物料搬運系統(tǒng)設(shè)計要點

1、第第9講講 目目 錄錄 搬運與倉儲設(shè)備簡述搬運與倉儲設(shè)備簡述(教材第教材第8章章)CH5 物料搬運系統(tǒng)設(shè)計物料搬運系統(tǒng)設(shè)計 5.1 物料搬運系統(tǒng)的基本概念物料搬運系統(tǒng)的基本概念 5.2 搬運系統(tǒng)分析方法（搬運系統(tǒng)分析方法（SHA） 5.3 搬運系統(tǒng)分析與設(shè)計搬運系統(tǒng)分析與設(shè)計 5.4 系統(tǒng)布置與搬運系統(tǒng)分析的結(jié)合系統(tǒng)布置與搬運系統(tǒng)分析的結(jié)合 （SLP+SHA)搬運與倉儲設(shè)備簡述搬運與倉儲設(shè)備簡述 (1)容器和單元化設(shè)備容器和單元化設(shè)備 (containers and unitizing equipment) (2)物料搬運設(shè)備物料搬運設(shè)備(transportation equipment) 傳

2、送帶和輸送機械傳送帶和輸送機械(conveyors) 起重機械起重機械(Cranes) 工業(yè)用車輛工業(yè)用車輛(Industrial Truck) (3)存取設(shè)備存取設(shè)備(storage and retrieval equipment) (4)自動辨識及通信設(shè)備自動辨識及通信設(shè)備 (automatic identification and communication equipment)(1)容器和單元化設(shè)備容器和單元化設(shè)備(containers and unitizing equipment) （P159P163） 容器容器: 托盤（托盤（pallet) 搬運箱等。搬運箱等。 負載單元化設(shè)備：

3、負載單元化設(shè)備： 滑板式托盤、縮緊打包和撐拉打包、堆集和集滑板式托盤、縮緊打包和撐拉打包、堆集和集裝箱裝箱 (2)物料搬運設(shè)備物料搬運設(shè)備(transportation equipment) 傳送帶和輸送機械（傳送帶和輸送機械（P192P198） 起重機械（起重機械（P198P205） 工業(yè)用車輛：人力小車工業(yè)用車輛：人力小車(托板車、托板車、 叉車叉車 (P214P218) 單軌列車、吊車和起重機單軌列車、吊車和起重機 自動導(dǎo)引小車自動導(dǎo)引小車(AGV)（ P218P225 ）67891011121314(3)存取設(shè)備存取設(shè)備(storage and retrieval equipment)

4、 即：存儲和揀貨設(shè)備（即：存儲和揀貨設(shè)備（P205） 普通儲存和揀貨設(shè)備普通儲存和揀貨設(shè)備 貨架、支架等貨架、支架等 自動化儲存和揀貨系統(tǒng)（自動化儲存和揀貨系統(tǒng)（AS/RS)1617(4)自動辨識及通信設(shè)備自動辨識及通信設(shè)備(automatic identification and communication equipment) P229CH5 物料搬運物料搬運物料搬運的重要性（從數(shù)據(jù)中看問題）物料搬運的重要性（從數(shù)據(jù)中看問題） 中等批量的生產(chǎn)車間里，零件在機中等批量的生產(chǎn)車間里，零件在機床上的時間僅占生產(chǎn)時間的床上的時間僅占生產(chǎn)時間的5%，而，而95%的時間消耗在原材料、工具、零的時間消耗

5、在原材料、工具、零件的搬運、等待上。件的搬運、等待上。 據(jù)統(tǒng)計，搬運費用占總生產(chǎn)費用的據(jù)統(tǒng)計，搬運費用占總生產(chǎn)費用的30%40%。5.1 物料搬運系統(tǒng)的基本概念物料搬運系統(tǒng)的基本概念一、物料搬運的一、物料搬運的定義定義二、物料搬運系統(tǒng)的二、物料搬運系統(tǒng)的目的目的三、物料搬運的三、物料搬運的活性理論活性理論四、物料搬運系統(tǒng)的四、物料搬運系統(tǒng)的原則原則五、物料搬運系統(tǒng)的五、物料搬運系統(tǒng)的考慮因素考慮因素六、物料搬運的六、物料搬運的單元化和標(biāo)準化單元化和標(biāo)準化2122232425262728表：活性的區(qū)分和活性指數(shù) 物品狀態(tài) 作業(yè)說明 已不需要的作業(yè)數(shù)目 活性指數(shù) 散放在地 集中、搬起、升起、運走

6、0 0 集裝箱中 搬起、升起、運走 1 1 托盤中 升起、運走 2 2 車中 運走 3 3 思考：在運動中的物料活性指數(shù)是多少29可以利用活性理論改善搬運作業(yè)可以利用活性理論改善搬運作業(yè)30313233Top 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 specificat

7、ion of the proposed methods are 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

8、should be standar-dized within the 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

9、should be minimized without sacrificing productivity or the level of service required of the operation.34Top 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 equi

10、pment to ensure safe and effective 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

11、objectives at each stage in the 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

12、 be made of all available space. Space in material handling is three dimensional and therefore is counted as cubic space.35Top 10 Principles of Material Handling (cont.)Principle 7. System Principle Material movement and storage activities should be fully integrated to form a coordinated, operationa

13、l system that spans receiving, inspection, 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 operati

14、onal efficiency, increase responsiveness, 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 s

15、electing alternative equipment and material handling systems.36Top 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 between 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