ISSN 2320 – 6020
IJBSTR RESEARCH PAPER VOL 1 [ISSUE 8] AUGUST 2013
An Analysis of Fork Lift Vehicle Based Automated Guided for Material Handling System VivekKumar1, R.N Mall2 and Rajneesh Kumar Singh3 ABSTRACT: One of the essential workings of the manufacturing system is its Material Handling Systems. I would like to first learn the diverse types of material handling systems that are at present in utilize. Then, we shall pick a common type of Material Handling system, a forklift truck, and look thesameinformation of how to go in relation todesign a forklift system for a factory. Numerical equation will developedto the process of vehicle-based material handling system. Equipment used in such includes industrial truck, automated. Key words: Forklift, Material Handling System, Electronic Sensor, Advanced Processor, Navigation System.
INTRODUCTION From the center nineteenth century to the near the beginning twentieth century proverb the developments that new forklifts. The Pennsylvania Railroad in 1906 introduces battery motorized platform trucks for moving bags to the Altoona Pennsylvania train station. World War I saw the expansion of diverse type of material handling equipment in the USA by Ransoms, Sims and Jeffries. IT was in fraction outstanding for labor shortage caused by the war. In 1917 Clark in the USA start just beginning and use of power tractor and power lift tractors in his industries. This report based on how the manual forklift is automatically become well on its self-using some electronics application, I have given some industrial technical data for my solving above formula. In the last several years material handling has become a new, complex, and rapidly evolving science. For moving material in and out of warehouse many types of equipment and system are in use, its depend of the kind of goods, amount to be handle. The equipment is used, in loading and unloading operations, for movement of goods over short distances. In warehouses, material handling system is done at the subsequent stage:
Receiving the inward material from transport vehicle. Moving the unloaded material to assigned storage place in warehouses. Copying the textile from its luggage compartment place during alternative. Author1: Vivek Kumar is currently pursuing master of technology program in Mechanical engineeringin MMMEC, Gorakhpur, India E-mail: vivekrkt@gmail.com Co-Autho3r: Rajneesh Kumar Singh Co-Author2: R. N. Mall is currently Assistance Professor in MMMEC, Gorakhpur, India.
Move from raw material to inspection and packing. Load parcels, boxes and cartons from the convey vehicle.
Fig.1 Toyota's first lift truck Material handling system strategy: - The material handling function reflects on the efficiency and speed of warehouse operation, which eventually outcome in stretched out of dense order conclusion period. For designing an effective and efficient material system, the guidelines normally followed are: Designing the system for continues flow of material, i.e. idle time should be zero. Going in for standard equipment, in which ensures low asset and elasticity in the use in material handling needs in the future. Incorporating gravity flow in material flow system Ensuring that the ratio of the dead weight to the payload of material handling equipment is minimum.
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IJBSTR RESEARCH PAPER VOL 1 [ISSUE 8] AUGUST 2013 A mixture of material handling systems is in the use, exact from that entirely physical to the ones that are fully automatic. It is the giving use as per in factors such as:  volume to be handling  high Speed in behavior  efficiency  Product kind such as, shape ,size and weight  character of the item for consumption ( perishable, crushable, hazardous) Guided vehicles monorail and other guided vehicles, certain types of conveyor System and certain type of crane operation .we assume that the vehicle operation at stable velocity during the operation and pay no attention to special effects of acceleration, deceleration and additional speed differences that depend on the vehicle loaded or empty or other manner
RESULT AND ANALYSIS DATA COLLECTION OF STATION: (1 TO 2) Table: 1 Data Collection of Station
A very typical delivery system in the operation of a vehicle based transport system consistsof:(1) (2) (3) (4)
loading at the pickup station travel time to the drop-off station unloading at the drop-off station , Vacant moving time of the vehicle to the deliveries.
The load cycle time per delivery per vehicle is given by
đ?‘ťđ?’„ = đ?‘ťđ?’? +
đ?‘łđ?’… đ?‘łđ?’† + đ?‘ťđ?’— + đ?’— đ?’—
. Where, Tc =delivery cycle time (min/del), Tl= time to load at load station (min.),LD= distance the velocity travel between load and unload station, v=carrier velocity (m/min),TV= time up to unload at unload station (min), Le =distance the vehicle travel empty until the start of the next delivery cycle (m). The delivery cycle time will used to find out all the parameter of attention in the vehicle-based transport system Material handling: designed for safe transportation Due to globalization of the economies of many countries, companies all over the world are making efforts to further expand their business areas. So the need for container transportation is being increased, and container terminals should satisfy such needs. For example, container terminals should provide better services to meet needs, should handle materials more speedily, and should reduce the cost. Since there are the same needs in other countries as well, the 365day 24-hour operable container terminals should be constructed. To meet the above-described needs, companies should establish.
Fig. 2: comparison between billet and delivery cycle time Table .2: Data collection of station (2 to 3)
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IJBSTR RESEARCH PAPER VOL 1 [ISSUE 8] AUGUST 2013
COST SAVING TABLE WHEN ADVANCE AUTOMATIC AGV USEG Table 4: Comparable Cost of Forklift and Driver Cost In 3 Shifts:-
Fig.3: Comparison between billet and delivery cycle time Table: 3 Data collection of station (3 to 4)
CAUSE—
25 % Employee reduced
55 % Factory space
87 % Reduce production time to material handling. Table 5: Utilization of AVG Forklift
Fig.4: comparison of delivery cycle time and finished product
fig.5: Utilization of AGV forklift vehicle
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IJBSTR RESEARCH PAPER VOL 1 [ISSUE 8] AUGUST 2013 CASE STUDY OF ―NDC AUTOMATION‖ AGV forklift leasing costs in “NDC Automation”
1. 2. 3. 4.
1.
1 vehicle pallet forklift kind AGV arrangement with tothe 20 loads and unload positions and a travel distance to 100 meters. Monthly cost for 5 years, with no residual: A$ 5,400/month
2.
3 vehicle pallet-forklift type AGV System with up to 50 load and unload positions and a moving distance to 200 meters. Monthly cost for 5 years, with no residualA$ 12,100/month
3.
5 vehicle pallet-forkliftstypes AGV System with up to 100 load and unload positions and a travel distance to 300 meters. Monthly cost for 5 years, through no residual A$ 19,200/month
4.
10 vehicle pallet-forklift type AGV system with up to 1000 load and unload positions and a travel distance of up to 500 meters and a small Warehouse Management Solution. Monthly cost for 5 years, with no residual: A$ 36,500/month.
Fig.6: Comparison of Load and Man Cost/Month Table 7: Forklift in NDC Automation
MAN forklift leasing costs in ―NDC Automation‖ comparable cost for 1 forklift and 3 drivers in a 3 shift operation~A$20,000/month comparable cost for 3 forklifts and 9 drivers in a 3 shift operation~A$60,000/month comparable cost for 5 forklifts and 15 drivers in a 3 shift operation~A$100,000/month comparable cost for 10 forklifts and 30 drivers in a 3 shift operation~A$200,000/month
Table 6: Table of AVG Vehicle in NDC Automation
Fig.7-Graph of comparison of AGVs cost/month and load
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IJBSTR RESEARCH PAPER VOL 1 [ISSUE 8] AUGUST 2013
suffer from injured products, sluggish pick rates, a lack of liberty, uselessness, or bottlenecks, don’t think throwing more people at it will solve the problem which short term help at best, and you’ll be stuck with ongoing costs which you cannot eliminate. REFERENCES 1.
2. Fig.8-Graph of comparison between AGV and MAN cost with load-
3. 4.
However the costs for the AGV drop dramatically in the following years, averaging only $4000 to $6000 per year.
5. 6. 7.
8. 9. 10.
CONCLUSIONS AND FUTURE SCOPE AGV is interfaced with PC and the input is given through PC. The process is made wireless using R.F. modems, which is used to send and receive signals. AGV’s is found to reduce the damage of inventory, it is make production scheduling extra flexible, and diminish staffing needs. But, as with any other mainresourceschoice, implementation of this systems be obliged to be undertaken guardedly.
11. 12. 13.
Abhishek Dwivedi , An Analysis and Development of Software for Assembly Line Balancing Problem of Manufacturing Industry, VSRD-MAP, Vol. 2 (2), 2012, 74-87 Automation production systems, and computer integrated manufacturing by MikellP.Groover “The Basics of Automated Guided Vehicles”. AGV Systems. Savant. 5 March 2006 "Guidance options for AGVs" Jervis B. Webb Company, 2007. Specifications for Platforms AGV Drive and Steering Options Transbotics Corp., 2009 Olmi, Roberto (2011). Traffic Management of the Automated Guided Vehicles in Flexible Manufacturing Systems by Ferrara (Italy) University of Ferrara. “Sonar sensor and mounting”. University of Birmingham. 5 March 2006 "Tow Type AGVs” Hi-Tech Robotic Systems Ltd. India, 2009. "Common AGV Applications: Raw Material Handling" JBT Corporation. 18 March 2009 "Work in Process Movement with AGVs" JBT Corporation. 18 March 2009 "Pallet Handling AGVs" JBT Corporation. 18 March 2009 "Automated Trailer Loading AGVs" JBT Corporation. 18 March 2009
Material handling systems power today’s well-organized distribution and manufacturing armed forces. It is use in the secret weapon in logistics operations for boost system productivity. Strikingcustomers examine and speed throughputs. When we ahead control of our warehouse, you gain control of our productivity. Efficient material handling systems create savings that helpfrankly to improve your bottom line. If your business relies heavily on themanufacturing, warehousing, storage or distribution, the potential savings are perhaps your supremeoccasion. If our
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