物料搬运系统创新设计要点

1、搬运与仓储设备简述(1)容器和单元化设备 (containers and unitizing equipment)(2)物料搬运设备(transportation equipment) 传送带和输送机械(conveyors) 起重机械(Cranes) 工业用车辆(Industrial Truck)(3)存取设备(storage and retrieval equipment)(4)自动辨识及通信设备 (automatic identification and communication equipment)(1)容器和单元化设备(containers and unitizing equipme

2、nt) P159P163容器: 托盘pallet) 搬运箱等。负载单元化设备： 滑板式托盘、缩紧打包和撑拉打包、堆集和集装箱 (2)物料搬运设备(transportation equipment)传送带和输送机械P192P198起重机械P198P205工业用车辆：人力小车(托板车、 叉车 (P214P218)单轨列车、吊车和起重机自动导引小车(AGV) P218P225 5 6 7 8 9 10 11 12 13(3)存取设备(storage and retrieval equipment)即：存储和拣货设备P205普通储存和拣货设备 货架、支架等自动化储存和拣货系统AS/RS) 15 16(

3、4)自动辨识及通信设备(automatic identification and communication equipment)P229CH5 物料搬运物料搬运的重要性从数据中看问题 中等批量的生产车间里，零件在机床上的时间仅占生产时间的5%，而95%的时间消耗在原材料、工具、零件的搬运、等待上。 据统计，搬运费用占总生产费用的30%40%。5.1 物料搬运系统的根本概念一、物料搬运的定义二、物料搬运系统的目的三、物料搬运的活性理论四、物料搬运系统的原那么五、物料搬运系统的考虑因素六、物料搬运的单元化和标准化一、物料搬运系统的定义物料搬运一般是指物料搬运作业，即利用机械或人力来执行一项移动物

4、料的动作。物料搬运系统那么更深入地探讨物料流动与设施布局之间的关系，将物料的移动流程和设施的布局设计相互配合，以期支持设施的生产或效劳系统作业。20一、物料搬运系统的定义1、物料搬运的定义 物料搬运是指在同一场所范围内进行的、以改变物料的存放支承状态装卸和空间位置搬运为主要目的的活动。即：对物料、产品、零部件或其他物品进行装上、卸下、移动的活动。21一、物料搬运系统的定义2、物料搬运系统 物料搬运系统是移动、储存、保护及控制物料的艺术与科学的结合。1物料：散装到单位装载的固体、液体、气体等形式。2移动3储存 (4) 保护5控制6艺术7科学22一、物料搬运系统的定义3、物料搬运系统的意义 物料搬

5、运系统的意义为在适当的本钱下，采用正确的方法、顺序、方向、时机在正确的位置提供正确数量、正确条件的正确物料。 正确本钱、方法、顺序、方向、时机、位置、数量、条件、物料。9个23二、物料搬运系统的目的主要从本钱和质量两方面考虑：本钱：物料搬运作业约占用1/4的总人力，/2的总空间，3/4的总生产工时，以及1/65/6之间的产品制造总本钱。质量：物料搬运所造成的毁损约占物料搬运量的3%5%24二、物料搬运系统的目的MHS设计的主要目的：(1)通过有效率的搬运方式以降低物料搬运本钱，也就是降低生产本钱。 (2)增加物流的效率，确保适时适地使用物料。(3)改善工场平安和工作状况。(4)改善设施使用效率

6、。(5)改善制造程序(6)增加生产能力。25三、物料搬运的活性理论 搬运活性指物料的存放状态对搬运作业的难易程度 物料的存放状态散放、装箱、支垫和装车 搬运作业集中、搬起、升起、运走 搬运活性指数指搬运某种状态下的物料所需要进行的四项作业中已经不需要进行的作业数目。26 27思考：在运动中的物料活性指数是多少28可以利用活性理论改善搬运作业29四、物料搬运系统的原那么1.系统整合方面 (1)指导原那么；(2)方案原那么； (3)系统原那么； (4)流程原那么；2.搬运作业与设备方面(1)单元载荷;(2)空间利用；(3)标准化；(4)人因化； (5)机械化；(6)弹性化；(7)简单化； (8)电

7、脑化； (9)能源；(10)生态； (11)重力； (12)平安； (13)布局；(14)本钱；(15)维护；(16)汰旧。3031 32Top 10 Principles of Material HandlingPrinciple 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

8、completely defined at the outset. The plan should be developed in consultation between the planner(s) and all who will use and benefit from the equipment to be employed.Principle 2. Standardization Principle Material handling methods, equipment, controls and software should be standar-dized within t

9、he limits of achieving overall performance objectives and without sacrificing needed flexibility, modularity, and throughput. Standardization means less variety and customization in the methods and equipment employed.Principle 3. Work Principle Material handling work should be minimized without sacr

10、ificing productivity or the level of service required of the operation.33Top 10 Principles of Material Handling (cont.)Principle 4. Ergonomic PrincipleHuman capabilities and limitations must be recognized and respected in the design of material handling tasks and equipment to ensure safe and effecti

11、ve operations. Ergonomics is the science that seeks to adapt work or working conditions to suit the abilities of the worker. Principle 5. Unit Load PrincipleUnit loads shall be appropriately sized and configured in a way which achieves the material flow and inventory objectives at each stage in the

12、supply chain. A unit load is one that can be stored or moved as a single entity at one time, such as pallet, container or tote, regardless of the number of individual items that make up the load. Principle 6. Space Utilization PrincipleEffective and efficient use must be made of all available space.

13、 Space in material handling is three dimensional and therefore is counted as cubic space.34Top 10 Principles of Material Handling (cont.)Principle 7. System Principle Material movement and storage activities should be fully integrated to form a coordinated, operational system that spans receiving, i

14、nspection, storage, production, assembly, packaging, unitizing, order selection, shipping, transportation and the handling of returns. Principle 8. Automation PrincipleMaterial handling operations should be mechanized and/or automated where feasible to improve operational efficiency, increase respon

15、siveness, improve consistency and predictability, decrease operating costs, and eliminate repetitive or potentially unsafe manual labor.Principle 9. Environmental PrincipleEnvironmental impact and energy consumption should be considered as criteria when designing or selecting alternative equipment a

16、nd material handling systems.35Top 10 Principles of Material Handling (cont.)Principle 10. Life Cycle Cost PrincipleA thorough economic analysis should account for the entire life cycle of all material handling equipment and resulting system. Life cycle costs include all cash flows that occur betwee

17、n the time the first dollar is spent to plan or procure a new piece of equipment, or to put in place a new method, until that method and/or equipment is totally replaced. Life cycle costs include capital investment, installation, setup and equipment programming, training, system testing and acceptance, operating (labor, utilities, etc.), maint