: 1,728 mm

Zowell RSEW series 2.5 ton electric multi-directional forklift is one product suitable for moving long cargo whose length is within 10m.It adopts thumb switch and proportional function to make the truck more stable and ...

Contact us to discuss your requirements of AGV and CMR Conveyor Supplier. Our experienced sales team can help you identify the options that best suit your needs.

• 1. UNIT-4
• 2. MATERIAL HANDLING FUNCTION  The development of material handling system to move materials from one stage of production to another is very important.  Materials handling includes moving, packaging, and storing all the materials used by the production unit.  Materials handling is one of the important activities in materials management and also in production.  Materials are received by rail or truck. It is moved into the plant and thereafter to the storeroom. When material is needed, it is moved along the path of assembly.  Plant layout and materials handling are closely inter-related. This statement is true as materials handling activity needs to be adjusted as per the layout of the plant.
• 3. Contd… • Material handling. ... It utilizes a wide range of manual, semi- automated, and automated equipment and includes consideration of the protection, storage, and control ofmaterials throughout their manufacturing, warehousing, distribution, consumption, and disposal. Role of material handling: Material handling plays an important role in manufacturing and logistics, which together represent over 20% of the U.S. economy. Almost every item of physical commerce was transported on a conveyor or lift truck or other type of material handling equipment in manufacturing plants, warehouses, and retail stores.
• 4. Contd… Types of material handling: Manual handling Automated handling Manual handling: Manual handling refers to the use of a worker’s hands to move individual containers by lifting, lowering, filling, emptying, or carrying them. It can expose workers to physical conditions that can lead to injuries that represent a large percentage of the over half a million cases of musculoskeletal disorders reported in the U.S. each year, and often involve strains and sprains to the lower back, shoulders, and upper limbs
• 5. Contd…. Automated handling: Whenever technically and economically feasible, equipment can be used to reduce and sometimes replace the need to manually handle material.  Most existing material handling equipment is only semi- automated because a human operator is needed for tasks like loading/unloading and driving that are difficult and/or too costly to fully automate, although ongoing advances in sensing, machine intelligence, and robotics have made it possible to fully automate an increasing number of handling tasks.
• 6. TYPES OF EQUIPMENT USED Industrial Trucks:  Industrial trucks are trucks that are not licensed to travel on public roads  Industrial trucks are used to move materials over variable paths and when there is insufficient (or intermittent) flow volume such that the use of a conveyor cannot be justified. Conveyors:  Conveyors are used when material is to be moved frequently between specific points over a fixed path and when there is a sufficient flow volume to justify the fixed conveyor investment.
• 7. Contd… Cranes: Cranes are used to transport loads over variable (horizontal and vertical) paths within a restricted area and when there is insufficient (or intermittent) flow volume such that the use of a conveyor cannot be justified. Cranes provide more flexibility in movement than conveyors because the loads handled can be more varied with respect to their shape and weight
• 8. Contd… Automated guided vehicle: An automated guided vehicle or automatic guided vehicle (AGV) is a portable robot that follows markers or wires in the floor, or uses vision, magnets, or lasers for navigation. They are most often used in industrial applications to move materials around a manufacturing facility or warehouse. Application of the automatic guided vehicle broadened during the late 20th century.
• 9. CONVEYOR SYSTEMS • A conveyor system is a common piece of mechanical handling equipment that moves materials from one location to another. Conveyors are especially useful in applications involving the transportation of heavy or bulky materials. • Conveyor systems allow quick and efficient transportation for a wide variety of materials, which make them very popular in the material handling and packaging industries. • Many kinds of conveying systems are available and are used according to the various needs of different industries.
• 10. Contd….. Types of conveyor systems: Conveyor belt: A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt conveyor). A belt conveyor system is one of many types of conveyor systems. A belt conveyor system consists of two or more pulleys, with an endless loop of carrying medium—the conveyor belt—that rotates about them. One or both of the pulleys are powered, moving the belt and the material on the belt forward.
• 11. Contd… Chain conveyor: Chain conveyors utilize a powered continuous chain arrangement, carrying a series of single pendants. The chain arrangement is driven by a motor, and the material suspended on the pendants are conveyed.  Chain conveyors are used for moving products down an assemble linen and/or around a manufacturing or warehousing facility. Chain conveyors are primarily used to transport heavy unit loads, e.g. pallets, grid boxes, and industrial containers. These conveyors can be single or double chain strand in configuration. The load is positioned on the chains, the friction pulls the load forward. Chain conveyors are generally easy to install and have very minimum maintenance for users.
• 12. Contd…
• 13. Contd… Screw conveyor: A screw conveyor or auger conveyor is a mechanism that uses a rotating helical screw blade, called a "flighting", usually within a tube, to move liquid or granular materials. They are used in many bulk handling industries. Screw conveyors in modern industry are often used horizontally or at a slight incline as an efficient way to move semi-solid materials, including food waste, wood chips, aggregates, cereal grains, animal feed, boiler ash, meat and bone meal, municipal solid waste, and many others. The first type of screw conveyor was the Archimedes' screw, used since ancient times to pump irrigation water.
• 14. Contd…
• 15. Contd…. Vertical conveyor systems: Vertical conveyor - also commonly referred to as freight lifts and material lifts - are conveyor systems used to raise or lower materials to different levels of a facility during the handling process.  Examples of these conveyors applied in the industrial assembly process include transporting materials to different floors. While similar in look to freight elevators, vertical conveyors are not equipped to transport people, only materials.
• 16. Contd….
• 17. Contd.. Line shaft roller conveyor:  A lines haft roller conveyor or line-shaft conveyor is, as its name suggests, powered by a shaft beneath rollers. These conveyors are suitable for light applications up to 50 kg such as cardboard boxes and tote boxes.
• 19. CONTENTS • Introduction • History of AGV’S • What is AGV? • Types of AGV’s • Why consider AGV’s • Types of navigations in AGV’s • Applications of AGV’s
• 20. INTRODUCTION • AGVs increase efficiency and reduce costs by helping to automate a manufacturing facility or warehouse. • AGVs can carry loads or tow objects behind them in trailers. The trailers can be used to move raw materials or finished product. The AGV can also store objects on a bed. some AGVs use fork lifts to lift objects for storage. AGVs are employed in nearly every industry, including, paper, metals, newspaper and general manufacturing
• 21. Continued… • An AGV can also be called a laser guided vehicle(LGV) or self-guided vehicle (SGV). In Germany the technology is also called Fahrerlose Transport system (FTS) and in Sweden Forarlosa trucker. • AGVs are available in a variety of models and can be used to move products on an assembly line, transport goods throughout a plant or warehouse.
• 22. History of AGV’S • The first AGV was brought to market in the s, by Barrett Electronics of Northbrook, and at the time it was simply a tow truck that followed a wire in the floor instead of a rail. over the years the technology has become more sophisticated and today automated vehicles are mainly Laser navigated ex: LGV. • In an automated process, LGVs are programmed to communicate with other robots to ensure product is moved smoothly through the warehouse, whether it is being stored for future use or sent directly to shipping areas. Today the AGV plays an important role in the design of new factories and warehouses.
• 23. AGV? • AGV is a material handling system that uses independently operated, self-propelled vehicles guided along defined pathways.
• 24. COMPONENTS OF AGV • Vehicle • Guided path • Control unit • Computer interface
• 25. CarryBee(AGV) Dolly type(D type) 1. Towing type 2. Loading type Low height type  Short type (S type)  Mid-sized type (M type)  Heavy-duty type (H type)  Super low height type (L type)  Super low speed type  Low height towing (Kai) Kit (K type)
• 32. Why consider AGVs? • Reduces the labor cost. • Flexible. • Intelligent. • Time consuming. • Can significantly reduce production & warehouse costs. • Transforming the materials handling industry.
• 33. TYPES OF NAVIGATION IN AGV’S • Wired navigation • Guide tape navigation • Laser target navigation
• 34. WIRED NAVIGATION • The wired sensor is placed on bottom of the AGV’S and is placed facing the ground. • A slot is cut in the ground and a wire is placed approximately 1 inch below the ground. • The sensors detects the radio frequency being transmitted from the wire and follows it.
• 36. GUIDE TAPE NAVIGATION • The AGV’S( some known as automated guided carts or AGC’S) use magnetic tape for the guide path. • The AGC’S is fitted with the appropriate guide sensors to follow the path of the tape. • It is considered a “passive” system since it does not require the guide medium to be energized as wire does.
• 37. GUIDE TAPE NAVIGATION AGV’S
• 38. LASER TARGET NAVIGATION • The AGV’S carry’s a laser transmitter and receiver on a rotating turret. • The laser is sent off then received again the angle and distances are automatically calculated and stored into AGV’S memory. • The AGV’S has reflector map stored in memory and can correct its position based on errors between the expected and received measurements. • It can then navigate to a destination target using the constantly updating position.
• 39. LASER TARGET NAVIGATION AGV’S
• 40. COMMON AGV APPLICATIONS Automated Guided Vehicles can be used in a wide variety of applications to transport many different types of material including pallets, rolls, racks, carts, and containers. RAW MATERIAL HANDLING: AGVs are commonly used to transport raw materials such as paper, steel, rubber, metal, and plastic. This includes transporting materials from receiving to the warehouse, and delivering materials directly to production lines.
• 41. WORK-IN-PROCESS MOVEMENT: Work-in-Process movement is one of the first applications where automated guided vehicles were used, and includes the repetitive movement of materials throughout the manufacturing process. PALLET HANDLING: Pallet handling is an extremely popular application for AGVs as repetitive movement of pallets is very common in manufacturing and distribution facilities.
• 42. FINISHED PRODUCT HANDLING: Moving finished goods from manufacturing to storage or shipping is the final movement of materials before they are delivered to customers. These movements often require the gentlest material handling because the products are complete and subject to damage from rough handling.
• 44. GUIDANCE SYSTEMS What is a guidance system? A guidance system is what directs the vehicle on the path it will take to get from point “A” to point “B.” The decision about the type of guidance system that will be used is one of the most crucial that will be made. Some guidance systems have a high reliability and very rarely fail, but these same guidance systems restrict the flexibility of the factory.
• 45. TYPES OF GUIDANCE SYSTEM • WIRE GUIDANCE • OPTICAL GUIDANCE • Spot Guidance • Paint/Chemical Guidance • LASER GUIDANCE • INERTIAL GUIDANCE • DEAD-RECKONING GUIDANCE SYSTEM • BEACON GUIDANCE
• 46. WIRE GUIDANCE Wire guidance is the most common type of guidance system. It is known to be reliable, but not very flexible. The wire that carries an electric current is embedded in concrete along the pre-determined path. The groove that carries the guidance wire can also be used to carry communication cables so messages can be transmitted to the AGV without the use of an RF modem.
• 47. OPTICAL GUIDANCE • There are two basic types of optical guidance systems. The first is spot guidance system that uses spots of reflective material on the ground to guide the vehicle. • The second system is the painted line guidance system that uses a paint or chemical path for guidance.
• 48. SPOT GUIDANCE • A spot guidance system uses lights on the bottom of the vehicle such as halogen lamps. • This light is reflected off reflective spots on the floor such as a small glass beads to a camera or other sensor on the bottom of the vehicle. • Different shapes of glass bead can have different meanings to the vehicle such as: Stop, turn left, turn right, etc.
• 49. PAINT/CHEMICAL GUIDANCE • This type of system uses a line of fluorescent particles or dye to indicate the path for the vehicle to follow. • Once again, sensors on the vehicle are used to detect reflected light to indicate to the vehicle its position in relation to the specified path. • Information codes can also be set on the path and the sensor will “read” the codes and perform the action instructed by the code such as: Stop, turn left, slow down, etc.
• 50. LASER GUIDANCE Laser guidance using reflective targets and a laser scanner, the exact location of the AGV can be calculated. Unlike the wire guided and optical systems, “a laser guidance system does not rely on floor-based reference points”. The targets are mounted on the wall and are scanned by the scanner on the AGV.
• 51. INERTIAL GUIDANCE The inertial guidance system is different from any of the other guidance systems previously discussed. The inertial guidance system uses a gyroscope to determine the direction the AGV is moving. The vehicle can be programmed to take a variety of courses without additional costs due to moving wire or setting up new “targets.”
• 52. DEAD-RECKONING GUIDANCE SYSTEM • Dead-reckoning refers to another non-wire system. This system uses an optical encoder on the drive wheels to measure rotation and steer angle. • A controller is used to calculate the position of the AGV based on the starting position, the internal map, and the information that is provided by the optical encoder. • The dead-reckoning guidance system adds flexibility over the wire guided system or optical systems, but they require smooth surfaces to run on
• 53. BEACON GUIDANCE • The beacon guidance system operates on a concept similar to that of the laser guidance system. In the beacon system, beacons are placed in strategic locations around the plant. The AGV is programmed with the exact location of these beacons. • As with all of the other non-wire guidance systems, the beacon system offers higher flexibility as compared to the wire guidance system or optical systems
• 54. ROUTING OF AGVS The routing of an AGVS defines the path the guidance system will take based on a number of design factors from the number of vehicles to be used to the amount of space available to run the AGV. FLOOR SPACE • The amount of floor space that is available restricts the number of vehicles that can pass through an area at the same time. • Floor space availability will affect the guide path due to some areas having more obstructions or foot traffic than others will
• 56. STATIC PATH Static guide paths are used when every possible pick-up or drop- off point is known. If these points are known, there will be a finite number of routes that can be taken to get from one to the other. Unidirectional Systems Bi-directional Systems
• 57. UNIDIRECTIONAL SYSTEMS • The vehicles are only allowed to travel in one direction. The vehicles are given a single lane, and they travel in somewhat of a loop to and from the destinations. • . Even though AGVs are only allowed to travel a certain direction in a given lane, if a particular aisle can support more than one lane, it can still be unidirectional as long as each lane only has traffic proceeding in one direction.
• 58. BI-DIRECTIONAL SYSTEMS • A bi-directional system allows vehicles to use the same lane to travel in either direction. “This functionality can be accomplished by providing turnaround points for vehicles or by using bi-directional vehicles…” • Bi-directional systems do increase the complexity of dispatching due to multiple vehicles going two directions on the same path, but as previously noted, there are some benefits to it.
• 59. DYNAMIC PATH • A dynamic path system is not typically used in the industrial environment. In this type of system, the vehicle must have a map of the area. • Once it receives its next location, it plots its own course, and uses ultrasonics or other sensors to avoid collisions. • . This is an extremely flexible system because there are no beacons to set, not target to hit, and no wires to follow.
• 60. WORK ZONE TRAFFIC CONTROL & SAFETY
• 61. WORK ZONE TRAFFIC CONTROL • Influences drivers’ perception of risk • Provides information on potential hazards • Minimizes aggressive behavior • Assists in navigation • Engineering concerns for work zones • Primary focus: Safe and efficient movement of vehicles through work zone • Relatively less emphasis on safety of construction workers
• 62. TYPE OF BARRIER • Rigid Barriers • Provide separation between • Opposing traffic lanes • Traffic lanes and work area • Cause damage to motorists if struck Concrete barrier separating opposing traffic Concrete barrier separating traffic lanes and work area
• 63. TYPE OF BARRIER • Flexible barriers (channelizing devices) – Provide nominal protection for workers – Flexible and deformable, do not cause damage if struck Flexible barrier separating traffic lanes and work area Channelizing devices for delineation Concrete barriers to separate work area
• 64. • Advanced Warning Area • Transition Area • Activity Area • Work space • Traffic space • Buffer space • Termination Area COMPONENTS OF TEMPORARY TRAFFIC CONTROL ZONES(Source: MUTCD )
• 65. WORKER SAFETY CONSIDERATIONS IN WORK ZONE TRAFFIC CONTROL • Modifying traffic control strategies to influence drivers’ perception of risk • Leads to more careful and slower driving • Improves safety for the workers • Examples: • Providing active warning devices • Illuminated arrow boards • Reliable advisory speed limit • Active message with flashers • Narrower lane widths • Longer and/or wider buffer zones
• 66. TYPES OF TTC APPLICATIONS • Each TTC zone is different • Many variables affect the needs of each zone: • Location of work • Duration of work • Highway type • Geometrics • Vertical and horizontal alignment, intersections, interchanges, etc. • Road user volumes • Road vehicle mix (buses, trucks, and cars) and road user speeds
• 67. WORK DURATION • Major factor in determining the number and types of devices used in TTC zones • As per the MUTCD, five categories of work duration are defined: • Long-term stationary is work that occupies a location more than 3 days • Intermediate-term stationary is work that occupies a location more than one daylight period up to 3 days, or nighttime work lasting more than 1 hour • Short-term stationary is daytime work that occupies a location for more than 1 hour within a single daylight period • Short duration is work that occupies a location up to 1 hour • Mobile is work that moves intermittently or continuously.
• 68. MOBILE WORK • Often involve frequent short stops for activities • Such as litter cleanup, pothole patching, or utility operations, and are similar to short-duration operations • TTC zones may includes: • Warning signs, high-intensity rotating, flashing, oscillating, or strobe lights on a vehicle, flags, and/or channelizing devices • Flaggers • A shadow vehicle equipped with an arrow panel or a sign following the work vehicle • Appropriately colored and marked vehicles with signs, flags, high- intensity rotating, flashing, oscillating, or strobe lights, truck- mounted attenuators, and arrow panels or portable changeable message signs may follow a train of moving work vehicles
• 69. • Key elements that should be considered to improve worker safety: • Training • Worker safety apparel • Temporary traffic barriers • Speed reduction measures • Planning of activity area • Planning for worker safety WORKER SAFETY CONSIDERATIONS Worker safety apparel
• 70. • All workers should be trained on: • Working safely adjacent to vehicular traffic • Work zone traffic control techniques • Device Usage • Safety devices • Traffic control devices • Placement of traffic control devices • Relevant OSHA Regulation • 29 CFR .21, Safety Training and Education WORKER SAFETY CONSIDERATION - TRAINING
• 71. • Workers near motor vehicle traffic should wear bright, visible clothing • Relevant OSHA Regulation • 29 CFR .95, Criteria for Personal Protective Equipment WORKER SAFETY CONSIDERATION- WORKER SAFETY APPAREL
• 72. • Barriers shall be placed along the work zone depending on: • Lateral clearance of workers from adjacent traffic • Speed of traffic • Duration and type of operations • Time of day • Volume of traffic • Relevant OSHA Regulations • 29 CFR .200(g), Traffic Signs • 29 CFR .201, Signaling • 29 CFR .202, Barricades WORKER SAFETY CONSIDERATION - TEMPORARY TRAFFIC BARRIERS Concrete Barriers
• 73. Speed of passing motorists may be influenced by: • Regulatory speed zoning • Funneling • Use of law enforcement • Lane reduction • Presence of flaggers WORKER SAFETY CONSIDERATION – SPEED REDUCTION MEASURES
• 74. • Plan internal work space and activities • Minimize the use of backing maneuvers of construction vehicles • Minimize interactions between on-foot workers, equipment and trucks • Minimize worker exposure to risk • Develop internal traffic control plan and operations • Refer to “Module 2: Safe Operations and Internal Traffic Control in the Work Space” WORKER SAFETY CONSIDERATION – PLANNING THE ACTIVITY AREA
• 75. • Hazard assessment should be conducted based on: • Characteristics of work site • Job classifications required in the work area • Must comply with all relevant OSHA regulations • Assess worker risk exposures for each job site and job classification • 29 CFR .20, General Safety and Health Provisions • 29 CFR .20 (b) (2) WORKER SAFETY CONSIDERATION – PLANNING FOR WORKER SAFETY
• 76. • Common for mobile and constantly moving operations OPTIONAL WORKER SAFETY ELEMENTS- SHADOW VEHICLE Shadow vehicle with rear mounted crash attenuator • Should be equipped with: – Appropriate lights – Warning signs – Rear-mounted impact attenuator
• 77. • Reduce worker vulnerability to risk of injury • Provide more spacious areas to conduct work activities • Eliminate threat of intruding vehicles from passing traffic • Aid in faster project completion OPTIONAL WORKER SAFETY ELEMENTS - ROAD CLOSURE Freeway closure for one direction of traffic
• 78. SAMPLE WORK ZONE TRAFFIC CONTROL LAYOUT • For a Single Lane Closure as per MUTCD – Pre-construction speed limit is 70 mph Channelizing Devices KEY Sign Location Note: Distance in feet, drawing not to scale W21-4 W20-5 R2-5b W4-2R R2-1 G20-2 REDUCED SPEED XX AHEAD REDUCED SPEED XX AHEAD REDUCED SPEED XX AHEAD XX AHEAD XX SPEED LIMIT XX SPEED LIMIT SPEED LIMIT ’ 700’ 600’700’700’700’ 700’ Flashing Arrow Panel Median REDUCED SPEED XX AHEAD REDUCED SPEED XX AHEAD REDUCED SPEED XX AHEAD XX AHEAD XX SPEED LIMIT XX SPEED LIMIT SPEED LIMIT
• 79. WORK ZONE TRAFFIC CONTROL • MUTCD provides minimum requirements • Various demanding situations may warrant enhanced safety precautions, such as: • Nighttime work • Inclement weather conditions • Unusual roadway geometry and environment • Combinations of the above • Going beyond existing standards/guidelines may be necessary to ensure highest levels of traffic and worker safety
• 80. HAZARDS OF WORK ZONE TRAFFIC CONTROL • Passing motorist intruding into the work space • Hazards related to flagging • Nighttime hazards COMMON HAZARDS
• 81. HAZARDS OF WORK ZONE TRAFFIC CONTROL • Conditions unexpected by the moving traffic • Violation of driver expectancy • Conditions unexpected by the workers • Aggressive drivers • Unplanned work zone/activity • Injuries can occur due to • Motorists’ mistakes • Workers’ mistakes • Deficiencies in the work zone environment CAUSAL FACTORS
• 82. • Traffic Control • Use additional warning devices • Maintain signs properly • Use Proper lane markings GENERAL PREVENTIVE MEASURES • Flaggers – Use a flashing slow/stop paddle • On-foot workers – Use portable radio communication equipment • Law enforcement – Use officers and radar surveillance for traffic speed control
• 83. • Hazard mitigation measures • Use of proper speed reduction methods • Proper design of the wok zone • Provide effective traffic control measures • Causes of Hazards – High approach speed – Improper geometry of the lane shift – Improper traffic control – Inadequate information system No physical separation between work space and traffic lane HAZARD: PASSING MOTORISTS INTRUDING INTO WORK SPACE
• 84. SAMPLE WORK ZONE TRAFFIC CONTROL LAYOUT WITH ADDITIONAL SAFETY FEATURES • For a Single Lane Closure Truck Mounted Attenuator W21-4 W20-5 R2-5b W4-2R R2-1 REDUCED SPEED XX AHEAD REDUCED SPEED XX AHEAD REDUCED SPEED XX AHEAD XX AHEAD XX SPEED LIMIT XX SPEED LIMIT SPEED LIMIT D D G20-2 D G20-2 DDDD L XX Your Speed is XX Your Speed isWhite Pavement Markings Symbol Retroreflective Raised Pavement Markers Increase Buffer Area Radar Triggered Speed Display Temporary Rumble Strips Flashing Arrow Panel Channelizing Devices KEY : Sign Location D L Length of Longitudinal Buffer Space Distance Between Traffic Control Devices Channelizing Devices KEY : Sign Location D L Length of Longitudinal Buffer Space Distance Between Traffic Control Devices
• 85. VERTICAL SAFETYCADE • Designed to replace standard channelizing devices • Benefits: • Better visibility • More positive guidance • Greater portability • Improved recoverability • Collapsible frame Vertical Safetycades
• 86. CB WIZARD ALERT SYSTEM • Trailer-mounted system • Broadcasts a recorded message to all CB-equipped motorists • Notify drivers of downstream work zones • Allows truck drivers to lower their speeds in advance of work zone CB Wizard Advanced Warning Unit CB Wizard Unit
• 87. RADAR-TRIGGERED SPEED DISPLAY • Back-lit dynamic speed display • Standard speed limit sign • Strobe flash (optional) • Strobe will flash when a vehicle exceeds a certain speed • Trailer mounted
• 88. LANE DROP ARROWS • Alert driver in advance of lane closure • Encourage drivers to reduce speed and move to the open lane
• 89. 12/20/ 89 UNIT IV MATERIAL FLOW PATH ANALYSIS IN MANUFACTURING
• 90. MATERIAL HANDLING: PRINCIPLES & EQUIPMENT DESCRIPTION Definition of Material Handling: “ Material Handling embraces all of the basic operations involve in movement of bulk, packaged, & individual products in semisolid or solid state by means of machinery, & within the limits of place of business” /20/
• 91. OBJECTIVE OF MH 1. To increase efficiency of material flow by ensuring availability of materials when & where they needed 2. To reduce MH cost 3. To improve facilities utilization 4. To improve safety & working conditions 5. To facilitate mfg processes 6. To increase productivity /20/
• 92. 12/20/ 92 AUTOMATED STORAGE AND RETRIEVAL SYSTEMS (AS/RS) To get right parts, pallets, fixtures, and tools to the right place at the right time, an efficient system for their storage and retrieval together with a material transportation system is required. An integrated FMS, AGVS, and AS/RS system provides an efficient production system for manufacturing low- to medium- volume and middle- to high-variety products. INTERFACING HANDLING AND STORAGE WITH MANUFACTURING
• 93. 12/20/ 93 Function of storage systems and definition of AS/RS Receiving, identification and sorting, dispatching to storage, placing in storage, storage, retrieving from storage, order accumulation, packing, shipping, and record keeping for raw materials, purchased parts, work in process, finished product, pallets, fixtures, tools, spare parts, rework and scrap, office supplies, and so forth have traditionally been considered the functions of storage systems. An AS/RS attempts to achieve these functions by automating most of these procedures in a cost-effective and efficient manner.
• 94. 12/20/ 94 AS/RS components and terminology used An automated storage and retrieval system comprises the following: 1. A series of storage aisles having storage racks. 2. Storage and retrieval (S/R) machines, normally one machine per aisle, to store and retrieve materials. 3. One or more pickup and delivery stations where materials are delivered for entry to the system and materials are picked up from the system.
• 95. 12/20/ 95 Why an AS/RS? An AS/RS is highly space efficient. Space now occupied by raw stock, work in process, or finished parts and assemblies can be released for valuable manufacturing space. Increased storage capacity to meet long-range plans. Improved inventory management and control. Quick response time to locate, store, and retrieve items. Improved stock rotation. Improved security and reduced pilferage because of closed storage area. Flexibility in design to accommodate a wide variety of loads.
• 96. 12/20/ 96 Type of AS/RS 1. Unit load AS/RS: is used to store and retrieve loads that are palletized or stored in standard-size containers. 2. Mini-load AS/RS: is designed to handle small loads such as individual parts, tools, and supplies. The system is suitable for use where there is a limit on the amount of space that can be utilized and where the volume is too low for a full-scale unit load system and tool high for a manual system. 3. Person-on-board AS/RS: allows storage of items in less than unit load quantities. 4. Deep-lane AS/RS: The items are stored in multi-deep storage with up to 10 items per row rather than single or double deep. This leads to a high density of stored items. 5. Automated item retrieval system
• 97. 12/20/ 97 Design of an AS/RS 1. Determining load sizes 2. Determining the dimensions of an individual storage space 3. Determining the number of storage spaces considering Dedicated storage Randomized storage 4. Determining the system throughput and number of S/R machines Speed of S/R machine Mix of single- and dual-cycle transaction 5. Determining the size parameters of the storage and retrieval system 6. Determining single- and dual-command cycle times for unit load AS 7. Determining utilization of S/R machine
• 98. UNIT LOAD CONCEPT Unit Load: “ It is defined as number of items arranged such that they can be handled as a single object” Unit load can be accomplished by: 1. Palletization: It is assembling & Securing of individual items on a platform that can be moved by a truck or a crane 98 Palllet 12/20/
• 99. UNIT LOAD CONCEPT (Cont..) Unit load can be accomplished by: 2. Unitization: It is also the assembling of goods, but as one compact load. Unlike Palletization additional materials are used for packaging & wrapping the items as a complete unit /20/
• 100. UNIT LOAD CONCEPT (Cont..) Unit load can be accomplished by: 3. Containerization: It is assembling of items in a box or a bin. It is most suitable for use with conveyors, especially for small items /20/
• 101. UNIT LOAD CONCEPT (Cont..) • In general, the factors that influence the solution of the unit load type are the weight, size, & shape of the material; compatibility with the material handling equipment; cost of the unit load; & the additional functions provided by the unit load stacking & protection of material. /20/
• 102. 12/20/ 102 MATERIAL HANDLING SYSTEM DESIGN • Assuming there is a layout plan on hand, the steps to be followed in designing a material handling system: – State the intended function of the handling system; whether it is for a warehouse. – Collect the necessary data about the material, such as its characteristics and the quantities involved. – Identify the moves, their origin and destination, their path, and their length. – Determine the basic handling system to be used and the degree of mechanization desired. – Perform an initial screening of suitable equipment and select a set of candidate equipment among them. Evaluate the candidate equipment on the basis of such measures as cost and utilization. Always match the equipment with the material characteristics. – Select a set of suitable unit loads and match them with material and equipment characteristics.
• 104. 12/20/ 104 Important factors that influence the designer in making decisions at each step of designing process: – Costs of equipment and unit loads and availability of funds. This will affect the degree of mechanization to be achieved in the design. – Physical characteristics of the building and the available space. Aisle width and number will be affected by the available space, which in turn will influence decisions regarding mobile equipment. Overhead equipment may or may not be considered, depending on the height of the ceiling. – Management attitude toward safety and employee welfare, which will affect the degree of involvement of material handling personnel in manual handling. – Degree of involvement between handling and processing. • During the design process, the objectives and the principles of MH should be kept in mind. Achieving as many of the objectives and principles as possible will result in a satisfactory and efficient design.
• 105. 12/20/ 105 To analyze an existing MH system is to determine whether it is functioning efficiently without creating any bottlenecks or excessive inventories and is transporting the units when and where needed. The problems in an existing MH system will be evident if one can observe one or more of the following symptoms in the system: •Excess manual effort, •Excess walking, •Failure to use gravity, •Fragmented operations, •High indirect labor costs, •Idle machines, •Inefficient use of skilled worker, •Lack of cube storage, •Lack of parts, •Lack of supplies, •Long hauls, •Material piled up on the floor, •No standardization, •Poor inventory control, •Product damage, •Repetitive handling, •Service areas not conveniently located, •Truck delayed or tiled up, It is also a good idea to examine the entire material handling system in the plant with a checklist and identify the problems.
• 106. 12/20/ 106 Once the problem areas have been identified, they must be re-examined for possible improvements. In performing such a study, some basic questions must be asked, such as: Why? What? Where? When? How? Who? • Liberal use of the question “Why?” is essential to separate what must be from what has been; asking what and why defines the correct materials to be handled; asking where, when, and why identifies the necessary moves to be performed; asking how, who, and why establishes the correct methods to be used; and asking which and why yields the preferred design.
• 107. 12/20/ 107 Productivity ratios: used as indicators of the performance of a system. – Material Handling-Labor Ratio, The ratio should be less than 1, and a reasonable value would be less than 0.30 in a plant, while in a warehouse a higher value should be accepted. – Handling Equipment Utilization Ratio, Ideally, the ratio should be close to 1.0; however, equipment breakdown, poor scheduling, housekeeping, building geography can reduce the load movement. – Storage Space Utilization Ratio, If the storage areas (such as bins or racks) are only partially full, then the percent of utilization should be estimated and included in the calculation.
• 108. 12/20/ 108 A value close to 1 indicates assignment of appropriate space for the storage activities. – Aisle Space Percentage, It should have a value between 0.10 and 0.15. – Movement/Operation Ratio, It indicates the amount of material handling performed. The moves involved may consist of material moved from receiving, from storage to an operation and back to storage, and so on. A high value indicates room for improvement. Manufacturing Cycle Efficiency, Time not spent in production could be caused by delays in material movement, poor scheduling, machine failure, and storage limitation, among others. For increasing machine utilization, the delay should be eliminated or at least minimized. The performance index should be observed over a time period for consistency.