物料搬运系统设计要点

Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,Click to edit Master title style,*,西南科技大学制造科学与工程学院工业工程教研室 石宇强,设施规划与物流分析,Slide Title,Body Text,Second Level,Third Level,*,西南科技大学制造学院,IE,教研室石宇强,设施规划与物流分析,单击此处编辑母版标题样式,单击此处编辑母版文本样式,*,*,-,*,-,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,*,第,9,讲 目 录,搬运与仓储设备简述,(,教材第,8,章,),CH5,物料搬运系统设计,5.1 物料搬运系统的基本概念,5.2 搬运系统分析方法（SHA）,5.3 搬运系统分析与设计,5.4 系统布置与搬运系统分析的结合,（SLP+SHA),搬运与仓储设备简述,(1),容器和单元化设备,(containers and unitizing equipment),(2),物料搬运设备,(transportation equipment),传送带和输送机械,(conveyors),起重机械,(Cranes),工业用车辆,(Industrial Truck),(3),存取设备,(storage and retrieval equipment),(4),自动辨识及通信设备,(automatic identification and communication equipment),(1),容器和单元化设备,(containers and unitizing equipment),（,P159P163,）,容器,:,托盘（,pallet),搬运箱等。,负载单元化设备：,滑板式托盘、缩紧打包和撑拉打包、堆集和集装箱,(2),物料搬运设备,(transportation equipment),传送带和输送机械（,P192P198,）,起重机械（,P198P205,）,工业用车辆：人力小车,(,托板车、,叉车,(P214P218),单轨列车、吊车和起重机,自动导引小车,(AGV),（,P218P225,）,6,7,8,9,10,11,12,13,14,(3),存取设备,(storage and retrieval equipment),即：存储和拣货设备（,P205,）,普通储存和拣货设备,货架、支架等,自动化储存和拣货系统（,AS/RS),16,17,(4),自动辨识及通信设备,(automatic identification and communication equipment),P229,CH5,物料搬运,物料搬运的重要性（从数据中看问题）,中等批量的生产车间里，零件在机床上的时间仅占生产时间的,5%,，而,95%,的时间消耗在原材料、工具、零件的搬运、等待上。,据统计，搬运费用占总生产费用的,30%40%,。,5.1,物料搬运系统的基本概念,一、物料搬运的,定义,二、物料搬运系统的,目的,三、物料搬运的,活性理论,四、物料搬运系统的,原则,五、物料搬运系统的,考虑因素,六、物料搬运的,单元化和标准化,一、物料搬运系统的定义,物料搬运,一般是指物料搬运作业，即利用机械或人力来执行一项移动物料的动作。,物料搬运系统,则更深入地探讨物料流动与设施布局之间的关系，将,物料的移动流程和设施的布局设计,相互配合，以期支持设施的生产或服务系统作业。,21,一、物料搬运系统的定义,1,、物料搬运的定义,物料搬运,是指在同一场所范围内进行的、以改变物料的,存放（支承）状态,（装卸）和,空间位置,（搬运）为主要目的的活动。即：对物料、产品、零部件或其他物品进行装上、卸下、移动的活动。,22,一、物料搬运系统的定义,2,、物料搬运系统,物料搬运系统,是移动、储存、保护及控制物料的艺术与科学的结合。,（,1,）,物料,：,散装到单位装载的固体、液体、气体等形式。,（,2,）,移动,（,3,）,储存,(4),保护,（,5,）,控制,（,6,）,艺术,（,7,）,科学,23,一、物料搬运系统的定义,3,、物料搬运系统的意义,物料搬运系统,的意义为在适当的成本下，采用正确的方法、顺序、方向、时机在正确的位置提供正确数量、正确条件的正确物料。,正确,成本、方法、顺序、方向、时机、位置、数量、条件、物料,。（,9,个）,24,二、物料搬运系统的目的,主要从成本和质量两方面考虑：,成本,：物料搬运作业约占用,1/4,的总人力，,/2,的总空间，,3/4,的总生产工时，以及,1/65/6,之间的产品制造总成本。,质量,：物料搬运所造成的毁损约占物料搬运量的,3%5%,25,二、物料搬运系统的目的,MHS,设计的主要目的：,(1),通过有效率的搬运方式以降低物料搬运成本，也就是降低生产成本。,(2),增加物流的效率，确保适时适地使用物料。,(3),改善工场安全和工作状况。,(4),改善设施使用效率。,(5),改善制造程序,(6),增加生产能力。,26,三、物料搬运的活性理论,搬运活性,指物料的存放状态对搬运作业的难易程度,物料的存放状态,散放、装箱、支垫和装车,搬运作业,集中、搬起、升起、运走,搬运活性指数,指搬运某种状态下的物料所需要进行的四项作业中已经不需要进行的作业数目。,27,28,思考：在运动中的物料,活性指数是多少,29,可以利用活性理论改善搬运作业,30,四、,物料搬运系统的原则,1,.,系统整合方面,(1),指导原则；,(2),计划原则；,(3),系统原则；,(4),流程原则；,2.,搬运作业与设备方面,(1),单元载荷,;(2),空间利用；,(3),标准化；,(4),人因化；,(5),机械化；,(6),弹性化；,(7),简单化；,(8),电脑化；,(9),能源；,(10),生态；,(11),重力；,(12),安全；,(13),布局；,(14),成本；,(15),维护；,(16),汰旧。,31,32,33,Top 10 Principles of Material Handling,Principle 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 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 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 should be minimized without sacrificing productivity or the level of service required of the operation.,34,Top 10 Principles of Material Handling(cont.),Principle 4.Ergonomic Principle,Human capabilities and limitations must be recognized and respected in the design of material handling tasks and equipment 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 Principle,Unit loads shall be appropriately sized and configured in a way which achieves the material flow and inventory 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 Principle,Effective and efficient use must be made of all available space.Space in material handling is three dimensional and therefore is counted as cubic space.,35,Top 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,inspection,storage,production,assembly,packaging,unitizing,order selection,shipping,transportation and the handling of returns.,Principle 8.Automation Principle,Material handling operations should be mechanized and/or automated where feasible to improve operational efficiency,increase responsiveness,improve consistency and predictability,decrease operating