Material Handling Equipment 1 Outline failures of material

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Material Handling Equipment 1

Material Handling Equipment 1

Outline ö failures of material handling systems 2008, Heathrow Terminal 5 ö 1998, New

Outline ö failures of material handling systems 2008, Heathrow Terminal 5 ö 1998, New Hong Kong International Airport ö 1995, Denver Airport ö ö ö types of material handling equipment useful web sites for MHS an example of MHS steps to install an MHS 2

Words of Caution on MHS ö material handling systems ö efficient “software” systems ö

Words of Caution on MHS ö material handling systems ö efficient “software” systems ö efficient ö good and streamlined procedure coordinated ö understanding of one’s needs ö big trouble during malfunction of MHS 3

Terminal 5, Heathrow Airport, 2008 4

Terminal 5, Heathrow Airport, 2008 4

Heathrow Airport ö material handling equipment: demand dependent ö busiest airport in UK: Heathrow

Heathrow Airport ö material handling equipment: demand dependent ö busiest airport in UK: Heathrow Airport ö passengers ö 2008 passengers: 3 rd in the world 67 million ö ö aircraft movement ö 2008 aircraft movement: 13 th in the world, 478, 518 ö ö 1 st Hartfield-Jackson, Altlanta, 90 mill Hartfield-Jackson, Altlanta, 978, 8424 cargo ö 2008 cargo: 16 th, 1. 48 mill metric tonnes ö 1 st Memphis, 3. 7 mill metric tonnes 5

Heathrow Terminal 5 ö a new terminal to suit the needs for expansion (March

Heathrow Terminal 5 ö a new terminal to suit the needs for expansion (March 2007) ö ö nice design if something went wrong, what would it be? 6

Heathrow Terminal 5 ö opening on March 27 (Th), 2008 ö chaos in the

Heathrow Terminal 5 ö opening on March 27 (Th), 2008 ö chaos in the baggage system ö > 100 flights cancelled on Th and Fri, another 54 flights on Sat ö suspension of luggage check-in 7

Heathrow Terminal 5 ö what were reasons (0: 46 – 3: 16)? 8

Heathrow Terminal 5 ö what were reasons (0: 46 – 3: 16)? 8

Heathrow Terminal 5 ö backlog of baggage in apron for insufficient baggage team members

Heathrow Terminal 5 ö backlog of baggage in apron for insufficient baggage team members ö propagation of baggage backlog first to the conveyor system and then to the check-in counters ö reasons ö ö insufficient car parking provision ö delays in staff security screening ö staff unfamiliar with the area ö inadequate staff signage inadequate personnel training 9

Hong Kong International Airport July 1, 1998 10

Hong Kong International Airport July 1, 1998 10

Kai Tak Airport ö construction (9: 00 -13: 00) ö over night move in

Kai Tak Airport ö construction (9: 00 -13: 00) ö over night move in 7 hours from Kai Tak Airport in the city center to the current location on July 6, 1998 (2: 55 - 3: 50) ö problems (37: 00 – 39: 00) 11

1998 New Hong Kong International Airport (6: 10 7: 40 & 8: 20 8:

1998 New Hong Kong International Airport (6: 10 7: 40 & 8: 20 8: 44) ö reasons 12

1998 New Hong Kong International Airport (6: 10 7: 40 & 8: 20 8:

1998 New Hong Kong International Airport (6: 10 7: 40 & 8: 20 8: 44) ö airport opened on July 6, 1998 ö first flight 6: 30 am ö after 8 am: hard to find baggage for some passengers ö information gradually broken down ö baggage reclaim display either blank or incorrect ö incorrect, inconsistent, or no flight information in both landside and the airside ö many gates changes, leaving passengers and even airline staff in blank 13

1998 New Hong Kong International Airport (6: 10 7: 40 & 8: 20 8:

1998 New Hong Kong International Airport (6: 10 7: 40 & 8: 20 8: 44) ö airport passengers ö ö ö ö public telephones not working mobile phone networks overloaded air-conditioning not functioning properly long queue for toilets, which not working properly some failure of escalators insufficient and unsatisfactory signage overcrowded restaurants and refreshment facilities garbage bins spilled over 14

1998 New Hong Kong International Airport (6: 10 7: 40 & 8: 20 8:

1998 New Hong Kong International Airport (6: 10 7: 40 & 8: 20 8: 44) ö ramp handlers ö unknown aircraft locations for serving ö unknown stand allocation to aircraft ö improper interface between ramp handler and HACTL ö insufficient number of dollies ö large number of pallets and containers piling up ö hard for air cargo terminal personnel to identify, locate and remove 15

1998 New Hong Kong International Airport (6: 10 7: 40 & 8: 20 8:

1998 New Hong Kong International Airport (6: 10 7: 40 & 8: 20 8: 44) ö aircraft ö ö arriving aircraft delayed in gate assignment or parked remotely waiting for long time to unload passengers apron crowded of aircraft baggage ö ö arriving passengers waiting two to three hours for baggage, some leaving without bags without owners 16

1998 New Hong Kong International Airport (6: 10 7: 40 & 8: 20 8:

1998 New Hong Kong International Airport (6: 10 7: 40 & 8: 20 8: 44) ö Super. Terminal I ö slow and inefficient throughout 6 July 1998 ö huge building up of cargo on north airside ö 7 July 1998, early morning, disappearing of cargo inventory record in computer ö cargo processing back to Kai Tak ö 8 July 1998: an embargo on most imported cargo except for a very small number of items ö extension of embargo to 9 July and then to 18 July but full recovery until 23 August 1998 in four phases 17

Baggage System of Denver Airport 18

Baggage System of Denver Airport 18

Denver Airport ö 2005 passengers: 11 th in the world, 43 million ö 2005

Denver Airport ö 2005 passengers: 11 th in the world, 43 million ö 2005 aircraft movement: 7 th in the world, 560, 669 ö 2005 cargo: beyond top 30 th of the world, and beyond top 10 in US 19

Denver Airport ö money saving in early 1990's by airlines through automation ö an

Denver Airport ö money saving in early 1990's by airlines through automation ö an automatic baggage system in Denver Airport ö a 26 -mile conveyor system with thousands of carts ö real-time computer controlled ö fewer flight delays, less waiting at luggage carousels and big savings in airline labor costs 20

Denver Airport ö ö ö costs ö $186 million for construction ö $1 million

Denver Airport ö ö ö costs ö $186 million for construction ö $1 million penalty per day in 1994 when failures in baggage handling delayed airport opening (opened in 1995) adopted only by United Airline & for outgoing baggage ö $1 million per month for maintenance ö $60 million a year until 2025 completely closed down in 2005 21

Types of Material Handling Equipment 22

Types of Material Handling Equipment 22

Types of Material Handling Equipment ö transportation ö ö ö ö conveyors cranes industrial

Types of Material Handling Equipment ö transportation ö ö ö ö conveyors cranes industrial trucks positioning unit load formation storage identification and control 23

Useful Web Sites for MHS 24

Useful Web Sites for MHS 24

Useful Web Sites on Material Handling Equipment ö Material Handling Equipment Taxonomy, By Dr.

Useful Web Sites on Material Handling Equipment ö Material Handling Equipment Taxonomy, By Dr. Michael G. Kay, North Carolina State University ö Material Handling Industry of America (MHIA) ö association of providers of material handling & logistics solutions ö http: //www. mhi. org/mediabank/general. asp ö ö ö case studies, videos, … Daifuku America Corporation ö material handling equipment provider ö case studies, videos, photos, material handling glossary Warehouse Education and Research Council 25

An Example of MHS 26

An Example of MHS 26

A Distribution Center of Itochu Food Products ö ITOCHU Corporation (伊藤忠商事株式会 社) ö leading

A Distribution Center of Itochu Food Products ö ITOCHU Corporation (伊藤忠商事株式会 社) ö leading Japanese sogo shosha, more than 150 offices in about 80 countries ö food: one of the seven major types of business 27

A Distribution Center of Itochu Food Products ö a food distribution center in Sagamihara

A Distribution Center of Itochu Food Products ö a food distribution center in Sagamihara ö area: close to 200 K ft 2 ö products: 4, 500 types; small (condiments, canned goods, candies, and liquor) ö throughput: 22, 000 cases daily ö role: distribution hub for 50 supermarkets nearby 28

A Distribution Center of Itochu Food Products consolidated goods to supermarkets ö possible improvements

A Distribution Center of Itochu Food Products consolidated goods to supermarkets ö possible improvements ö ö distribution center ö improve pick accuracy ö reduce sorting, picking, and processing time ö pack goods shop by shop; deliver all at once ö supermarkets: reduce sorting time 29

A Distribution Center of Itochu Food Products ö solution: a MHE system ö ö

A Distribution Center of Itochu Food Products ö solution: a MHE system ö ö combination of conveyors, flow racks, storage racks, picking carts, and sorters storage: unit load buffer storage (1, 782 slots); flow rack (600 slots); pallet rack (224 slots); heavy duty rack (379 slots); portable pallet rack (204 slots) picking: 30 pick carts sorting: sliding shoe sorter with 26 chutes, 6 K pieces per hour 30

A Distribution Center of Itochu Food Products ö benefits ö pick accuracy: 99. 997%

A Distribution Center of Itochu Food Products ö benefits ö pick accuracy: 99. 997% ö processing time in stores: by 30%-40% ö total inventory and distribution cost: ö service level of stores: ö service level of supermarkets: 31

Steps to Install MHS 32

Steps to Install MHS 32

Selection and Installation of MHE ö 10 Steps to Install MHE ö Walkthrough of

Selection and Installation of MHE ö 10 Steps to Install MHE ö Walkthrough of your present system ö Logistics study ö Site visits ö Preliminary system design ö Executive summary and cost justification 33 ö System design and simulation ö Hardware and software purchase ö Management team assignments ö System installation and implementation ö Service and periodic system audits

Selection and Installation of MHE ö Framework to select MHE ö many web pages

Selection and Installation of MHE ö Framework to select MHE ö many web pages …. 34

Comments on Assignment #1 35

Comments on Assignment #1 35

Some Observations ö silly mistakes, e. g. , öa nameless answer script ö a

Some Observations ö silly mistakes, e. g. , öa nameless answer script ö a table cut into two pieces on two pages ö more important mistakes ö ö not answering the question grammatical errors 36

The Question ö “In this assignment, you first browse the web for statistics related

The Question ö “In this assignment, you first browse the web for statistics related to container terminals. Then put down your assertions (observations, points, claims, conjectures, etc. ) in about 300 words. Use the statistics collected to substantiate your assertions. ” 37

The Question ö the question asks for ö (1) statistics related to container terminals

The Question ö the question asks for ö (1) statistics related to container terminals ö (2) your assertions ( ) from statistics ö (3) justifications of assertions by statistics observations, points, claims, conjectures, etc. ö more than simpler supplying statistics 38

Some Observations ö the most important mistakes: directly copying sentences from web ö plagiarism,

Some Observations ö the most important mistakes: directly copying sentences from web ö plagiarism, one of the biggest mistakes in school ö loss of opportunity of self improvement ö at the end of the day, your abilities and skills that matter, not your degree 39

To Avoid Plagiarism drop down statistics but not phrases, certainly not sentences ö summarize

To Avoid Plagiarism drop down statistics but not phrases, certainly not sentences ö summarize ideas and points in your own words ö reorganize material in the way suitable for the purpose, not the structure of your source ö 40

My Grading Principle ö looking for ideas, organization, presentation, grammar Self-Expressing Strong ideas and

My Grading Principle ö looking for ideas, organization, presentation, grammar Self-Expressing Strong ideas and organization Strong Weak 41 Weak