MF F219
Operations Management
BITS Pilani Girish Kant Garg
Department of Mechanical Engineering
Pilani Campus
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Learning Objectives
Analysis of Material Transport Systems
• Vehicle based systems
• Conveyor
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BITS Pilani, Pilani Campus
Material Transport System
Two categories of logistics:
External logistics - transportation and related activities
that occur outside of a facility (between different
geographical locations)
• Five traditional modes of transportation: rail, truck, air,
ship, and pipeline
Internal logistics - material handling within a facility
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BITS Pilani, Pilani Campus
Material Transport Equipment
Five categories:
1. Industrial trucks
2. Automated guided vehicles
3. Rail-guided vehicles (e.g., monorails)
4. Conveyors
5. Cranes and hoists
Layout Type Characteristics Material Handling
Equipment
Process Medium production rate, Hand trucks, Forklift
Medium product variety trucks, AGV
Product High production rate, Conveyors
Low product variety
Fixed Position Large product size, Low Cranes, Hoists,
production rate Industrial trucks 4
BITS Pilani, Pilani Campus
Industrial Trucks
Two basic categories:
1. Non-powered
Human workers push or pull loads
2. Powered
Self-propelled
Guided or driven by human operator
Common example: forklift truck
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Automated Guided Vehicles
An Automated Guided Vehicle System (AGVS) is a material
handling system that uses independently operated, self-
propelled vehicles guided along defined pathways
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Vehicle Guidance Using Guide
Wire
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Rail-Guided Vehicles
Self-propelled vehicles that ride on a fixed-rail system
Fixed rail system
Overhead monorail - suspended overhead from the
ceiling
On-floor - parallel fixed rails, tracks generally protrude up
from the floor
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Conveyor Systems
To move materials over fixed paths, usually in large
quantities or volumes
1. Non-powered
Materials moved by human workers or by gravity
2. Powered
Power mechanism for transporting materials is contained in the
fixed path, using chains, belts, rollers or other mechanical devices
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Cranes and Hoists
Handling devices for lifting, lowering
and transporting materials, often as
heavy loads
Cranes
For horizontal movement of materials
Hoists
For vertical lifting of materials
Cranes usually include hoists so that
the crane-and-hoist combination
provides
Horizontal transport
Vertical lifting and lowering
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BITS Pilani, Pilani Campus
Material Transport Equipment
Handling Features Applications
Equipment
Industrial Trucks Low cost, Low rate of deliveries Moving light loads
(Manual)
Industrial Trucks Medium cost Movement of pallet loads
(Powered)
AGV High cost, Battery powered, Flexible Moving WIP along variable
routing, Non-obstructive pathways routes in low and medium
production
RGV High cost, Flexible routing, On the Moving WIP along variable
floor or overhead types routes in large quantity
Conveyors In-floor, on-the floor, overhead Move products along a
manual assembly line
Crane and hoists Lift capacities of more than 100 tons Moving large, heavy items
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Analysis of
Material Transport Systems
How many vehicles will be required to satisfy a specified
flow rate
Analysis of vehicle-based systems
Types of systems: industrial trucks, AGVS, rail-guided vehicles etc.
From-to charts and network diagrams
Network diagram showing
From-To chart showing flow rates,
deliveries between load/unload
deliveries/hr and travel distances, m
stations
between stations
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BITS Pilani, Pilani Campus
Analysis of vehicle based
systems
A typical delivery cycle in the operation of a vehicle based
transport system consists of
Loading at the pick up station
Travel time to the drop-off station
Unloading at the drop-off station
Empty travel time of the vehicle between deliveries
𝐿𝑑 𝐿𝑒
𝑇𝑐 = 𝑇𝑙 + + 𝑇𝑈 +
𝑣𝑐 𝑣𝑐
𝑇𝑐 = Delivery cycle time, min/del
𝑇𝑙 = Time to load at load station, min
𝐿𝑑 = Distance the vehicle travels between load and unload staion, m
𝑇𝑈 = Time to unload at unload station, min
𝐿𝑒 = Distance the vehicle travels empty until the start of next delivery cycle, m
𝑣𝑐 = Carrier velocity, m/min
BITS Pilani, Pilani Campus
Analysis of vehicle based
systems
Delivery cycle time can be used to calculate
Rate of deliveries per vehicle
Number of vehicles required to satisfy a specified total delivery
requirement
𝐴𝑇 = 60𝐴𝐹𝑡 𝐸𝑤
𝐴𝑇 = Available time in 1 hour, min/hr
𝐴 = Availability
𝐹𝑡 = Traffic factor
𝐸𝑤 = Worker efficency
𝐴𝑇
𝑅𝑑𝑣 =
𝑇𝑐
𝑅𝑑𝑣 = hourly delivery rate, deliveries/hr
BITS Pilani, Pilani Campus
Analysis of vehicle based
systems
𝑅𝑓
𝑛𝑐 =
𝑅𝑑𝑣
𝑅𝑓 = Total delivery requirements in the system, deliveries/hr
𝑛𝑐 = number of carriers required
𝑊𝐿
𝑛𝑐 =
𝐴𝑇
𝑾𝒐𝒓𝒍 𝒍𝒐𝒂𝒅: 𝑡𝑜𝑡𝑎𝑙 𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑤𝑜𝑟𝑘, 𝑒𝑥𝑝𝑟𝑒𝑠𝑠𝑒𝑑 𝑖𝑛 𝑡𝑒𝑟𝑚𝑠 𝑜𝑓 𝑡𝑖𝑚𝑒, 𝑡ℎ𝑎𝑡 𝑚𝑢𝑠𝑡 𝑏𝑒
𝑎𝑐𝑐𝑜𝑚𝑝𝑙𝑖𝑠ℎ𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑡𝑟𝑎𝑛𝑠𝑝𝑜𝑟𝑡 𝑠𝑦𝑠𝑡𝑒𝑚 𝑖𝑛 1 ℎ𝑟.
𝑊𝐿 = 𝑅𝑓 𝑇𝑐
𝑊𝐿 = workload, min/hr
BITS Pilani, Pilani Campus
Conveyor Analysis
𝐿𝑑
𝑇𝑑 =
𝑣𝑐
𝑇𝑑 = Delivery time, min
𝐿𝑑 = Length of conveyor between load and unload stations, m
𝑣𝑐 = Conveyor velocity, m/min
BITS Pilani, Pilani Campus
Conveyor Analysis
Flow rate of materials an the conveyor is determined by the rate
of loading at the load station.
𝑅𝑓 ≤ 𝑅𝑙
1 𝑉𝑐
𝑅𝑙 = =
𝑇𝑙 𝑆𝑐
𝑅𝑓 = material flow rate, parts/min
𝑅𝑙 = Loading rate, parts/min
𝑇𝐿 = Loading time, min/part
m
𝑠𝑐 = Center−to−center spacing of materials on the conveyor,
part
1
𝑇𝑈 ≤
𝑅𝑓
𝑇𝑈 = Unloading time, min/part
BITS Pilani, Pilani Campus
Conveyor Analysis
𝑛𝑝 𝑣𝑐
𝑅𝑓 =
𝑠𝑐
𝑅𝑓 = material flow rate, parts/min
𝑛𝑝 = number of parts per container
m
𝑠𝑐 = Center−to−center spacing of containers on the conveyor,
container
𝑇𝐿 = Loading time per container, min/container
BITS Pilani, Pilani Campus
Thanks
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