Material Handling and Facility Design Procedures

Introduction

Material handling and facility design procedures play a crucial role in production management. These procedures are essential for optimizing the movement and storage of materials within a production facility, as well as for designing efficient layouts that maximize productivity. In this topic, we will explore the key concepts and principles of material handling and facility design procedures, step-by-step walkthroughs of typical problems and solutions, real-world applications and examples, and the advantages and disadvantages of implementing these procedures.

Key Concepts and Principles

Material Handling Equipments

Material handling equipments are tools and machinery used to move, store, and control materials during the production process. There are various types of material handling equipments, including:

1. Conveyors: Conveyors are used to transport materials from one location to another. They can be belt conveyors, roller conveyors, or overhead conveyors.

2. Forklifts: Forklifts are used to lift and move heavy materials. They are commonly used in warehouses and manufacturing facilities.

3. Automated Guided Vehicles (AGVs): AGVs are self-guided vehicles that can transport materials without human intervention. They are programmed to follow specific paths and can be used to transport materials in a flexible manner.

The selection of material handling equipments depends on various factors, such as the type of materials being handled, the distance of transportation, and the required speed and accuracy. When selecting material handling equipments, it is important to consider factors such as cost, efficiency, safety, and flexibility.

Different material handling equipments have their own advantages and disadvantages. For example, conveyors are efficient for continuous material flow but may require a fixed path, while AGVs offer flexibility but may have higher initial costs.

Facility Design Procedures

Facility design procedures involve the layout planning and design of a production facility. The objective of facility design is to create an efficient and productive layout that optimizes the flow of materials, equipment, and personnel.

There are several factors to consider in facility design, including:

1. Space utilization: Efficient use of available space is crucial for maximizing productivity and minimizing costs. It is important to consider the size and shape of the facility, as well as the placement of equipment and storage areas.

2. Material flow: The flow of materials within the facility should be smooth and uninterrupted. It is important to minimize bottlenecks and congestion by designing logical material flow paths.

3. Safety: The facility design should prioritize the safety of workers and minimize the risk of accidents. This includes considering ergonomic factors, such as the placement of equipment and workstations.

There are various techniques and tools available for facility layout planning, such as CORELAP (Computerized Relationship Layout Planning) and CRAFT (Computerized Relative Allocation of Facilities Technique). These techniques help in optimizing the layout by considering factors such as material flow, space utilization, and safety.

Different facility design procedures have their own advantages and disadvantages. For example, CORELAP is a computer-based technique that can handle complex layouts but requires accurate input data, while CRAFT is a simpler technique that is suitable for smaller facilities.

Step-by-Step Walkthrough of Typical Problems and Solutions

In this section, we will walk through two typical problems related to material handling and facility design and discuss their solutions.

Problem 1: Inefficient Material Flow in a Production Facility

1. Identifying Bottlenecks and Constraints: The first step in solving this problem is to identify areas in the facility where material flow is inefficient or congested. This can be done by observing the production process and analyzing data on material movement.

2. Redesigning Material Flow Paths: Once the bottlenecks and constraints are identified, the next step is to redesign the material flow paths. This may involve rearranging workstations, changing the placement of equipment, or implementing conveyors or AGVs to automate material movement.

3. Implementing Material Handling Equipment to Improve Efficiency: The final step is to implement the selected material handling equipments to improve efficiency. This may involve purchasing new equipment, modifying existing equipment, or training employees on how to use the equipment effectively.

Problem 2: Inadequate Facility Layout

1. Analyzing Current Layout and Identifying Issues: The first step in solving this problem is to analyze the current facility layout and identify any issues or inefficiencies. This can be done by conducting a thorough evaluation of the facility and gathering feedback from employees.

2. Utilizing Layout Planning Techniques to Optimize Facility Design: Once the issues are identified, layout planning techniques such as CORELAP or CRAFT can be used to optimize the facility design. These techniques consider factors such as material flow, space utilization, and safety to create an efficient layout.

3. Implementing Changes and Evaluating the Results: The final step is to implement the changes to the facility layout and evaluate the results. This may involve moving equipment, rearranging workstations, or creating new storage areas. The effectiveness of the changes can be measured by monitoring key performance indicators such as productivity, material flow, and worker satisfaction.

Real-World Applications and Examples

In this section, we will explore two real-world case studies that demonstrate the application of material handling and facility design procedures.

Case Study 1: Automotive Manufacturing Facility

1. Material Handling Equipment Selection for Assembly Line: In an automotive manufacturing facility, the selection of material handling equipments for the assembly line is crucial for efficient production. This may involve choosing the appropriate conveyors, AGVs, and forklifts to transport materials between workstations.

2. Facility Design Procedures for Efficient Production Flow: The facility design procedures in an automotive manufacturing facility focus on optimizing the flow of materials, equipment, and personnel. This includes designing logical material flow paths, organizing workstations for efficient assembly, and ensuring the safety of workers.

Case Study 2: Warehouse Operations

1. Material Handling Equipment Selection for Storage and Retrieval: In warehouse operations, the selection of material handling equipments for storage and retrieval is essential for maximizing efficiency. This may involve choosing the appropriate forklifts, conveyors, and automated storage and retrieval systems (AS/RS) to handle different types of products.

2. Facility Design Procedures for Maximizing Storage Capacity: The facility design procedures in a warehouse focus on maximizing storage capacity while maintaining efficient material flow. This includes optimizing the layout of storage racks, implementing AS/RS systems for high-density storage, and utilizing space-saving techniques such as mezzanine floors.

Advantages and Disadvantages of Material Handling and Facility Design Procedures

Advantages

1. Improved Efficiency and Productivity: Material handling and facility design procedures help in optimizing the flow of materials, equipment, and personnel, resulting in improved efficiency and productivity.

2. Enhanced Safety for Workers: Proper material handling and facility design can minimize the risk of accidents and injuries, ensuring the safety of workers.

3. Cost Reduction through Optimal Resource Utilization: By optimizing material flow and facility layout, material handling and facility design procedures can reduce costs associated with wasted time, energy, and resources.

Disadvantages

1. Initial Investment Cost for Material Handling Equipments: Implementing material handling equipments can involve significant initial investment costs, including the purchase of equipment and training of employees.

2. Need for Continuous Monitoring and Maintenance: Material handling equipments and facility layouts require regular monitoring and maintenance to ensure optimal performance and safety.

3. Potential Disruption during Facility Layout Changes: Making changes to the facility layout can disrupt production and require careful planning and coordination to minimize downtime.

Conclusion

Material handling and facility design procedures are essential for optimizing production processes and ensuring efficient material flow within a facility. By understanding the key concepts and principles, analyzing typical problems and solutions, exploring real-world applications, and considering the advantages and disadvantages, production managers can make informed decisions to improve productivity, safety, and cost-effectiveness in their operations.

Summary

Material handling and facility design procedures are crucial in production management. Material handling equipments such as conveyors, forklifts, and AGVs are used to move and control materials, while facility design procedures involve layout planning and design to optimize material flow and space utilization. Typical problems related to material flow and facility layout can be solved by identifying bottlenecks, redesigning material flow paths, and implementing appropriate material handling equipments. Real-world case studies in automotive manufacturing and warehouse operations demonstrate the application of these procedures. The advantages of material handling and facility design procedures include improved efficiency, enhanced safety, and cost reduction, while the disadvantages include initial investment costs, the need for continuous monitoring and maintenance, and potential disruptions during layout changes.

Analogy

Imagine you are building a puzzle. The material handling equipments are like your hands that help you pick up and move puzzle pieces from one place to another. The facility design procedures are like the layout of the puzzle pieces on the table. By arranging the puzzle pieces in an organized and logical manner, you can complete the puzzle efficiently. Similarly, in production management, material handling and facility design procedures help in optimizing the movement and storage of materials, resulting in efficient production processes.