物流专业英语（第5版） 电子课件 Ch9

MaterialHandlingChapter9chapteroutline(1)PartIMaterialHandlingSystemIntroductionofMaterialHandlingSystemTypesofMaterialHandlingSystemsMechanizedMaterialHandlingSystemsSemi-automatedMaterialHandlingSystemsAutomatedMaterialHandlingSystemsAutomatedStorage/RetrievalSystemschapteroutline(2)PartIIMechanizedMaterialHandlingEquipmentIntroductionLiftTrucksWalkie-riderPalletTrucksTowlinesTowTractorwithTrailersConveyorsCarouselschapteroutline(3)PartIIISupplementaryReading

SafetyinMaterialHandlingWhatshouldWorkersKnowbeforeHandlingMaterialPotentialHazardsforWorkersPrecautionsshouldbeTakenWhenMovingMaterialsManuallyPrecautionsshouldbeTakenWhenMovingMaterialsMechanicallySafetyMeasuresRegardingConveyorsSafetyMeasuresRegardingCranesSafetyPrecautionsforOperatingPoweredIndustrialTrucksIntroductionofaterialHandlingSystemsMaterialhandlingequipmentsandsystemsoftenrepresentamajorcapitalinvestmentforanorganization.Likethedecisionsrelatedtothenumber,size,andlocationofwarehouses,materialhandlingcanaffectmanyaspectsofthefirm’soperation.TheMaterialHandlingInstitute,anindustrytradeassociationformanufacturersofmaterialhandlingequipmentsandsystems,hasestimatedthat:PartIMaterialHandlingSystemsThehardwareandsoftwareusedtomove,store,control,contain,andunitizematerialsinfactoriesandwarehousesexceed$50billionannually.Muchofthegrowthinsizeandvarietyofthemarketisfueledbymajorchangesintherequirementsofwarehouseanddistributionoperations(e.g.,reducedordercycletimes,reducedinventorylevels,reducedordersizes,SKUproliferation).Materialhandlingsystemcanbeclassifiedasmechanized,semi-automated,automated,andinformation-directed.Acombinationoflaborandhandlingequipmentisutilizedinmechanizedsystemstofacilitatereceiving,processing,and/orshipping.Generally,laborconstitutesahighpercentageofoverallcostinmechanizedhandling.TypesofMaterialHandlingSystems

Automatedsystems,incontrast,attempttominimizelaborasmuchaspossiblebysubstitutingequipmentcapitalinvestment.Whenacombinationofmechanicalandautomatedsystemsisusedtohandlematerial，thesystemisreferredtoassemi-automated.

Aninformation-directedsystemappliescomputerizationtosequencemechanizedhandlingequipmentanddirectworkeffort.Mechanizedhandlingsystemsaremostcommon,buttheuseofsemi-automatedandautomatedsystemsisincreasing.Themaindrawbacktoautomatedhandlingislackofflexibility.Onefactorcontributingtolowlogisticalproductivityisthatinformation-directedhandlinghasnotyettoachieveitsfullpotential.Thissituationispredictedtobedramaticallychangedduringthefirstdecadeofthe21stcentury.MechanizedMaterialHandlingSystemsMechanizedmaterialhandlingequipmenthasbeenthemainstayofthetraditionalwarehousingandwilllikelycontinuetobeimportantevenwiththemovetowardautomatedwarehousing.Mechanizedmaterial

handlingsystemsemployawiderangeofhandlingequipment.Suchequipmentcanbecategorizedaccordingtothefunctionsperformed,thatis,storageandorderpicking,transportationandsorting,andshipping.Semi-automatedMaterialHandlingSystemsMechanizedhandlingisoftensupplementedbysemiautomaticequipment.Typicalequipmentsutilizedinsemi-automatedhandlingsystemsincludesautomatedguidedvehiclesystems(AGVS),computerizedsortation,roboticsandvariousformsofliveracks.Theappealofautomationisthatitsubstitutescapitalequipmentforlabor.Inadditiontorequiringlessdirectlabor,anautomatedsystemoperatesfasterandmoreaccuratelythanitsmechanizedcounterpart.Table8-1showsthebenefitsofautomatedmaterialhandlingsystems.Forseveraldecadestheconceptofautomatedhandlinghasofferedgreatpotential.Initialautomatedhandlingeffortsfocusedonmastercartonorderselectionsystems.Recently,emphasishasshiftedtoautomatedhigh-risestorageandretrievalsystems.AutomatedMaterialHandlingSystemsTable9-1BenefitsofautomatedmaterialhandlingsystemsBenefitProportionofrespondentsthat“agree”or“stronglyagree”Laborcostreduction98.8%Abilitytoincreaseoutputrate95.2%Improvementinconsistencyofservice92.1%Reductioninmaterialhandling92.1%Increasedaccuracylevel89.5%Serviceavailability87.0%Improvementinspeedofservice81.0%However,automatedsystemsarenotwithoutdisadvantages.Itsshortcomingsarethehighcapitalinvestment,maintenancecosts,inflexibilityandusertraining.ItisdefinedbytheAS/RSproductsectionoftheMaterialHandlingInstituteasastoragesystemthatusesfixed-pathstorageandretrieval(S/R)machinesrunningononeormorerailsbetweenfixedarraysofstorageracks.AtypicalAS/RSoperationiscalledasinglecommand(SC)operation,involvingtheS/Rmachinespickingupaloadatthefrontofthesystem,transportingtheloadtoanemptylocation,deposingtheloadintheemptylocation,andreturningemptytotheinput/output(I/O)point.AAutomatedStorage/RetrievalSystemsAnautomatedstorage/retrievalsystemforpalletsiscommonlyreferredtoasaunitloadAS/RS.dualcommand(DC)operationinvolvestheS/RmachinepickingupaloadattheI/Opoint,travelingloadedtoanemptylocation,depositingtheload,travelingemptytotheI/Opoint,anddepositingtheload.Thekeyideaisthatinadualcommand,thetwooperations,astorageandaretrieval,areaccomplishedbetweensuccessivevisitstotheI/Opoint.Theconceptofinformation-directedisappealingbecauseitcombinesthecontroltypicalofautomatedhandlingwiththeflexibilityofmechanizedsystems.Information-directedsystemsusemechanizedhandlingcontrolledbyinformationtechnology.Twocommonexamplesofinformation-directedmaterialhandlingsystemsareRF-controlledequipmentandlight-directedoperations.Information-directedmaterialhandlingSystemNewWordsandExpressionsassociation/əˌsəʊsiˈeɪʃən/n. 协会proliferation/prəˌlɪfəˈreɪʃən/n. 增殖，扩散automate/ˈɔːtəmeɪt/v. 使自动化，自动操作combination/ˌkɒmbəˈneɪʃən/n. 组合，合并sequence/ˈsiːkwəns/n. 次序，顺序flexibility/ˌfleksəbɪləti/n. 灵活性vehicle/ˈviːɪkəl/n. 交通工具，车辆sortation/sɔːˈteɪʃən/n. 分类robotics/rəʊˈbɒtɪks/n.

机器人学，机器人技术initial/ɪˈnɪʃəl/adj. 最初的，初始的retrieval/rɪˈtriːvəl/n.

检索，取回pallet/ˈpælɪt/n.

托盘，货板IntroductionTheprimarymissionofmaterialhandlingequipmentistofacilitatemerchandiseflowinanorderlyandefficientmannerfrommanufacturertopointofsale.Inthissectionthefocusofdiscussionisputonthemechanizedmaterialhandlingequipment.Thefollowingequipmentiscommonplaceinmanualwarehousing.PARTIIMechanizedMaterial

HandlingEquipmentLiftTrucks

Lifttrucks,alsocalledforklifts,canmoveloadsofmastercartonsbothhorizontallyandverticallybutarenotlimitedtounitloadhandling.Boxesmayalsobetransporteddependinguponthenatureoftheproduct.Manytypesoflifttrucksareavailable.High-stackingtrucksarecapableofupto40feetofverticalmovement.Palletlessside-clampversionsareavailableforhandlingbulkyproductwithoutpallets.Otherlifttruckvariationsareavailablefornarrowaisleandside-loadingoperations.Particularattentiontonarrow-aislelifttruckshasincreasedinrecentyears,aswarehousesseektoincreaserackdensityandoverallstoragecapacity.Thelifttruckisnoteconomicalforlong-distancehorizontalmovementbecauseofthehighratiooflaborperunitoftransfer;itismosteffectivelyutilizedinshippingandreceivingandplacingmerchandiseinhighcubestorage.Walkie-riderpallettrucksWalkie-riderpallettrucksprovidealow-cost,effectivemethodofgeneralmaterialhandlingutility.Typicalapplicationsincludeloadingandunloadingoftransportationequipment,orderselectionandaccumulation,andshuttlingloadsoverlongertransportationdistancesthroughoutthewarehouse.Walkie-riderpallettrucksarewidelyusedingrocerywarehouse.TowlinesTowlinesconsistofeitherin-floororoverhead-mountedcableordragdevices.Theyareutilizedtoprovidecontinuouspowertofour-wheeltrailers.Themainadvantageofatowlineiscontinuousmovement.However,suchhandlingdeviceshavefarlessflexibilitythanlifttrucks.Themostcommonapplicationoftowlinesisfororderselection.Orderselectorsplacemerchandiseonfour-wheeltrailersthatarethentowedtotheshippingdock.Anumberofautomateddecouplingdevicesareavailabletoroutetrailersfromthemaintowlinetotheshippingdocks.TowTractorwithTrailersAtowtractorwithtrailerconsistsofadriver-guidedpowerunittowinganumberofindividualfour-wheeltrailersthatholdseveralunitizedloads.Thetypicalsizeofthetrailersis4*8feet.Thetowtractorwithtrailer,likethetowline,isusedtofacilitateorderselection.Themainadvantageofatowtractorwithtrailersisflexibility.Itisnotaseconomicalasthetowlinebecauseitrequiresmorelabor.Conveyorsareusedwidelyinshippingandreceivingoperationsandformthebasichandlingdeviceforanumberoforderselectionsystems.Conveyorsareclassifiedaccordingtopower,gravity,androllerorbeltmovement.Inpowersystems,theconveyorispoweredbyadrivechainfromeitheraboveorbelow.Considerableconveyorflexibilityisofferedinsuchpowerconfigurationinstallations.Gravityandrollerorbeltsystemspermitthebasicinstallationtoberearrangedwithminimumdifficulty.Portablegravity-stylerollerconveyorsareoftenusedforloadingandunloadingand,insomecases,aretransportedonover-the-roadtrailerstoassistinunloadingvehicles.Conveyorsareeffectiveinthatonlytheproductismoved,eliminatingtheneedforamovementunittoreturn.ConveyorsAcarouseloperatesonadifferentconceptthanmostothermechanizedhandlingequipment.Ratherthanrequiringtheorderselectortogototheinventorystoragelocation,thecarouselmovesinventorytotheorderselector.Acarouselconsistsofaseriesofbinsmountedonanovaltrackorrack.Theremaybemultipletracklevels,allowingforveryhigh-densitycarouselstorage.Theentirecarouselrotates,movingtheselectionbintoastationaryoperator.Thetypicalcarouselapplicationistheselectionofpackagesinpack,repack,andserviceparts.CarouselsTherationalebehindcarouselsystemsistoshrinkorderselectionlaborrequirementsbyreducingwalkinglengthandtime.Carousels,particularlymodernstackablesystems,alsosignificantlyreducestoragespacerequirements.Somecarouselsystemsalsoutilizecomputer-generatedpicklistsandcomputer-directedcarouselrotationtofurtherincreaseselectionproductivity.Thesesystemsarereferredtoaspaperlesspickingbecausenopaperworkexiststoslowdownemployeeefforts.Avariationofthecarouselsystemismovableracks.Suchracksmovehorizontallytoeliminatethepermanentaislebetweentheracks.Thissystem,oftenusedinlibraries,providesmorestoragedensitybutreducespickingefficiencysincetheracksmustbemovedtoaccessspecificproducts.Themechanizedmaterialhandlingequipmentdiscussedisrepresentativeofawiderangeofalternatives.Mostsystemscombinedifferenthandlingdevices.Forexample,lifttrucksmaybeusedforverticalmovementswhiletowtractorwithtrailersandwalkie-riderpallettrucksaretheprimarymethodsofhorizontaltransfer.NewWordsandExpressions

Introduction

Handlingandstoringmaterialsinvolveoperationssuchasliftinguptonsofsteelwithacrane;drivingatruckloadedwithconcreteblocks;carryingbagsormaterialsmanually;andstackingpalletsorothermaterialssuchasdrums,barrels,andlumber.

Theefficienthandlingandstoringofmaterialsareveryimportanttoindustry.Unfortunately,theimproperhandlingandstoringofmaterialsoftenresultincostlyinjuries.Toreducethenumberofaccidentsassociatedwithworkplaceequipment,workersmustbetrainedintheproperuseoftheequipmenttheyoperate,includingsafelyandeffectivelyuseequipmentssuchaspoweredindustrialtrucks,conveyors,cranesandslings.

PARTIIISupplementaryReading:SafetyinMaterialHandlingWhatShouldWorkersKnowBeforeHandlingMaterials?Applyinggeneralsafetyprinciples—suchasproperworkpractices,equipment,andcontrols—canhelpreduceworkplaceaccidentsinvolvingthehandlingmaterials.Whethermovingmaterialsmanuallyormechanically,workersshouldknowandunderstandthepotentialhazardsassociatedwiththetaskathandandhowtocontroltheirworkplacestominimizethedanger.

Becausenumerousinjuriescanresultfromimproperlyhandlingandstoringmaterials,workersshouldalsobeawareofaccidentsthatmayresultfromtheunsafeorimproperhandlingofequipmentandfromimproperworkpractices.Inaddition,workersshouldbeabletorecognizethemethodsforeliminating,orminimizing,theoccurrenceofsuchaccidents.Workersshouldexaminetheirworkplacestodetectanyunsafeorunhealthfulconditions,practices,orequipmentandtakecorrectiveaction.PotentialHazardsforWorkersWorkersfrequentlymentiontheweightandbulkinessofobjectsthattheyliftasmajorfactorsoftheirinjuries.In1999,forexample,morethan420,000workplaceaccidentsresultedinbackinjuries.Bending,followedbytwistingandturning,werethemorecommonlymentionedmovementsthatcausedbackinjuries.Otherhazardsincludefallingobjects,improperlystackedmaterials,andvarioustypesofequipment.

PrecautionsShouldbeTakenWhenMovingMaterialsManuallyWhenmovingmaterialsmanually,workersshouldattachhandlesorholderstoloads.Inaddition,workersshouldalwayswearappropriatepersonalprotectiveequipmentanduseproperliftingtechniques.Topreventinjuryfromoversizeloads,workersshouldseekhelpinthefollowing:Whenaloadissobulkythatworkerscannotproperlygrasporliftit,Whenworkerscannotseearoundoroveraload,orWhenemployeescannotsafelyhandleaload.Usingmechanicalequipmenttomoveandstorematerialsincreasesthepotentialofinjuries.Workersmustbeawareofsafeequipmentoperatingtechniques.Employeesshouldavoidoverloadingequipmentwhenmovingmaterialsmechanicallybylettingtheweight,size,andshapeofthematerialbeingmoveddictatethetypeofequipmentused.Allmaterialhandlingequipmenthasratedcapacitiesthatdeterminethemaximumweighttheequipmentcansafelyhandleandandtheconditionsunderwhichitcanhandlethatweight.Workersmustensurethattheequipmentcapacityisdisplayedoneachpieceofequipmentandisnotexceededexceptforloadtesting.

PrecautionsShouldbeTakenWhenMovingMaterialsMechanicallyAlthoughworkersmaybeknowledgeableaboutpoweredequipment,theyshouldtakeprecautionswhenstackingandstoringmaterial.Whenpickingupitemswithapoweredindustrialtruck,workersmustdothefollowing:CentertheloadontheforksasclosetothemastaspossibleAvoidoverloadingalifttruckAdjusttheloadtothelowestpositionwhentravelingFollowthetruckmanufacturer’soperationalrequirementsPileandcross-tierallstackedloadscorrectlywhenpossibleSafetymeasuresregardingconveyorsWhenusingconveyors,workersmaygettheirhandscaught,bestruckbymaterialfallingofftheconveyor,ormaygetcaughtintheconveyoranddrawnintotheconveyorpathasaresult.Topreventorreducetheseverityofaninjury,followingprecautionsmustbetakentoprotectworkers:Installanemergencybuttonorpullcorddesignedtostoptheconveyorattheworkstation.

Designtheemergencystopswitchsothatitmustberesetbeforetheconveyorcanberestarted.Prohibitworkersfromridingonamaterials-handlingconveyor.Provideguardswhereconveyorspassoverworkareasoraislestokeepworkersfrombeingstruckbyfallingmaterial.SafetymeasuresregardingcranesEmployersmustpermitonlythoroughlytrainedandcompetentworkerstooperatecranes.Operatorsshouldknowwhattheyareliftingandwhatitweighs.Forexample,theratedcapacityofmobilecranesvarieswiththelengthoftheboomandtheboomradius.Whenacranehasatelescopingboom,aloadmaybesafetoliftatashortboomlengthorashortboomradius,butmayoverloadthecranewhentheboomisextendedandtheradiusincreases.

Equipallcranesthathaveadjustableboomswithboomangleindicators.

Providecraneswithtelescopingboomswithsomemeanstodetermineboomlengthsunlesstheloadratingisindependentoftheboomlength.

Requireworkerstoalwayscheckthecrane’sloadcharttoensurethatthecranewillnotbeoverloadedbyoperatingconditions.

Instructworker