MATERIAL HANDLING, COMPUTERIZATION, and PACKAGING ISSUES 物料搬运、计算机化 和包装问题 Chapter 9

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MATERIAL HANDLING,COMPUTERIZATION,

and PACKAGING ISSUES

物料搬运、计算机化和包装问题

Chapter 9

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Materials HandlingEquipment – Manual

手工物料搬运系统货架 Racking

– 传统托盘货架 Conventional pallet racks– 驶入式货架 Drive-in racks– 驶过式货架 Drive-through racks– 高层货架 High-rise racks– 悬臂式货架 Cantilever racks– 托盘堆存架 Pallet stacking frames– 重力传送货架 Gravity-flow racks

隔板 Shelving抽屉 Drawers移动货架或隔板 Mobile racking or shelving

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Materials HandlingEquipment – Automated

自动化物料搬运系统• 单位型负载自动化存取货系统 Unit load Automate

d Storage and Retrieval System (AS/RS)• 袖珍型负载自动化存取货系统 Miniload Automated

Storage and Retrieval System (AS/RS)• 水平旋转式传送带 Horizontal carousels• 垂直旋转式传送带 Vertical carousels• 人工骑乘机械 Man-ride machines• 自动导引车系统 Automatic guided vehicles syste

ms (AGVS) • 机器人 Robots

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Advantages of AutomatedMaterials Handling Systems

• Labor cost reduction• A large one time increase in the output

rate• Improvement in consistency of service• Reduction in materials handling• Increased accuracy level• Service availability• Improvement in speed of service

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Disadvantages of AutomatedMaterials Handling Systems

• Initial capital costs• Downtime or reliability of equipment• Software related problems• Capacity problems• Lack of flexibility• Maintenance costs• User interface and training• Worker acceptance• Obsolescence

Downtime ( 工厂等由于检修 , 待料等的 ) 停工期

Obsolescence 荒废 , 退化

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Ross AS/RS Statistics

• Eight Aisles have a computer driven mobile crane servicing both sides of the aisle.

• Each side is 13 pallets high by 68 pallets wide and is 2 pallets deep.

• Therefore each side has 884 facings and holds 1,768 pallets

• …and each aisle has 1,768 facings and 3,536 pallets

There are a total of 14,144 facings and 28,288 pallets positions with some lost space for imbedded fire protection and other equipment.

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FISHER MANUFACTURINGGENERAL DESCRIPTION• Flat one-high warehouse with 256 pallet positions.• We have 5 products manufactured in batches of 2

0.• Normal level is 1 open batch and 1 batch of safety

stock.• Average inventory is 5(0.5x20+20)=150 or 58.6%• Maximum inventory is 5(2x20)=200 or 78.1%• Pallets are 2-way which must be handled at 90o to

the aisle

GMPs• Batches can not be split.• Two batches of the same product can not touch.• No batch can go in front of another batch.• Shifting of stock is to be avoided to prevent errors.

QUESTION• The boss says that with a max of 200 she doesn't• understand why we say we can't add a 6th product.

Can we add a 6th product?

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FISHER MANUFACTURINGANSWER• Easy! But not without a good WMS that will allow

us to• get around the GMPs.

• We install RF based random storage. Every pallet slot

• and every pallet is tagged with bar-code or RFID,

GMPs• Batches can now be split.• Batches of a same product can now touch or be

mingled.• Shifting of stock is no longer a source of errors.• Rule about no batch in front of another batch is re

tained.

• We now have 6 products manufactured in batches of 20.

• Average inventory is now 6(0.5x20+20)=180 or 70.3%

• Maximum inventory is now 6(2x20)=240 or 93.8%

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Warehousing in a JITEnvironment

JIT 环境下的仓储管理• 全面质量承诺

Total commitment to quality• 减少生产批量规模

Reduced production lot sizes• 减少无附加值的活动

Elimination of nonvalue-added activities• 物料快速流动

Rapid flow through of materials

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Functions of Packaging包装的功能

营销 Marketing» 信息 Information» 促销 Promotion

物流 Logistics» 盛装 Containment» 保护 Protection» 分装 Apportionment» 合并 Unitization» 方便 Convenience» 交流 Communication

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Benefits of Good Packaging

• Lighter packaging may save transportation costs• Careful planning of packaging size/cube may

allow better space utilization• More protective packaging may reduce damage

and requirements for special handling• Environmentally conscious packaging may save

disposal costs• Returnable containers provide cost savings and

environmental benefits

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Warehouse ManagementSystem (WMS) Benefits

仓库管理系统的益处• 减少直接劳动

Reducing direct labor

• 增加物料搬运设备的有效性Increasing materials handling equipment efficiency

• 增加仓库空间利用效率Increasing warehouse space utilization

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Local Area Networks (LANs)局域网

• LANs facilitate transmission of data between a number and variety of “wired” devices such as terminals, word processors, bar-code readers, robots, conveyors, and AS/RSs.

• LANs often include devices that are connected by RF (“wireless” radio frequency) communications such as AGVs, operator driven lift trucks, hand-held bar code readers and computers.

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What’s wrong with these pictures?

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How about these?

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Another poor load….The stacking frame was a good idea but the buckets will still crush when over 8 high.

Crush 压碎 , 碾碎 , 压服 , 压垮 , 粉碎 , ( 使 )变形

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One solution for crushing…

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Effective use of stacking frames.

Stacking 堆垛

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Manual shrink wrapping. The pallet will go through a heat-tunnel or be shrunk by hand with a portable heater.

shrink wrapping 收缩包装

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Fixed and Hand Scanners

Hand scanners can also be installed in many PDAs.

PDA abbr.Personal Digital Assistant 个人数字助理 Scanner 扫描器，扫描仪

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A man-powered Pallet Jack or “Pallet Walkie”

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Stacking frames being used in a specialized side unloading transporter. I think they are engines. Very fast load and unload, No dock required.

Unloading 卸载dock 码头 , 船坞

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Damage waiting to happen…