case study material handling

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• Published: 27 June 2020

Case study: evaluation of the automation of material handling with mobile robots

• Adriana F. Melo 1 &
• Lindsay M. Corneal   ORCID: orcid.org/0000-0002-9102-2859 1  

International Journal of Quality Innovation volume  6 , Article number:  3 ( 2020 ) Cite this article

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The automation of material handling is one of the solutions that many companies are relying on to reach their goals related to productivity increment, floor space optimization, higher standards for factory’s safety, and allocation of workers to value-added activities. Therefore, the objective of this study was to evaluate the current state of the material flow of finished goods for an automotive parts supplier plant and the technology available on the market to verify if it was worthwhile to invest in material handling automation. The analysis included the use of discrete event simulation to evaluate the different layout approaches combined with the mobile robots’ performance. It was proven that the tandem layout was the most beneficial approach to the analyzed plant’s reality with a minimal of three robots. Improvements to the material flow and automation of the labeling process were also proposed based on the study.

Introduction

Automated guided vehicles (AGVs) first started to be used in the 1950s for manufacturing. This technology began the trend of automation of material transportation. They have proved to be reliable and efficient technological equipment for more than 50 years. However, the need of fixed routes and the minimal on-board intelligence were restricting the use of AGVs to applications that required little variability on the pickup and drop off points of materials, as well as no interruption to its path. Changes to the pathways were simply too expensive and disruptive to be cost-effective as they are typically installed in the floor.

In response to the AGV’s drawbacks, a more sophisticated solution to material handling was recently introduced to the market, the autonomous mobile robots (AMRs). These robots have on-board intelligence and real-time adaptive capabilities, which support the increasing market demand for flexibility and for agility to comply with modification to products or processes [ 1 ].

In contrast with fixed route required by the AGVs, AMRs navigate via maps that its software constructs on-site or via pre-loaded facility drawings. The AMR uses data from cameras and built-in sensors and laser scanners as well as sophisticated software that enables it to detect its surroundings and choose the most efficient route to the target. To change its mission, the AMR only needs simple software adjustments. This functionality allows the same robot to perform a variety of different tasks at different locations, automatically adjusting to meet changing environments and production requirements. This flexibility also makes the AMRs more cost-effective as an AMR does not need wires, magnetic stripes, or other costly modifications to the building infrastructure.

Regarding the safety of these mobile systems, many of them are based on the same technology as is used for autonomous vehicles, which apply LIDAR (light detection and ranging) sensors [ 1 ]. These sensors are commonly used for pedestrian recognition. When compared with cameras, LIDARs can provide accurate range information and a larger field of view [ 2 ]. From a safety standpoint, this technology has what is recognized as a capable safety system to detect objects and people and to react appropriately [ 1 ].

It is important to emphasize, however, that new safety concerns are being raised due to this new technology. As the mobile robots are becoming more autonomous, correcting their path while in motion and the integration of new features and attachments on them, the robotics online marketing team within the Robotic Industries Association states that the existing safety standards present gaps that fail to cover some of these latest technologies to ensure the well-being of other laborers. To overcome this issue, the outlining guidelines for robot manufacturers and system integrators are being developed. The fast pace of the development of the safety standards reflects not only the urgent need for safety standards but the expectation that industrial mobile robots will continue to be implemented at a rapid rate [ 3 ].

Regarding its implementation, Gutta et al. state that facility layout design methodology is one of the primary aspects to be dealt with for an efficient and economical working of a mobile robot system. The decisions concerning material handling within the facility can have a significant impact on the effectiveness of the layout plan. Hence, for proper sequential working of a manufacturing system, it is important that the layout plan and material handling system for a facility are designed simultaneously [ 4 ].

For this study, two aspects were studied to evaluate the best way to automate the material handling at the selected plant: the plant layout and the material flow.

Facility layout design involving the implementation of mobile robots is categorized into layout design, pickup and delivery points, and flow path design. In layout design, the workspace can be seen as a set of complex polygons known as cells. The material flow system, in its turn, is characterized in terms of flow path design and direction of vehicle flow, and number and location of pickup and delivery points [ 5 ]. The flow path and location of pickup and delivery points must be determined effectively as they influence the path that a mobile robot must track, which impacts the flexibility and operational costs of a manufacturing system [ 6 ].

Typically, there are three main types of layout designs in the AMRs: single loop, tandem, and conventional layout. In a single-loop layout, AMRs travel in a unidirectional loop. When this system is used, the vehicle flow is constrained to travel only in one direction. As all the vehicles travel in the same loop, it requires less complexity in the control system. However, with this layout, the distance traveled by the vehicle might be greater when moving from one point to another, as each vehicle must travel the whole loop to visit the same point again. Another disadvantage of this kind of layout is that a vehicle breakdown can destroy the whole system [ 7 ].

The tandem layout overcomes some of the disadvantages presented by the single-loop layout. This layout design decomposes into non-overlapping loops, which can contain one or more vehicles. Previous studies showed that the tandem loop with multiple vehicle (TLMV) layout has out-performed single loop and tandem with single-vehicles layouts in terms of mean flow time and vehicle utilization. The main advantage of TLMV is it is less susceptible to vehicle breakdown [ 8 ].

The conventional layout design mainly includes unidirectional layout, bidirectional layout, and multi-lane hybrid layout. The main advantage of a bidirectional layout lies in the achievement of less vehicle travel time by reducing the travel distance due to the possibility of taking shortcuts and/or using a smaller layout space. However, the complexity of the control system is very high [ 9 ].

To compare these layout different approaches and to support the decision-makers within the company, this study made use of discrete simulation modeling. The design of the simulation model is subordinated to the method which is closely connected to the chosen software solution. The software used on this project was FlexSim 2018 Update 1, and the following steps were followed for the creation of the simulation models:

Creation of pathways and control points for vehicle movement

Add the AMR process flow template

Adapt the process flow template to fit the scenario being analyzed

Develop additional programming to imitate the variability and randomness of the real world

Verification and validation of the created model

The devolvement of this study was focused on proposing a solution to address the shortage of labor in an automotive parts supplier’s factory and to prepare the plant for the projected increase in demand in the coming years. It is important to emphasize that the automation of material handling includes not only the implementation of mobile robots but also the automation of the labeling process and the changes to the feeding system for the production cells, sorting area, receiving/shipping area, and the warehouse. To enable this, it may be necessary to change the layout of the plant.

Case description—automotive parts supplier

With the economic growth associated with the trend to automation and Industry 4.0, the company being studied has heavily invested in robotics. For the last 5 years, this company has identified the need to automate the material handling in order to meet customer demand. This decision was based on the lack of labor on the production floor, combined with the need to increase traceability of the materials and to reduce the production lead time.

As the turnover of operators is considerably high at the company, it is essential to allocate the qualified employees to more value-added activities, such as operating complex machines. Also, a lot of effort has been expended to trace material or to adjust inventory due to human errors while scanning the products or by misplacing them.

The three main goals of this project were as follows:

Minimize the labor required on material

Improve floor space utilization to allow the installation of more production cells

Optimize the current material handling flow

The challenge of this application was due to the desire to implement mobile robots on the production floor rather than warehouses.

Current state

The current state analysis was focused on the finished goods and on the processes that were impacted with the automation of the material handling. There were six production cells that would be impacted with the use of mobile robots—cells SD1, BK1, BK2, DF4, DF5, and DF6—plus the sorting area and the shipping area.

Figure 1 shows the layout of the plant at the beginning of this project development. The representation of the material flow in Fig. 1 shows the material flow that is standardized. The labeling process flow was not represented there because the forklift driver has the flexibility to go to any of the labeling stations, as well as frequently the supervisor provides the label to the cell’s operator when the quantities and weight are known.

Current material flow and plant layout

Analyzing this initial layout, it could be easily verified that the flow of material of the finished goods was not linear. For example, the location of the sorting area added unnecessary travel distance. Also, SD1 was placed close to the shipping area due to its high volume. However, if the parts built there needed to be sorted, the flow was increased tremendously as they must travel to the sorting area.

It is important to highlight that the location of the production cells could not be easily modified, as they are complex-automated cells with constraints of infrastructure installation and ceiling height. Therefore, they were considered fixed locations for this analysis.

The general process for the material handling in these cells was the forklift driver brings the raw material from the receiving area to the cell. With a hand scan, the driver scans the material to execute the warehouse transfer between the previous location and its current destination. Once the parts are assembled and one tote is full, the forklift driver scans the tote and takes it to a labeling station. The tote is weighed, and a raw material (RM) label is printed. The RM label executes the transaction in the enterprise resource planning (ERP) system, which deducts the raw materials used and adds to the inventory the amount of material produced. After this label is applied to the tote, the driver takes it to its destination, which can be either the BK1 cell, the BK2 cell, the sorting area, or the shipping area. Once the tote is at its destination, the driver must scan it again, so the virtual warehouse transfer takes place.

This current process was susceptible to many errors due to its dependency on the manual labor.

Layout proposal

With the understanding of the current state of the production floor, changes were proposed to enable the automation and to improve the utilization of the mobile robots.

One way to increase the AMR efficiency was by reducing its traveling distance. Knowing that changing the location of the production cells was to be avoided, this study focused on the investigation of changes in the sorting area, shipping area, and in the labeling process.

For the sorting area, its reallocation to an area close to shipping or near to the cells which demand the most inspection was studied. Analyzing the plant layout, a solution was to move the sorting area to the market place (see Fig. 2 ).

Proposed material flow and plant layout

With the sorting happening at the market place, the traveling distances of the parts coming from the DF4, DF5, DF6, BK1, and BK2 would be reduced significantly. On the other hand, evaluating the parts coming from SD1, the flow of material would still not be desirable as the parts’ traveling distance would more than double for the scenario when a quality inspection is required.

To solve this, it was proposed that the sorting for this cell was done in line. The high volume of SD1 supported this decision. Thus, the parts would always leave SD1 and go straight to the shipping area. Figure 2 shows the flow of material according to the changes proposed.

Regarding the shipping area, it was proposed to create an area dedicated to the SD1 parts due to the high demand. As the interaction between the mobile robots and the forklift is to be avoided, it was suggested to place the shipping area for these parts on the same side of the aisle as the cell. This would help to eliminate forklift and AMRs traveling on the same aisle in some of the layout approaches that will be discussed in the following sections. Implementing a path dedicated to the mobile robots, as well as putting in place processes that minimize the interruption of the AMRs’ flow promotes the learning curve necessary when a new automation is implemented.

The end goal of the material handling automation was to have one piece flow between the production cells and the shipping area. To enable this, some enhancements were proposed to the production cells, such as the implementation of vision inspection to ensure the quality of the parts and the automation of the final packaging.

The modifications proposed in this study reduced the products lead time as they reduce their traveling distance, and decrease their cycle time by minimizing the need of manual sorting, manual labeling, and manual packaging. It also reduces the amount of labor needed.

Layout scenarios

As discussed previously, three scenarios were developed to decide which layout concept would be most appropriate for this application. The first scenario is the conventional layout, presented in Fig. 3 . In this scenario, every AMR can handle the material from any production cell. This concept allows the mobile robot to judge the best route to be taken to reach its destination, and it guarantees a balanced workload between the robots. It also optimizes the priority rules, as it is applied on the whole system and not just within a section.

Conventional layout scenario

In addition, this concept gives more flexibility for storage location and parking spots. Also, the failure mode for this situation is less critical when compared with the other two approaches, as the tasks can be delegated to a different AMR, and the robots have more flexibility to choose a path in a blockage situation.

One of the drawbacks is that all the aisles on which the AMR will be running need to be wider to permit the passage of two AMRs on the same aisle. It requires a robust control system. This scenario also does not support the interaction avoidance between AMRs and forklifts for the SD1 cell.

The second scenario used the tandem layout, shown in Fig. 4 . This approach presents a mix between the single loop concept and the conventional layout. For this simulation, the cells were divided into two sections: the first group consists of the SD1 cell and the second group handles the sorting and all the DF cells. The difference between this approach and the single loop is that more than one AMR can be placed in one section.

Tandem layout scenario

The tandem approach minimizes some of the drawbacks associated with the single loop (as identified below). It reduces the number of locations dedicated to storage, as all the totes for the DF cells can be put in the same place, and it permits the implementation of only one labeling station. It also gives the AMR more flexibility to select the best path to reach its destination.

This concept also allows the isolation of the SD1 cell. By putting one AMR dedicated to the SD1, a unidirectional aisle can be dedicated to the mobile robot translation which eliminates the interaction between AMRs and forklifts.

The disadvantage of the tandem layout is that if more than one AMR is allocated within one section, it necessitates wider aisles. This fact also increases the complexity of system control as the deadlock and collision situations must be addressed.

The last model followed the single loop approach, presented in Fig. 5 (3 single loops) and Fig. 6 (4 single loops). In this scenario, the plant was divided into sections where only one AMR would be responsible to handle the materials. The advantage of this solution is the reduced complexity of the control system, as the deadlock avoidance and the collisions do not need to be addressed. Also, it minimizes the width of the aisle as the AMR would not need to cross each other.

Single loop layout scenario with 3 loops

The single loop layout increases the number of storage places, parking areas, and labeling stations. It also required an intermediate location for the parts produced in DF5 and DF6 that need to go to the BK1 or BK2 cells. This scenario might also generate significant imbalanced workloads between the AMRs, and a failure mode of one robot could have a tremendous impact on the production schedule of its section. Modification on how the sections are divided would require a substantial amount of effort in programming the robots and in reallocating parking spots, storage locations, and labeling stations.

In this scenario, the AMR always follows the same path and every AMR must have a unique path.

Two options of this scenario were analyzed. In the first option, shown in Fig. 5 , the production cells were divided into three sections: the first area was designated to the SD1 cell, both finished goods and brackets. The second section was for DF4 and sorting, and the third area was for DF5 and DF6. The general shipping area would have to allow the delivery of parts from both sides.

The second option was to add one more segment to separate DF5 and DF6. Thus, the workstations were divided into four sections as shown in Fig. 6 . The first area was dedicated to SD1, both finished goods and brackets. The second section was dedicated to DF4. The third area was for sorting and DF5. The last one was dedicated to DF6.

Single loop layout scenario with 4 loops

It was not proposed to have a single loop with 5 divisions because it would be counterproductive due to the lack of paths to the shipping area and the high amount of intermediate storage that would be required. In both the single loop and tandem approaches, it was desired to leave SD1 by itself due to its volume and its physical separation from the rest of the cells. In all the scenarios where there is more than one AMR responsible for the material handling within a section, it was necessary to create unidirectional double paths rather than bidirectional single paths. The reason for that was the extensive blockage situations presented when single paths were applied.

Comparison of scenarios

To decide which approach would be most appropriate with the plant’s reality, all three layout scenarios were simulated using FlexSim. For each layout, multiple scenarios were considered. The model parameter value that changed in each scenario was the number of mobile robots.

The performance measures were the percentage of idle time of the AMRs and the percentage of time each cell had a tote waiting for transportation. The maximum and minimal value was captured to verify the statistical dispersion of the results, as well as the confidence intervals with 99% degree of confidence. As a waiting tote can stop the cell from running, it was required that the average cells blockage be below 2%.

Blockage for the DF cells means the cell is unable to produce parts due to the lack of empty totes for the new parts. A low percentage of waiting time is acceptable as the cells can manage a small buffer. However, the goal is to design a process where the wait for transportation is zero. Table 1 shows a summary of the scenarios simulated.

Also, the charging base of the AMRs was placed in their parking spots, where there was one charger for each AMR. The AMR was charging every time it was located at the parking spot. Each AMR would go to its parking spot whenever it was idle. Therefore, the amount of time the AMR was charged was equivalent to the idle time. Reviewing the specifications of the AMRs, it was decided that the AMR had to charge on average 30% of its operational time.

With respect to the demand for work, it was decided to use the production cells maximum real capacity, which accounts for machines unavailability and manufacturing errors. These measurements reduce the cells’ capacity to 75% or 80% depending on the cell. This decision was based on the fact that it was completely undesired for the AMRs to be the bottleneck. For the sorting area because there are parts built in work cells other than the DF cells that need to be sorted, the data from a normal work week was used.

The average hourly demand was used with the normal distribution for internal variability of the demand estimated between 11 and 20% of the mean. The estimation of the variability was selected by analyzing 1 week of the main cells’ historical data.

For safety measures, even though the majority of AMRs on the market can go up to 2 m/s, the maximum speed of all the AMRs was set to 0.8 m/s. When the robot was carrying a load, the maximum speed was reduced to 0.6 m/s. On a curved path, the speed was set to 0.6 m/s when empty and 0.5 m/s when loaded. The loading and unloading time were considered as 40 s, and the labeling time was set to 60 s. Table 2 summarizes the system’s parameters.

From the results of the scenarios simulated, showed in Table 1 , there were 4 scenarios that were feasible and of interest. To define if the scenario were feasible and of interest, it was analyzed using the average, the maximum, and the minimum percentage of the idle time of the robots, as well as the percentage of the cells, blocked time. Tables 3 and 4 show the overall results of each selected scenario. It also presents the confidence interval with a 99% degree of confidence level. Comparing these results, the best layout approach was the tandem layout, where the plant was divided into two sections. The AMRs presented higher average idle time when compared with the conventional layout scenarios using 3 robots. Also, the results from scenario 4 Conv did not justify the cost of adding one more robot.

When compared with the single loop, the tandem is more beneficial due to a better workload balance between the AMRs and a better material flow.

Discussion and evaluation

The key performance indicators (KPIs) that were chosen to evaluate the material handling automation system were throughput, response time, total labor dedicated to material handling, management of buffers, starvation avoidance, blocking avoidance, deadlock avoidance, dealing with disruptions, and capital cost of automation. Evaluating the chosen layout with regards to the KPIs identified, the tandem layout satisfies the throughput of the cells when 3 AMRs are used, and the starvation avoidance. This was proven by the low percentage of blockage time. This layout also provides the ability of quick response time in both sections of the system. In the DF cells section, if there is an urgency, one of the AMRs can be easily selected to execute the task. In the SD1 section, on the other hand, the AMR is dedicated to the one unique cell which will also allow for an immediate response.

Analyzing the flexibility to deal with disruptions and the blocking and deadlock avoidance, there is a tradeoff to be studied for this approach. The DF cells present a more flexible set up to deal with disruptions, as one AMR can be removed, and the cells will still be fed. However, the blockage avoidance and the deadlock avoidance need more sophisticated programming to be accomplished in this section. On the other hand, the SD1 section does not require this complex programming as there will be only one AMR operating. However, having just one AMR reduces the ability to deal with disruptions, such as breakdowns. These last two aspects need to be considered when choosing the AMR, as well as when deciding the interface between the mobile robots and the cells.

Conclusions

The next step of this project is the actual implementation. As Haneayah et al. state, the automation of the material handling is a complex installation that comprises various processes, such as inbound, storage, batching, sorting, picking, and outbound processes [ 10 ]. Therefore, it is important that the management support it as well as a culture change on the production floor.

The 5S concepts are vital for the success of this project. The cells and aisles need to be kept organized, allowing the flow of the mobile robots. The blockage of aisles can have major impacts on the performance of the AMRs.

Another important point is the cooperation of the forklifts’ drivers. As the material will be handled by AMRs and forklifts, the forklifts must be trained and be attentive to the AMRs to avoid blockage or damage.

With the changes required and the learning curve, it is recommended that during the first phase of the implementation the interaction between forklifts and the AMRs be avoided. This can be done by creating a separate aisle for the AMRs or creating traffic rules limiting the flow of forklifts in certain areas.

As manufacturing plants are not static places and pathways in them tend to collapse to the minimum allowable over time, this theorical study presents potential limitation regarding the adequacy for the real-world operation. However, the discrete simulation tool can be easily edited to represent the reality over time.

Availability of data and materials

The data that support the findings of this study are available from the company for which the study was completed but restrictions apply to the availability of these data, and so are not publicly available. Data are however available from the authors upon reasonable request and with permission of the company for which the study was completed.

Abbreviations

Automated guided vehicles

Autonomous mobile robots

Key performance indicators

Light detection and ranging

Tandem loop with multiple vehicle

Raw material

Enterprise resource planning

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Acknowledgements

The authors would like to acknowledge the contributions of Dr. Charles R. Standridge and Dr. David W. Zeitler of Grand Valley State University for their review of the analysis completed for this study.

Funding for this study came from the company for which the study was completed. An author of this paper (AM) was an employee of the company for which the study was completed. The company’s management had no role in the collection, analysis, or interpretation of the data.

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AM prepared the simulation model, ran the simulations, and was a major contributor in writing the manuscript. LC reviewed all simulation results, provided guidance on the analysis of the results, and contributed to the writing of the manuscript. Both authors read and approved the final manuscript.

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Correspondence to Adriana F. Melo .

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The author, AM, was a paid intern at the company for which this study was done. The author, LC, had no affiliation to the company.

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Melo, A.F., Corneal, L.M. Case study: evaluation of the automation of material handling with mobile robots. Int J Qual Innov 6 , 3 (2020). https://doi.org/10.1186/s40887-020-00037-y

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Received : 07 February 2020

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Published : 27 June 2020

DOI : https://doi.org/10.1186/s40887-020-00037-y

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Case Study: From Pick to Shout to Pick to Light

NOVEMBER 26, 2019

“ The post Case Study : From Pick to Shout to Pick to Light appeared first on Logistics Business® Magazine. This does not mean that we have time left over when distributing fresh products, but that we have more time after each wave to prepare for the next wave. As a result, we now have more control over the process.

Case Study: Yale and Forkway Enable Stelrad to Radiate Success

JUNE 18, 2018

As the materials handling equipment supplier to Stelrad for over 15 years, Yale sub-dealer, Forkway, is best placed to advise and guide the company on the most efficient operation in their warehouse and distribution centre. For us to achieve our goals, the equipment needs to be running throughout the 24-hour shift period,” said Paul.

Case Study: Smelling the Coffee with JCB’s Teletruk

JUNE 7, 2019

The need to add the strap brings an element of manual handling that we are keen to avoid.”. After discussing the various issues with the company’s materials handling equipment supplier, Hiremech, Freshways opted to trial JCB Teletruk technology at the Acton site.

Case Study: STILL RX70 Truck Handles Agri Business

MARCH 19, 2019

We have a range of distribution, production and galvanising facilities here at IAE so we needed a strong materials handling partner to aid in our complex operations. The post Case Study : STILL RX70 Truck Handles Agri Business appeared first on Logistics Business® Magazine. What were your requirements?

Case Study: Why UK Ports and Shipping Firm Chose Hyundai

MAY 30, 2019

Award-winning Acclaim Handling is a forklift hire sales and materials handling equipment specialist, headquartered in Purfleet in Essex. Acclaim Handling has recently secured a brand-new customer, leading Shipping and Port company, SEACON, based in Northfleet, Kent. .

Case Study: Cesab Ergonomics and Safety Perfect for UK Public Sector Firm

DECEMBER 3, 2018

With over 25,000 delivery points across the UK and weekly deliveries to customers to send out, reliable materials handling equipment is essential. The post Case Study : Cesab Ergonomics and Safety Perfect for UK Public Sector Firm appeared first on Logistics Business® Magazine. ” Tweet.

Case Study: Multipurpose Electric Trucks Reign Supreme at Crown Imperial

NOVEMBER 29, 2018

The wide variety of raw materials and the varying dimensions of finished products that need to be moved around and stored at the 10,000m² production facility required versatile equipment, and Store Manager Bruce Whiting was also keen to reduce the level of ride-on forklift traffic, particularly in areas where a lot of other personnel are present.

Dematic Doubles-up to Reinforce Mission

FEBRUARY 2, 2024

For the first time, Dematic can be found hosting two stands at the largest logistics tradeshow in Europe: in Hall 1 H/61 and Hall 10 C/38 next to fellow KION Group brands STILL and Linde Material Handling . The focus is on automated processes and customer services for tomorrow’s warehouse.

Case Study: Hubtex Sideloaders Optimize Space and Storage

MAY 8, 2019

Effective materials handling and warehouse management is crucial to the success of a company, which is why Gaugler & Lutz oHG is banking on an intelligent storage system at its new logistics centre in Aalen-Ebnat (Nord) in Germany.

Case Study: Handling the Tough Wood Supply Chain

AUGUST 21, 2018

Any materials handling equipment used in zoned areas needs to be ATEX 2014/34/EU compliant to legally work in these areas. The post Case Study : Handling the Tough Wood Supply Chain appeared first on Logistics Business® Magazine.

Case Study: Loading Bay Technology at High-Spec Business Park

DECEMBER 13, 2018

The post Case Study : Loading Bay Technology at High-Spec Business Park appeared first on Logistics Business® Magazine.

Case Study: It’s a Shoe-in at Skechers EDC

AUGUST 30, 2018

The post Case Study : It’s a Shoe-in at Skechers EDC appeared first on Logistics Business® Magazine. UniCarriers knows our business right down to the tiniest detail and is able to provide us with solid advice on optimising logistics processes.

Navigating the Loading Bay’s Hidden Risks

APRIL 26, 2024

One survey found that 64% of businesses across materials handling , distribution, or fulfilment had forgone business worth more than 25% of their revenue in 2022 because of staffing issues. Recruitment challenges. For the reasons mentioned, recruiting new employees to replace the logistics workforce has proven extremely difficult.

Warehouse Capacity – My Warehouse is Full

Logistics Bureau

OCTOBER 8, 2019

Listen to this case study : As mentioned in the video, here are some links to the blogs that cover this topic: Warehouse Automation and Robotics with Mal Walker. But what if I tell you, maybe you don’t have to do these? Warehouse Automation & Robotics Part 2 with Mal Walker.

FANUC unveils speakers for Open House event

OCTOBER 28, 2022

and the future of manufacturing, the power of partnerships and the route to net zero in a series of panel discussions, keynote speeches and in-depth case studies across the three-day event aimed at showcasing the benefits of automation to UK manufacturers. Day 1 – The power of partnerships.

Find your Warehouse Rhythm

NOVEMBER 23, 2023

The company’s IT solutions create demand for its automated materials handling products and vice-versa. There has been a gold rush of entrants to the AMR market so we can evaluate the case studies . Another issue is the friction between WMS and TMS. Which has priority when an order comes in?” But it’s not a big value-add.

Editor’s Pick: Profiles in Yard Management Excellence – Universal Logistics

Talking Logistics

AUGUST 10, 2017

In this post, Rafael Granato from PINC Solutions summarizes a video case study we featured recently on Talking Logistics, part of our “Profiles in Yard Management Excellence” series where we highlight companies (in this case , Universal Logistics) that are leading the way in driving continuous improvement and innovation in yard management.

Free IMHX Seminars to Tackle Supply Chain Challenges

JUNE 24, 2019

As well as a Keynote Arena and The Big Bang @ IMHX Skills Zone, visitors can attend informative sessions within the Technology Solutions Forum where they can learn how new cost-saving logistics technology is being implemented within operations from real life case studies .

Sitma named “outstanding company” by Kotler

DECEMBER 3, 2021

Sitma, a specialist in designing and producing solutions for automation in the logistics industry, has been chosen as a case study for the book Essentials of Modern Marketing by Philip Kotler together with Weevo, which looked at more than 30 examples of outstanding Italian companies in different fields of production.

How to Find a Food-Grade Warehouse in Indiana

FW Logsitcs

MAY 25, 2023

These can include factors such as material handling services, ease of access, amenities, and security features. Examining past performance reviews or case studies from other businesses that have worked with that particular facility can provide valuable insights into how reliable the service is likely to be.

DKSH Leverages Advanced Technology to Combat Epidemics

Logistics Manager

AUGUST 24, 2020

DKSH’s technology experts also shared some industry insights, market trends, and global case studies on the potential growth of infectious disease prevention technology and its implications towards Thailand’s business landscape.

IMHX 2019 Passes 400 Exhibitor Milestone

The seminar programme will also offer practical knowledge, strategic insights driven by real-life case studies , and further essential professional career development. The compelling conference programme at IMHX 2019 will feature a roster of inspiring thought leaders from organisations that are changing the face of logistics.

ISM 2018: The digitization of procurement

247 Customs Broker

MAY 11, 2018

There were other sessions on block chain in the afternoon, and sessions on dashboards, analytics, machine learning, digital procurement, cyber security, control towers and a case study presentation on the digitization of a procurement organization. About the Author. Bob Trebilcock. He can be reached at 603-357-0484.

Outstanding Supply Chain Solutions on Show at TRANSLOG Budapest

OCTOBER 18, 2018

r and visit the vehicle production and the press- and body shop, attend case study presentations and pre-schedule one-to-one business meetings with major regional and international solution providers such as Waberer’s International, SSI SCHÄFER, Arviem, Raben Group, Trans.eu, DHL, C.H.

Case Study: How Yale Dealer Helped Soft Paper Producer

MARCH 13, 2019

The facility manager at the Kimberly-Clark Group operation in Niederbipp has seen many different materials handling providers come and go. The post Case Study : How Yale Dealer Helped Soft Paper Producer appeared first on Logistics Business® Magazine. Andreas Nussbaum is not easily impressed.

Case Study: Innovative Loading Bay for Shannon Airport

The post Case Study : Innovative Loading Bay for Shannon Airport appeared first on Logistics Business® Magazine. Developments such as this are vitally important in terms of providing warehousing solutions that meet the needs of the changing landscapes of the courier and logistics industry.

Case Study: Optimizing Supply Chain via On-Demand Warehousing

NOVEMBER 5, 2018

The post Case Study : Optimizing Supply Chain via On-Demand Warehousing appeared first on Logistics Business® Magazine. The new 5500 sq. warehouse allows for a dedicated pick and pack section where 500-1000 picks are done daily.”. Find out more about Stowga’s unique model here.

Case Study: Cut Those Curtainsider Complications

MAY 14, 2019

The company’s founder, Brian Bingham, says: “The efficiency of the materials handling equipment that we use across our East Kilbride facility plays an essential role in helping Highlander reach current and future throughput targets.”. A fleet of eight JCB Teletruks is in operation at the site.

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Review Case Study for Improving Manual Material Handling in “Population” Workplace

2013, TJPRC

Manual material handling (MMH) work contributes to a large percentage of the over half a million cases of musculoskeletal disorders reported annually in the United States. Musculoskeletal disorders often involve strains and sprains to the lower back, shoulders, and upper limbs. They can result in protracted pain, disability, medical treatment, and financial stress for those afflicted with them, and employers often find themselves paying the bill, either directly or through workers’ compensation insurance, at the same time they must cope with the loss of the full capacity of their workers. Scientific evidence shows that effective ergonomic interventions can lower the physical demands of MMH work tasks, thereby lowering the incidence and severity of the musculoskeletal injuries they can cause. Their potential for reducing injury-related costs alone makes ergonomic interventions a useful tool for improving a company’s productivity, product quality, and overall business competitiveness. But very often productivity gets an additional and solid shot in the arm when managers and workers take a fresh look at how best to use energy, equipment, and exertion to get the job done in the most efficient, effective, and effortless way possible. Planning that applies these principles can result in big wins for all concerned.

Related Papers

Advances in Physical Ergonomics & Human Factors

Bankole Fasanya , Musibau Shofoluwe

Rising healthcare and workers’ compensation costs due to an increase in work-related musculoskeletal disorders (WMSDs) have made Occupational Ergonomics the focus of most organizations nationwide. These organizations are required to ensure worker safety by reducing or eliminating musculoskeletal disorders (MSDs) while complying with applicable occupational safety and health regulations. MSDs such as carpal tunnel syndrome often lead to intractable pain, repeated surgery, employee time off, low productivity, and, ultimately, higher costs for the employer. Work activities such as; loading and unloading, lifting, reaching, and workplace design factors; such as wrong work surfaces height, uncomfortable chairs and tables, and poorly designed tools; all contribute to an increased risk of MSDs. A case study on ergonomic issues was conducted to evaluate the behaviors and ergonomic injury complaints of workers from various work activities. The goal of the study was to highlight other critical aspects of occupational ergonomics, less considered by employers and workers in the manufacturing industry that could result in WMSDs. The findings revealed that employers tend to ignore some critical aspects of the job that may have high impacts on worker safety and performance. Several recommendations for improvement were offered, including improvement in the contents of the workers’ training packages, job process redesign and analysis, and involvement of ergonomics experts in the training of new employees. Feedbacks confirmed an improvement in WMSDs experience by the workers after the suggested recommendations were implemented.

Vedecké práce Materiálovotechnologickej fakulty Slovenskej technickej univerzity v Bratislave so sídlom v Trnave

Rastislav Beno

International Journal of Occupational Safety and Ergonomics Jose

Altan Koltan

Ergonomics and Musculoskeletal Disorders: RESEARCH ON MANUAL MATERIALS-HANDLING, 1983-1996

Michael S . Wogalter , Waldemar Karwowski

Injuries associated with manual materials handling (MMH) represent the single largest source of losse many industries, costing billions of dollars for workers' compensation, medical care, and lost wages. These losses explain why the research directed toward the prevention of MMH-related injuries in the industrial workplace has been one of the most active areas of the field of industrial ergonomics. This book contains 61 of the best papers (selected from 120 candidate papers) from 14 years of HFES Annual Meeting proceedings, one of the foremost sources of basic and applied research in this area.

IntechOpen eBooks

Daniel Odebiyi

Applied Ergonomics

Jörgen Winkel

Sarita Lakra

IJSREM Journal

Over the past few years, doctors realized that workers who carried heavy loads or maintained body positions with such loads for extended periods developed musculoskeletal problems and work environment hazards. In the long-ago years of research, the connections between specific job tasks and Musculoskeletal Disorders (MSD) with the study of ergonomics have been established. Ergonomics has become a significant contribution to the working environment to achieve or to complete the allotted work on time duration with perfection. This knowledge is necessary since the participation of all workers from the higher end to the lower end with the planning of intervention can create a suitable means of solutions in the industry. Some of the operational problems like repetitive work due to continuous sitting, standing and hazards may create fatigue. Hence, there is a need to find solutions for all these problems. The work gives analyses of ergonomics, hazards and safety techniques are related which develops a new framework to workers and safety is important with an ergonomics improvement of the workplace. The methodology classify and analyze the hazards in relation to physical, electrical and environmental parameters- as reported in the framework At conclusion of the study, the work reports data and insights from one manufacturing industry verifying different section with cases, which is relevant to industries.

Clare Pollock , Robin Burgess-Limerick

The purpose of this study was to assess the physical workloads for packing tasks in a printing ink manufacturing factory located in northern Taiwan, with an aim to lower the risk of musculoskeletal disorders (MSDs) among the workers. The BRIEF checklist and Key Indicator Method (KIM) were used to evaluate and identify the MSD risk factors associated with the ink packing tasks. The data collected include material weights, work posture, work pace, vertical distances, vertical lifting displacement, and lifting frequency. The ink-filling operator averagely filled 2000 1-kg ink cans per day and the ink-packing operator totally lifted 4166 times per day and the average lifting weight was 1.44 kg/lift. The BRIEF analysis results show that both of the operators have high possibility of developing MSDs. The KIM risk scores were evaluated as 40 (median high load) and 50 (high load) for the ink-filling and ink-packing operators, respectively. To reduce MSD risks for this work, a redesign workt...

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RōBEX Case Studies: Material Handling Systems & CNC Machine Tending

Real-world material handling systems.

RōBEX works with businesses of all sizes to find the most effective way to streamline processes and increase productivity. Read through the case studies below for more details about our approach to automation, inspection, and systems integration. Learn how RōBEX can help you optimize your material handling processes!

• Tripod Housing Gage Tool Compensation and CNC Machine Tending Lathe Cell
• Robot Lathe Tending & Gage Tool Compensation Automation Cell
• Case & Cover Machined Casting CNC Machine Tending & Laser Marking System
• Tripod Housing

In this system, parts enter the cell via a powered conveyor. Inside the cell, all material handling is managed by a robot. The robot tends the machining process on 3 CNCs.  The part is then inspected at an automatic inline gage station. Data reports are sent back to the cell computer where tool compensation values are calculated and reported back to the CNCs as required. Once complete the p arts leave via powered conveyors.

• The machining and inspection process was too labor intensive for material handling.
• The extensive process required inline gage feedback for tool compensation.
• The parts needed serialization and part marking for traceability.

1. Incoming Station

• Powered Belt Conveyor

2. Cell Tending Robot

• Custom Dual Gripper EOAT

3. CNC Machines

• Inline Machining
• Tool Compensation

4. Inspection Station

• Marking Impact Marking

5. Outgoing Station

• Outgoing Powered Belt Conveyor
• Outgoing Reject Conveyor
• Incoming Powered Conveyor
• FANUC Robotics
• Custom EOATs with Festo Pneumatic Grippers
• Solartron LVDT Probes
• Keyence Barcode Reader
• Keyence 2D Optical Micrometer
• Telesis Impact Pin Marker
• DMG Mori CNC
• Safety Interlocks
• Allen Bradley Controls

Design Gallery

• Output Carrier

In this system, two robots tending 5 lathes are located under a custom mezzanine structure equipped with moon roofs for safety access for the robot. Above the mezzanine, the robots also tend part handling and gages for in-process tool compensation feedback.

• Tight tolerances required in process tool compensation for lathes.
• Low available floor space.
• Gravity Roller Conveyor
• Part Metering

2. Operation One CNC Machining Automation

• Robotic Material Handling

3. Operation One Inline Gage Station

• I.D. Air Gaging
• Flange Thickness Contact Probe Inspection
• Hole Presence

4. Operation One Reject Station

• Gravity Roller

5. Operation Part Transfer

6. Operation Two CNC Machining Automation

7. Operation Two Inline Gage Station

• Step Depth Contact Probe Inspections
• Groove Depth Contact Probe Inspections
• OD Contact Probe Inspections

8. Operation Two Reject Station

9. Outgoing Station

• Custom Mezzanine Structure with P.E. approval
• Custom Incoming & Outgoing Gravity Roller Conveyors
• Custom Gravity Roller Reject Conveyors
• ABB Robotics
• Custom EOATs with Schunk Pneumatic Grippers
• Custom Air Gaging
• In-process Tool Compensation
• Automatic Gage Mastering
• RTGC Controls
• Rear Transmission Housing
• Front Transmission Housing

This system featured a material handling system with custom EOAT and a 7-axis robotic system to remove the manual labor from the process and meet the production demand. To address traceability, the incoming conveyance systems were equipped with an inline laser to add a barcode on 100% of the production parts that provides timestamp and part information. Each CNC then had a mounted code reader allowing the customer to know exactly which parts were run on the specific CNC and on what fixture. Finally, the system was connected to the customer’s factory information and integrated to provide seamless data to the process.

• The manufacturing process was too labor intensive for material handling in the CNC Process.
• The manufactured components required a method of data acquisition and part traceability.
• The equipment implemented needed to be flexible to protect for future product changes.

1. Front Incoming Station

• Power Zoned Conveyors
• Part Reintroduction Capable

2. Front Part Marking Station

• Automatic Part Fixturing
• Automatic Part Laser Marking

3. Front Part Robot Pick Station

4. Rear Part Incoming Station

5. Rear Part Marking Station

6. Rear Part Robot Pick Station

7. Robotic HNC Tending

• (5) CNC Management
• 7 th Axis Robot Material Handling
• Keyence Laser Marker
• Dorner Belt Conveyors
• Customer EOAT with Pneumatic Gripper
• FANUC 6-axis Robotics
• Escapements and Part Lifts
• Cognex Vision Inspection
• Allen Bradley Controls Structure

RōBEX Case Studies

Assembly lines.

View Case Studies

Inspection Cells

Ev solutions, pick, pack & palletizing.

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MATERIAL HANDLING CASE STUDIES

• Case Studies
• Cranes & Lifting Equipment
• Material Handling

Continuous Lift Machine Helps Maximize Efficiency

We recently worked with Tri-Fab to help a customer transport their products into their distribution center in the most efficient way possible. We helped develop a way of moving their finished, boxed products from manufacturing by vertically conveying them up, then discharging them onto a conveyor which takes them across the street via an elevated tunnel […]

Custom Lift Helps Major Construction Firm Stay on Schedule

A major US construction firm. What was the objective of the project? List any challenges that needed to be overcome: Our customer needed a custom lift that could lift and place 400+ very large custom aluminum hand rails into their proper location on multiple floors quickly and safely in the new StratCom HQ at the […]

Large Volume Ink Jet Printers Help Large Midwest Egg Producer Improve Accuracy, Efficiency and Reliability

One of the largest egg processors located in the Midwest that supplies millions of eggs to the nation daily. Challenges: The processor faced a challenge in ensuring reliable date codes were printed on the retail carton. Given the size of the egg processor, volume of orders and the multiple distribution channels the mechanical date stamp […]

Western Pacific Storage Solutions Teams Up with RMH Systems

This case study is brought to you by Western Pacific Storage Solutions. WPSS is a premier, customer-driven storage-product manufacturer committed to excellence, quality, value added service and building long-term relationships with our customers and vendors. They literally started from a hand drawn sketch. Breck & Sherry Loos, the owners of several Napa Auto Parts […]

Material Handling Solutions that Improve Floor Space, Productivity, and Safety

We sat down with Jack Boatman, sales manager of M3 Fabrication. When Jack and M3 Fab needed to create floor space, organize their work space, and make their operation safer and more efficient, they knew who to trust. [...]

Reducing Labor Costs & Providing Safe Solutions

Canadian Powder Coating Company A powder coating company that primarily focuses on the agricultural industry and also powder coats materials used in the oil field, medical and automotive industries. Grain bin foundations were loaded onto a powder coating line. This was accomplished using two men who were required to lift the bin foundations onto the line with a […]

Easy Arm Handles Dusty Environment Without Clogging

A manufacturer of paper products was using air balancers to change out roll cores in their plant. Multiple times each day, workers were required to remove the 50lb. cores from one roll and transfer them to another. Not only was the process difficult because of the weight and handling of the cores, but the constant […]

Safely Optimizing Pallet Flow & Pushback Rack Storage at a General Mills Plant

General Mills’ Cedar Rapids, Iowa plant had successfully used pallet flow and pushback rack systems, but ongoing growth, product changes and long use required a storage system update that would safely add capacity to their existing facility.[...]

5 Reasons why the Leibinger Jet 3Pro is Essential to Manufacturers

A well known Midwest dairy and juice producer.

Eliminate Simple End-of-Line Packaging Bottle Necks

Improving end of the line packaging is a constant battle that companies are always looking to improve. The BEL-505 is a semi-automatic case former designed to help customers solve this problem. The BEL-505 forms the bottom layer of a case allowing the operator to pack the case with both hands. This machine is a very good option […]

Forklift Truck Scale Raises Throughput by 30%

Cougle’s Recycling is a full-service recycling center for paper, corrugated paper, plastic, glass and non-ferrous metals. From its base in Hamburg, Pennsylvania (U.S.) it serves thousands of customers from small stores to complete communities. When Cougle’s identified that its weighing operation was slowing down production efficiency and affecting data accuracy, it was quick to consider […]

Optimizing Warehouse Space for 8,400 SKUs

A Fortune 500 agricultural company located in the Midwest partners with RMH Systems to maximize their current workspace.

Reliable Date Coding for Egg Industry

RMH Systems helps one of the largest egg processors in the Midwest deliver a more efficient, accurate and better egg.

Scale & Conveyor Combination Reduces Costs by 40%

This case study details a privately owned ham processor located in Nebraska that specializes in deboning hams for packers, further processors and export customers. The facility has been in operations since 1983, and has been providing quality pork products to customers throughout the world. The company debones more that one million pounds of bone-in hams […]

Eliminate Back Injuries and Fatigue for Frontline Workers

This case study details a seed company located in Iowa that develops, produces and sells high-yielding seeds.

Freestanding Monobox Crane Provides Strength Without Impeding on Shop Space

Freestanding Monobox Crane Provides Strength without Impeding on Shop Space The Client The client is a John Deere implementation dealer based out of Southeast Minnesota. The client sold and serviced John Deere tractors, combines [...]

How Implementing a Customized Storage Solution Helped an Automotive Part Manufacturer Buy More Efficiently

How Implementing a Customized Storage Solution Helped an Automotive Part Manufacturer Buy More Efficiently The client is a nationwide automotive part manufacturer based in Litchfield, IL. The client has over 20 warehouses, which housed all of [...]

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Case Study - Material Handling Systems

Lifting Performance and Safety with Overhead Cranes

Moving heavy objects has never been as safe and efficient as it is today thanks to the engineering excellence of Material Handling Systems (MHS). MHS of Florida has been designing, manufacturing, and installing overhead cranes for more than 45 years, and their goal has been to bring their customers the industry’s most advanced capabilities at the best price point.

Finding an affordable way to stop the sway

When a heavy load is moving horizontally, it eventually has to stop. So imagine a sudden stop with a bucket of red-hot molten steel. Although the crane may stop, the bucket’s momentum will cause it to sway back and forth like a pendulum.

Not good. Not safe. Not efficient.

While waiting for the pendulum to come to a stop, productivity comes to a stop as well. And having a worker try to manually stop the pendulum is a serious accident waiting to happen.

MHS customers were looking for an affordable anti-sway solution, but cost had frequently been a major barrier. The only anti-sway technology available was a terrifically expensive system that employed laser sensors. These systems required special expertise and took too much time to install. But for several years it was the only game in town.

That changed when MHS spoke with their VFD supplier, HPE Automation, a Diamond Elite Partner of Mitsubishi Electric Automation. HPE consulted with Mitsubishi Electric and they were able to offer MHS an affordable technology to stop the sway at 10% of the cost of a laser system.

Go faster. Stop faster. Sway less.

The answer was the Mitsubishi Electric FR-E800 series VFD. This highly affordable variable frequency drive offers built-in anti-sway technology, as well as vibration suppression control, fast torque build-up, and load-based speed control.

With the FR-E800, the operator can press and hold a button, which continues to ramp up the variable speed until the operator indicates otherwise. This two-step infinite speed device gives the operator more control over speed.

Thanks to this new capability, the swinging of an object is suppressed at the time of stopping, even without the operator's input or adjustment. The control cuts down the takt time and facilitates efficient operation because there's no need to wait for the load to settle. And no temptation for a worker to try and stop a sway as they may have in the past. It all adds up to a major lift in productivity—as much as a 5% improvement in a busy operation.

Superior service and support make all the difference

Before standardizing on Mitsubishi Electric, MHS had been using VFDs from another vendor. Initially, the supplier was responsive to service requests. But when product problems began to mount, the support seemed to evaporate.

According to MHS president and CEO, Ron Fontes, "We would call them and wouldn't hear back for a week. And when we did reach them and told them the product was failing, the supplier said, 'The product is fine. You must be doing something wrong.' They didn't even come and check it out.";

New capabilities, new applications, new opportunities

Henry Manson, MHS Vice President of Sales and Growth added, "When we turned to HPE Automation and Mitsubishi Electric Automation, we went from no support to an army of experts. It was a total game changer. They not only backed the products, which were superior – they worked with us to develop and install the anti-sway technology."

In short, the new team of suppliers designed a better system, added new features, and, as a result, enabled MHS to broaden their product offering.

A strong team means a strong future

MHS is now set to have a banner year, thanks to their new capabilities. And they can go forward with full confidence that they'll have the best in service, support, and innovations from Mitsubishi Electric and HPE.

Challenges of Material Handling System Design in the Context of Industry 4.0

• Conference paper
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• Zakarya Soufi 5 ,
• Pierre David 5 &
• Zakaria Yahouni 5  

Part of the book series: Studies in Computational Intelligence ((SCI,volume 1083))

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• International Workshop on Service Orientation in Holonic and Multi-Agent Manufacturing

1 Citations

Mastering Material Handling Systems is a crucial issue for numerous companies since the costs of material handling activities are far from being negligible. The demand for a sustainable industry and the introduction of Industry 4.0 technologies for material handling are renewing the Material Handling System design concerns. Many questions arise on whether it is suitable or not to bring technologies such as Autonomous Mobile Robots or Real-Time Location Systems to the shop floors. In the presented study, various companies are questioned on their utilization of new technologies and on their processes to manage and modify their Material Handling System. It appears that practices in Material Handling System design and management are diversified and that no consensus exists on how to efficiently design these systems. A cross-analysis is performed to identify the differences and the common patterns between the literature and the field study. This work discusses the need to better understand the relation between the different aspects of Material Handling System design and presents key challenges to be addressed in the context of Industry 4.0. To address these challenges, research directions are proposed. They are composed of four main challenges area: Material Handling specifications, Material Handling Equipment selection, Material Handling Equipment deployment, and Material Handling System analysis.

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Acknowledgments

The authors thank the French National Research Agency (ANR) that funded this research under the LADTOP project (grant ANR-19-CE10-0010-01). The authors would also like to thank the industrial companies for their participation in the field studies.

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Zakarya Soufi, Pierre David & Zakaria Yahouni

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Soufi, Z., David, P., Yahouni, Z. (2023). Challenges of Material Handling System Design in the Context of Industry 4.0. In: Borangiu, T., Trentesaux, D., Leitão, P. (eds) Service Oriented, Holonic and Multi-Agent Manufacturing Systems for Industry of the Future. SOHOMA 2022. Studies in Computational Intelligence, vol 1083. Springer, Cham. https://doi.org/10.1007/978-3-031-24291-5_23

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