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Daifuku America
Material Handling Information - Materials Travel Long Distances
Productivity
Materials Travel Long Distances
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Non-value-added touch is 70% of total Product crosses paths 4 times Total distance traveled ~ 3,000 ft
Non-value-added touches reduced to 64% Product crosses paths 2 times Total distance traveled reduced to ~2,400 ft.
Problem
Actual cycle time is much longer than theoretical cycle time.
Duplicate material stored throughout facility.
Excess damage to materials caused by multiple handling.
High congestion of fork truck traffic.
Operations are disjointed; product is heavily queued between each process.
Solution
Think straight-line flow.
Rearrange the operations to achieve straight line flow.
Connect operations with material transporters such as
conveyors
,
overhead monorails
,
Automatic Guided Vehicles (AGV)
, or
Sorting Transfer Vehicles (STV)
.
Centralize the operations
Locate the materials where they are needed, using
mini load
,
unit load
,
high-speed box buffers
, or
carousels
.
Think Just-in-Time:
Focus on the overall cycle time, not just individual operations.
Balance the operations so product flows from one operation to the next using Just-in-Time techniques.
Consider using outside expertise to refine ideas. See
10 Steps to Get Started
.
Case Study Applications
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