Flashcards
L#4: Material Handling
Cards in this deck (21)
- 1Define material handling (2)The art and science of moving, storing, protecting and controlling material (1). It is providing the right material at the right place in the right time, with the right amount, in sequence, and in the right condition. (1)
- 2Why is material handling so important in modern manufacturing? (1)It is a major contributor to costs (1)
- 3What is the goal of manufacturing engineers in relation to material handling? (1)To make important decisions to minimise the costs associated with material handling without compromising productivity. (1)
- 4Draw the diagram showing material flow from raw product to customer. (17)see notes (17)
- 5What is the main aim in material handling? (1)To minimise production costs (1)
- 6What is the best scenario for material handling? (1)That there is no handling at all (1)
- 7When might minimisation of handling be a goal? (4)In the design, renovation, or expansion of a manufacturing system. (4)
- 8What factors play a part in determining the minimisation of material handling? Why? (3)1. Aim to enhance safety safety and working conditions throughout material handling planning.
2. Physical possibility
3. In the long run these factors okay a major role in the effectiveness of the manufacturing system (3) - 9What are the three fundamental rules that have been developed to promote productivity in material handling? (3)1. Flow in straight line: The shortest distance between two points is the straight line connecting the points. Effort should be made, therefore, to enable material flow in a straight line between the sender and the receiver.
2. Use of gravity: Gravity is free. It is therefore advisable to use gravity to move material wherever possible.
3. Move more material at one time: If possible, several parts or batches of material should be transported together to minimise the required effort. - 10Why must the characteristics of the material to be transported be considered in material handling? (1)In order to devise correct strategies for its handling (1)
- 11Give the 6 categories and example measures for material characteristics that should be considered for material handling. (12)1. Physical state:
Solid, liquid, gas.
2. Size:
Volume; Length, width, height
3. Weight:
Per piece; per unit volume
4. Shape:
Long and flat, round, square, etc.
5. Condition:
Hot, cold, wet, pressurized etc.
6. Explosive, flammable, toxic, fragile etc. - 12Give and explain the four types of material handling equipment (8)1. TRANSPORT EQUIPMENT: The equipment that is used to physically move material from one location to another. These include: Industrial trucks, Automated guided vehicles (AGVs), monorails, conveyors, cranes and hoists.
2. STORAGE SYSTEMS:
Systems that allow material to be stored in a safe and accessible manner. These include: bulk storage, rack systems, shelving and bins, drawer storage and sophisticated automated storage systems.
3. UNITISING EQUIPMENT:
Equipment that allow a number of components to be unitised as a single element for transportation or storage. These include: pallets and skid boxes.
4. IDENTIFICATION AND TRACKING SYSTEMS:
Systems that enable the location of of the material to be tracked throughout the enterprise. These include: radio frequency identification devices (RFIDs) and Barcodes - 13Draw the table for selection of material transportation equipment (4)See notes
- 14What are the four measures used to asses the effectiveness of material handling scenarios? (4)1. Total material flow
2. Material handling labour ratio
3. Labour handling cost
4. Equipment utilisation - 15Define material flow as an effectiveness measure (3)The simplest measure
It is the weight of material that is transported in the factory multiplied by the distance that it is transported. (1) It is a measure that can be used to compare different variations of routes when planning material handling using the same transportation equipment (1). A lower value is better (1) - 16Describe 'material handling labour ratio' as an effectiveness measure. (4)- An indication of how much work needs to be done to handle material.
- It's the number of personnel working on the material handling divided by the total number of personnel.
- This measure is useful when staff have dedicated material handling roles
- A lower value is better - 17Explain 'Labour handling cost' as an effectiveness measure (4)- Represents the cost resulting from time spent by staff on material handling.
- It is calculated by dividing the time that is spent on material handling by total working time.
- This measure is useful when staff have different roles
- A lower value is better - 18Explain 'equipment utilization' as an effectiveness measure (3)- a general measure that is also used to gauge the effectiveness of material handling
- It is calculated by dividing the actual output by the theoretical output of the manufacturing system
- A higher value is better - 19Explain each of the ten principles of material handling, as given by the Material Handling Institute.1. PLANNING PRINCIPLE
All material handling should be the result of a deliberate plan where the needs, performance objectives and functional specification of the proposed methods are completely defined at the offset
2. STANDARDISATION PRINCIPLE
Material handling methods, equipment, controls and software should be standardized within the limits of achieving overall performance objectives without sacrificing needed flexibility, modularity and throughput in anticipation of changing future requirements.
3. WORK PRINCIPLE
Material handling work should be minimised without sacrificing productivity or the level of service required of the operation
4. ERGONOMIC PRINCIPLE
Human capabilities and limitations must be recognized and respected in the design of material handling tasks and equipment to ensure effective and safe operations.
5. UNIT LOAD PRINCIPLE
Unit loads shall be appropriately sized and configured in a way which achieves the material flow and inventory objectives at each stage in the supply chain
6. SPACE UTILIZATION PRINCIPLE
Effective and efficient use must be made of all available space.
7. SYSTEM PRINCIPLE
Material movement and and storage activities should be fully integrated to form a coordinated, operational system which spans receiving, inspection, storage, production, assembly, packaging, unitising, order selection, shipping, transportation and the handling of returns
8 AUTOMATION PRINCIPLE
Material handling operations should be mechanized and/or automated where feasible to improve operational efficiency, increase responsiveness, improve consistency and predictability
9. ENVIRONMENTAL PRINCIPLE
Environmental impact and energy consumption can be considered as criteria when designing or selecting alternative equipment and material handling systems
10. LIFECYCLE COST PRINCIPLE
A thorough economic analysis should account for the entire life cycle of all material handling equipment and resulting systems. - 20What are the five questions that need to be asked in a planning process? Draw the material handling planning flowchart1. WHY is the material being transported or stored? Can this movement (or storage) be eliminated?
2. WHAT exactly is being transported or stored? What are the characteristics and quantities?
WHERE is it coming from, where is it going to?
HOW should it be moved? What is the best method?
WHO should move it? What are the power requirements?
[These questions should be asked iteratively]
SEE NOTES for flowchart - 21Give the 5 equations for analysis of vehicle based systems. Defining all variables and assumptions.See notes
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- Manufacturing Operations and Technology Flashcards on L#4: Material Handling, created by Block on 30/04/2014.
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