物料搬運系統(tǒng)創(chuàng)新設(shè)計要點

1、搬運與倉儲設(shè)備簡述(1)容器和單元化設(shè)備 (containers and unitizing equipment)(2)物料搬運設(shè)備(transportation equipment) 傳送帶和輸送機(jī)械(conveyors) 起重機(jī)械(Cranes) 工業(yè)用車輛(Industrial Truck)(3)存取設(shè)備(storage and retrieval equipment)(4)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(containers and unitizing equipme

2、nt) P159P163容器: 托盤pallet) 搬運箱等。負(fù)載單元化設(shè)備： 滑板式托盤、縮緊打包和撐拉打包、堆集和集裝箱 (2)物料搬運設(shè)備(transportation equipment)傳送帶和輸送機(jī)械P192P198起重機(jī)械P198P205工業(yè)用車輛：人力小車(托板車、 叉車 (P214P218)單軌列車、吊車和起重機(jī)自動導(dǎo)引小車(AGV) P218P225 5 6 7 8 9 10 11 12 13(3)存取設(shè)備(storage and retrieval equipment)即：存儲和揀貨設(shè)備P205普通儲存和揀貨設(shè)備 貨架、支架等自動化儲存和揀貨系統(tǒng)AS/RS) 15 16(

3、4)自動辨識及通信設(shè)備(automatic identification and communication equipment)P229CH5 物料搬運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(jī)床上的時間僅占生產(chǎn)時間的5%，而95%的時間消耗在原材料、工具、零件的搬運、等待上。 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)的根本概念一、物料搬運的定義二、物料搬運系統(tǒng)的目的三、物料搬運的活性理論四、物料搬運系統(tǒng)的原那么五、物料搬運系統(tǒng)的考慮因素六、物料搬運的單元化和標(biāo)準(zhǔn)化一、物料搬運系統(tǒng)的定義物料搬運一般是指物料搬運作業(yè)，即利用機(jī)械或人力來執(zhí)行一項移動物

4、料的動作。物料搬運系統(tǒng)那么更深入地探討物料流動與設(shè)施布局之間的關(guān)系，將物料的移動流程和設(shè)施的布局設(shè)計相互配合，以期支持設(shè)施的生產(chǎn)或效勞系統(tǒng)作業(yè)。20一、物料搬運系統(tǒng)的定義1、物料搬運的定義 物料搬運是指在同一場所范圍內(nèi)進(jìn)行的、以改變物料的存放支承狀態(tài)裝卸和空間位置搬運為主要目的的活動。即：對物料、產(chǎn)品、零部件或其他物品進(jìn)行裝上、卸下、移動的活動。21一、物料搬運系統(tǒng)的定義2、物料搬運系統(tǒng) 物料搬運系統(tǒng)是移動、儲存、保護(hù)及控制物料的藝術(shù)與科學(xué)的結(jié)合。1物料：散裝到單位裝載的固體、液體、氣體等形式。2移動3儲存 (4) 保護(hù)5控制6藝術(shù)7科學(xué)22一、物料搬運系統(tǒng)的定義3、物料搬運系統(tǒng)的意義 物料搬

5、運系統(tǒng)的意義為在適當(dāng)?shù)谋惧X下，采用正確的方法、順序、方向、時機(jī)在正確的位置提供正確數(shù)量、正確條件的正確物料。 正確本錢、方法、順序、方向、時機(jī)、位置、數(shù)量、條件、物料。9個23二、物料搬運系統(tǒng)的目的主要從本錢和質(zhì)量兩方面考慮：本錢：物料搬運作業(yè)約占用1/4的總?cè)肆Γ?2的總空間，3/4的總生產(chǎn)工時，以及1/65/6之間的產(chǎn)品制造總本錢。質(zhì)量：物料搬運所造成的毀損約占物料搬運量的3%5%24二、物料搬運系統(tǒng)的目的MHS設(shè)計的主要目的：(1)通過有效率的搬運方式以降低物料搬運本錢，也就是降低生產(chǎn)本錢。 (2)增加物流的效率，確保適時適地使用物料。(3)改善工場平安和工作狀況。(4)改善設(shè)施使用效率

6、。(5)改善制造程序(6)增加生產(chǎn)能力。25三、物料搬運的活性理論 搬運活性指物料的存放狀態(tài)對搬運作業(yè)的難易程度 物料的存放狀態(tài)散放、裝箱、支墊和裝車 搬運作業(yè)集中、搬起、升起、運走 搬運活性指數(shù)指搬運某種狀態(tài)下的物料所需要進(jìn)行的四項作業(yè)中已經(jīng)不需要進(jìn)行的作業(yè)數(shù)目。26 27思考：在運動中的物料活性指數(shù)是多少28可以利用活性理論改善搬運作業(yè)29四、物料搬運系統(tǒng)的原那么1.系統(tǒng)整合方面 (1)指導(dǎo)原那么；(2)方案原那么； (3)系統(tǒng)原那么； (4)流程原那么；2.搬運作業(yè)與設(shè)備方面(1)單元載荷;(2)空間利用；(3)標(biāo)準(zhǔn)化；(4)人因化； (5)機(jī)械化；(6)彈性化；(7)簡單化； (8)電

7、腦化； (9)能源；(10)生態(tài)； (11)重力； (12)平安； (13)布局；(14)本錢；(15)維護(hù)；(16)汰舊。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