MATERIAL HANDLING
Material handling is the safe movement, storage, control, and protection of
materials and products throughout manufacturing, distribution, and disposal.
ROUTING SYSTEM
Routing refers to the process of deciding the path or sequence of operations
through which a material, or product moves from origin to destination.
There are two types of routing systems
FIXED AND VARIABLE ROUTING SYSTEMS
➢ A fixed routing system is a material handling system in which routes are
pre-decided in advance and followed continuously over a long period of
time.
➢ Fixed routing is designed for high-volume and mass production set up
where the repetitive movement between machines.
➢ Once the route is designed, materials and materials move on the same path
regularly without frequent changes.
➢ This system is adopted where demand, destinations, and operating
conditions are stable and predictable.
CHARACTERISTICS
I. Routes are predetermined, standardized, and permanent in nature.
II. The system offers little or no flexibility in route selection.
III. Mainly used for regular, routine, and repetitive transportation movements.
IV. Planning is done once and implemented
Equipment used
o Conveyors: Belt, roller, screw, and chain conveyors are the most
common example, moving items along a set track.
o Monorail systems: Overhead tracks that move materials in a fixed
path.
o Towline conveyors: In-floor systems often used in warehouses
VARIABLE ROUTING SYSTEM
➢ A variable routing system is a material handling system in which routes are
not fixed and can change frequently depending on various factors.
➢ Variable routing allows different work units to move through different,
flexible workstation sequences. There are no restrictions in the direction of
movement
➢ Routes are decided dynamically based on demand, product, material and
cost considerations.
➢ This system is adopted in situations where customer requirements, delivery
points, or market conditions frequently change.
➢ Material handling equipment do not follow standard paths,
CHARACTERISTICS
I. Routes are flexible and can be altered whenever required.
II. Offers a high degree of adaptability to changing conditions.
III. Can handle varied materials.
IV. Used in job-shop production, where items are not produced in a set
sequence.
Equipment used
o Forklifts and Industrial Trucks: Highly powered vehicles.
o Automated Guided Vehicles (AGVs): Vehicles that follow a flexible or
self-guided path to transport materials.
o Mobile Cranes/Hoists: Can move materials anywhere within a restricted
area
AUTOMATED STORAGE AND RETRIEVAL SYSTEM (ASRS)
An Automated Storage and Retrieval System (ASRS) is a computer-controlled
technology used to automatically store and retrieve materials with high precision
and speed, minimizing human labour.
Types of ASRS Systems
1. Vertical Lift Module (VLM)
A VLM is a dynamic storage system that works like an elevator – using
two columns of trays and a central extractor to lift and retrieve trays
VLMs are ideal for high-density storage are often used for cars, parts, tools,
and inventory that vary in size.
2. Vertical Carousels
Vertical carousels rotate vertically, bringing stored items to the operator
with the push of a button. These systems are particularly effective for items
of consistent shape or category.
CAROUSEL STORAGE SYSTEM
A carousel storage system is an automated material handling system having bins
on a revolving conveyor that transport items to an operator
Types of Carousel Storage Systems:
• Vertical Carousel: Operates like a wheel, moving carriers vertically up
and down to utilize overhead space. It is ideal for facilities with high
ceilings looking to maximize space in a small footprint.
• Horizontal Carousel: Rotates bins on a circular track, ideal for lower-
ceiling areas and fast-moving inventory.
INSPECTION
Inspection is the systematic process of measuring, examining, and testing
products or materials at various production stages to ensure they meet specified
quality standards and requirements.
Inspection technologies includes advanced methods for monitoring, measuring,
and testing materials or structures without damaging them.
Inspection Methods:
o Visual Inspection: Checking for surface flaws, dents, or misalignments.
o Dimensional Measurement: Using calipers and gauges to verify
precision.
o Functional Testing: Verifying that products operate correctly (e.g.,
electrical tests).
o Non-Destructive Testing (NDT): Evaluating internal properties without
damaging the item
Contact Inspection Methods
These techniques involve direct physical interaction between the measuring
instrument and the part.
• Coordinate Measuring Machines (CMMs): Use probes to trace surfaces
for high-accuracy dimensional measurement.
• Articulating Arms: Flexible probes for checking complex features in 3D
space.
• Gage Tools: Pins, blocks, and micrometers used for manual, high-
accuracy validation of dimensions.
• Contracers/Roundness Testers: Dedicated devices for measuring
profiles and contours.
• Applications: Machined parts, gears, bearings, fixtures, and GD&T
reporting.
Non-Contact Inspection Methods
These techniques use sensors to gather data without touching the component,
• Vision Systems (2D/3D): Cameras analyze images for fast, automated
dimensioning and defect detection.
• Laser Scanners: Project laser light to capture surface profiles and create
3D point clouds.
• Structured Light Scanners: Project light patterns to map complex shapes
with high precision.
• Computed Tomography (CT) Scanners: Use X-rays to inspect internal
structures and voids.
• Optical Comparators: Project a silhouette of a part onto a screen for
visual measurement.
• Applications: Soft materials, high-volume production lines, complex
geometries, and reverse engineering.
• Contact methods typically offer higher accuracy and are less affected by
surface color or texture.
• Non-contact methods are generally faster and ideal for high-volume
inspection or real-time monitoring.
• Non-contact is crucial for fragile or soft materials to avoid surface damage or
distortion.
• Non-contact sensors often have higher initial, specialized equipment costs.
MACHINE VISION SYSTEM
▪ Machine vision (MV) is the technology and methods used to provide
imaging-based automatic inspection and analysis.
▪ Machine Vision offers a fast, reliable way of inspecting parts inline.
▪ It allows inspection on every part of the line moving over the high-speed
range. In addition, it guarantees full safety.
▪ It involves the use of cameras, sensors, and image processing algorithms
to evaluate and verify the quality, integrity, and correctness of products.
Machine vision inspection systems are widely employed to ensure consistency,
accuracy, and efficiency in various industries.
CMM (Coordinate Measuring Machine)
➢ A Coordinate Measuring Machine (CMM) is a precision instrument to
accurately measures the physical dimensions and geometric characteristics
of an object.
➢ It operates by detecting discrete points on the surface of a part using a probe
and then recording their exact positions in a three-dimensional coordinate
system.
➢ A CMM machine consists of various components such as a probe, granite base,
bridge structure, and measurement axes (X, Y, Z) for precision results in
multidimensional measurement.
➢ A CMM machine (Coordinate Measuring Machine) works based on the three-
dimensional coordinate system to accurately measure the physical and
geometric characteristics of an object.
➢ A Coordinate Measuring Machine operates by utilizing a probe to capture
precise points on an object’s surface. These measurements are then processed
by a computer, which calculates and records the object’s dimensions within a
3D Cartesian Coordinate System.