TSI9O MPS 14494 MATERIALS HANDLING HANDBOOK David E. Mulcahy Grand Rapids, Michigan McGRAW-HILL New York San Francisco’ Washington, D.C. Auckland Bogota Caracas Lisbon London Madrid Mexico City Milan Montreal New Delhi San Juan Singapore Sydney Tokyo TorontoCONTENTS General Library System University of Wisconsin - i 728 State Street 7 Madison Madison, WI 53706-1408 U.S.A, Preface xvii Chapter 1. What Is Product Movement and What Is Its Future? 1.1 Introduction J Definition of Materials Handling or Product Transportation Concept Terms = 1.2 Economic Value and How Your In-Facility Product Transportation Concept Serves Your Company 1.6 Your Company’s Product Transportation Concept Objectives 1.6 Logistics Resources 1.6 Product Transportation Concept Activities 1.7 Product Load Activity 1.7 Load-Carrier Dispatch Activity 1.7 Travel Activity 1.8 Divert onto Spur or Location 1.8 Unload Activity 1.8 Run Out 18 Control Device 1.9 Maintenance Spur or Shop 1.9 Product Transportation Concept Design Parameters 1.9 Important Product Transportation Issues and Trends 1.10 Increased Employee Training 1.10 Impact of the Computer 1.10 Automatic Identification = L. JIT and Across-the-Dock Operations = 1.1 MRP andDRP L.JJ Increased Computer Simulation for Product Transportation 1.12 Materials Handling Equipment Technology 42 Remodeling Existing Facilities 1.13 Leasing Materials Handling Equipment and Buildings 1.13 Overview 1.13 On-Schedule, Accurate Performance Means Lower Costs and Satisfied Customers 1.13 Chapter 2. Facility Layout and Product Flow Pattern Effects on Product Transportation Productivity and Materials Handling Costs 21 Introduction 2.7 Purpose of the Facility and Your Product Transportation Concept 2. Design Year Product Volume Level 2.2 How to Determine Your Facility Size 2.3 Square Foot Calculation 2.3 Cubic Foot Calculation 2.3 Various Facility Activities 2.6vi CONTENTS, Facility Layout Is a Complex Project 2.6 Facility Layout Objectives 2.6 Product Transportation Concept or Equipment Characteristics and Facility Layout — 2.7 Value-Added Activities 2.8 Length of Your Product Transportation Concept 28 Travel-Path Length 2.9 SpurLength 29 Return Travel-Path Length 2.9 Maintenance Travel Path = 2.9 Run-Out Travel-Path Distance 2.9 Width of Your Product Transportation Concept 2.9 Height of Your Product Transportation Concept 2.0 Product Transportation Load-Carrying Surface Elevation Above the Finished Floor 2.10 Various Travel-Path Support Methods 2.10 Number and Type of Tums for Your Product Transportation Concept 2.1] Elevation Changes in Your Product Transportation Concept 2.// Number and Travel Speed of Load-Carrying Surfaces for Your Product Transportation Concept 2.12 The Complex Task of Designing Facility Activity Locations and Product Transportation Travel-Paths in a New Facility 2.42 Product Transportation Layout Design in an Existing Facility—A More Complex Project 2.12 Facility and Product Transportation Concept or Equipment Travel-Path Objectives 2.13 Computer Simulation of Your Product Transportation Concept 2.13 When to Use aComputer Simulation 2.14 Facility and Product Transportation Concept Layout Fundamentals = 2.1/4 Data Collection Process 2.4 Product Transportation Concept Layout 2.15 Minimizing the Number of Support Columns for Your Warehouse Ground or Mezzanine Floor = 2.5 Facility and Product Transportation Concept Presentation Methods 2.15 Block Layout Method 2.15 Layout Board and Standard Templates 2.16 Conventional or Computer-Aided Drawing Method = 2.17 Model Method = 2.19 ° Facility Layout Objectives and Principles 249 Adequate Aisles and Aisle-Width Principle 2.20 Type of Product (SKU) Handled in Your Product Transportation Concept 2.22 Product Flow 2.22 JIT Replenishment or Across-the-Dock Product Flow Philosophy 2.22 Store Gnventory)-and-Hold Concept 2.22 Bases for a Facility and Product Transportation Concept Layout 2.23 Various Facility, Materials Handling System, and Product Transportation Concept Philosophies 2.23 Type of Product Handled 2.24 Product Popularity or Pareto’s Law (80/20 Rule) 2.25 Unloading and Loading Product Transportation Ratio 2.26 Power or Fast-Moving Product or SKUs in One Storage Area 2.28 Product Transportation Concept or Equipment Travel Distance Philosophy 2.28 Product Characteristics Philosophy 2.30 Adequate Product Transportation Equipment Clear Ceiling Height and Clear Travel-Path Width Philosophy 2.30 Proper Fire Protection and Employee Safety Philosophy 2.37 Proper Building Column and Bay Size Philosophy 2.3 Use of Gravity Product Transportation Philosophy 2.32 Various Facility, Materials Handling System, and Product Transportation Concept Layout Principles 2.32 Racks and Aisle or Manufacturing Workstation Flow Direction Principle 2.33 Ajiste Length Principle 2.34 Storage Vehicle Principle 2.35CONTENTS vii Internal Product Transportation Principle 2.36 Receiving and Shipping Dock Area Principle 2.37 Facility Shape Principle 2.37 Product Flow Pattern Principle 2.40 Overview of Materials Handling System Principles 2.41 Chapter 3. Small-Item and Hanging Garment Horizontal Transportation Concepts 31 Introduction 3. Small-Item and Hanging Garment Terms 3. Horizontal Transportation Equipment and Concept Objectives 3.2 Small-Item and Hanging Garment Horizontal Transportation Equipment and Concept Design Parameters 3.2 Computer Simulation of the Small-Item or Hanging Garment Transportation Function 3.4 Nonpowered Horizontal Transportation Design Factors 3.4 Various Small-Item or Hanging Garment Horizontal Product Transportation Concepts 3.5 Small-Item and Hanging Garment Above-Floor Nonpowered Horizontal Product Transportation Group 3.5 Various Above-Floor Nonpowered Smalt-Item and Hanging Garment Horizontal Transportation Concepts 3.6 Human or Employee Carry Concept 3.6 Four-Wheel Cart Concept 3.7 Retail Shopping Cart Concept 3.28 Dolly Concept 3.28 Two-Wheel Hand-Truck Concept 3.28 Manual Pallet-Truck (Jack) Concept 3.29 Semilive Skid Concept 3.29 Platform-Truck Concept 3.29 Gravity or Nonpowered Conveyor Concepts 3.29 Slide or Chute Concept 3.29 Slick Rail or Slide Rail Concept 3.29 Wagon-Truck Concept 3.30 Above-Floor Powered Small-Item and Hanging Garment Horizontal Transportation Group 3.30 Various Above-Floor Powered Small-Item and Hanging Garment Horizontal Transportation Concepts 3.30 Powered Burden Carrier Concept 3.3 Electric-Powered Cart with a Towed Cart Concept 3.37 Miniload (Miniload Storage and Retrieval or Ministacker) Concept 3,34 Horizontal (Basket and Hanging Garment) Carousel Concept 3.41 Tele-Car Concept 3.41 Nova-Sort Concept 3.4/ Powered Conveyor Concept 3.42 Electric-Powered Pallet-Truck (Jack) Concept 3.59 Powered Tractor (Tugger) with a Towed Train of Carts Concept 3.60 Gull Wing Concept 3.60 Tilt-Tray Concept 3.60 Flap Sorter Concept 3.73 Bombay Drop Concept 3.76 SBIR 3.80 Lift-Truck and Order-Picker Truck Concept 3.80 Mini-AGV (Automatic-Guided Vehicle) Concept * 3.80 Mini-Cartrac or Shuttle-Car Concept = 3.87 Pneumatic Tube Concept 3.81 Overhead Nonpowered Horizontal Transportation Group 3.87 Various Overhead Nonpowered Horizontal Product Transportation Concepts 3.82viii CONTENTS Rope and Clip Concept 3.82 Nonpowered Overhead Trolley Concept 3.83 Overhead Powered Small-Item (Parts) or Hanging Garment Horizontal Transportation Concepts 3.138 Various Overhead Powered Small-Item and Hanging Garment Horizontal Transportation Concepts 3.139 Powered Conveyor Concepts 3.139 Powered Chain and Trolley with Pegs or a Basket 3.140 Pneumatic-Tube Concept 3.196 Overhead Towveyor Concept 3.200 Screw Conveyor Concept 3.200 Electric-Powered Monorail Concept 3.206 Electric-Powered Power and Free Conveyor Concept 3.207 In-Floor Nonpowered Small-Item Horizontai Transportation Concepts 3. 207 ‘Various {n-Floor Nonpowered Small-Item Horizontal Transportation Concepts 3.207 In-Floor Powered Small-Item and Hanging Garment Horizontal Transportation Concepts 3.208 Various In-Floor Powered Small-Item Horizontal Transportation Concepts 3.208 Towline Concept 3.208 Inverted Power and Free Conveyor Concept 3.208 Powered Conveyor in a Pit Below the Finished Floor or Below a Raised Floor Concept 3.209 Chapter 4. Small-item and Hanging Garment Vertical Transportation Concepts 41 Introduction 4.1 Smati-item and Hanging Garment Terms 4.2 Vertical Transportation Equipment and Concept Objectives 4.2 Small-Item and Hanging Garment Vertical Transportation Equipment and Concept Design Parameters 4.2 Computer Simulation of the Small-ltem or Hanging Garment Transportation Function 4.4 Nonpowered Vertical Transportation Design Factors 44 Various Small-Item or Hanging Garment Vertical Transportation Concepts 4.5 Small-Jtem and Hanging Garment Above-Floor Nonpowered Vertical Transportation Group 46 Vatious Small-ltem and Hanging Garment Above-Floor Nonpowered Vertical Transportation Groups 4.6 Human Carry Concept 4.6 Ramp with a Nonpowered Mobile Vehicle Concept 4.6 Incline Powered Above-Floor Small-Item and Hanging Garment Transportation Concepts 4.7 Various Incline Powered Above-Floor Small-Item and Hanging Garment Transportation Concepts 4.7 Pneumatic-Tube Concept 4.8 Powered Belt Conveyor Concept 4.8 Vertical Hanging Garment Lift Concept 4.12 Whiz-Lift Concept 4.15 Tilt-Tray Concept 4/5 Ramp with a Mobile-Powered Vehicle Concept 4.15 Vertical Carousel Concept 4.15 Continuous Vertical Lift Concept 4.21 Miniload Concept 4.2/ Small-Item and Hanging Garment Overhead Nonpowered Incline ‘Transportation Concepts 4.21 Small-Item and Hanging Garment Overhead Powered Incline Transportation Concepts 4.21 Various Small-Item and Hanging Garment Overhead Powered Incline Transportation Concepts 4.27CONTENTS ix Powered Chain and Trolley ona Rail Concept 4.22 Pneumatic-Tube Concept 4.32 Belt Conveyor Concept 4.32 Hanging Garment Carousel Concept 4.32 Monorail Concept _ 4.36 Power and Free Conveyor Concept 436 Overhead Towveyor Concept 4.36 Tele-Car Concept 4.36 Smail-Item and Hanging Garment Incline Nonpowered In-Floor Transportation Concepts 4.44 Small-Item and Hanging Garment Incline Powered In-Floor Transportation Concepts 4.44 Various Small-Item and Hanging Garment Incline Powered In-Floor Transportation Concepts 4.44 Towline Over a Ramp Concept 4.44 Powered Belt Conveyor in a Pit or Below a Raised Floor Concept 4.44 Inverted Power and Free Conveyor Concept 4.45 Small-Item and Hanging Garment Above-Floor Nonpowered Decline Transportation Concepts 4.45 Various Small-Item and Hanging Garment Above-Floor Nonpowered Decline Transportation Concepts 4.45 Human Carry Concept 445 Slides and Chute Concept 4.46 Gravity Roller or Skate Wheel Conveyor Concept 4.56 Ramp with a Nonpowered Mobile Vehicle Concept 4.56 Small-item and Hanging Garment Above-Floor Powered Decline Transportation Concepts 4.56 Various Small-Item and Hanging Garment Above-Floor Powered Decline Transportation Concepts 4.56 Pneumatic-Tube Concept 456 Belt Conveyor Concept 4.57 Whiz-Lift Concept 4.57 Tilt-Tray Concept 4.57 Ramp with a Mobile Powered Vehicle Concept 4.58 Vertical Carousel Concept 4.58 Continuous Vertical Lift Concept 4.58 Miniload Concept 4.58 Small-Item and Hanging Garment Decline Nonpowered Overhead Transportation Concepts 4.58 Various Small-Item and Hanging Garment Decline Nonpowered Overhead Transportation Concepts 4.59 Slide or Chute Concepts 4.59 Slick or Slide Rail Concepts 4.59 Gravity Roller or Skate Wheel Conveyor Concepts 4.59 Trolley on a Tubular Rail or Inverted Bar Stock Concepts 4.59 Small-Item and Hanging Garment Overhead Powered Decline Transportation Concepts 4.60 Various Smail-Item and Hanging Garment Overhead Powered Decline Transportation Concepts 4.60 Powered Chain with a Trolley That Has Pegs or a Basket Concept 4.60 Powered Belt Conveyor Concept 4.6 Pneumatic-Tube Concept 4.61 Hanging Garment Carousel Concept 4.67 Tilt-Tray Concept 462 Overhead Towveyor Concept 4.62 Tele-Car Concept 4.62 Monorail Concept 4.62 Small-Item In-Floor Nonpowered Decline Transportation Concepts 4.63 Various Smail-Item In-Floor Nonpowered Decline Transportation Concepts 4.63 Slides or Chutes Concepis 4.63 . Gravity Roller or Skate Wheel Conveyor Concepts 4.63x CONTENTS. Small-Item In-Floor Powered Decline Transportation Concepis 4.64 Various Small-Item In-Floor Powered Decline Transportation Concepts 4.64 Powered Belt Conveyor in a Pit or Below a Raised Floor Concept 4.64 Towline Concept 4.64 Inverted Power and Free Conveyor Concept 4.65 Chapter 5. Container, Box, Tote, or Carton Horizontal Transportation Concepts 5.1 Tntroduction 5.1 . Horizontal Transportation Equipment and Concept Objectives 5.1 Carton Horizontal Equipment and Concept Design Parameters 5.2 Computer Simulation of the Carton Horizontal Transportation Function 5.3 Container, Box, Tote, or Carton Terms 5.4 Nonpowered Horizontal Transportation Design Factors 5.4 Various Carton Horizontal Transportation Concepts 5.5 Above-Floor Nonpowered Horizontal Transportation Group 5.5 Various Above-Floor Nonpowered Carton Horizontal Transportation Concepts 5.6 Human or Employee Carry Concept 5.6 Four-Wheel Cart Concept 5.7 Retail Shopping Cart Concept 5.7 Dolly Concept 5.8 Two-Wheel Hand Truck Concept 5.12 Freight Pry Bar Concept 5.19 Platform Truck 5.22 Manually Powered or Hand Pallet Truck or Jack - 5.22 Semilive Skid Concept | 5.22 Nonpowered Conveyor Concept 5.29 Roller Paliet Concept 5.82 Wagon Truck Concept 5.82 Above-Floor Powered Carton or Container Horizontal Transportation Concepts 5.86 Various Above-Floor Powered Carton or Container Horizontal Transportation Concepts 5.86 Burden Carrier Concept 5.87 Powered Conveyor Concept 5.90 Nova-Sort Concept 5.218 Electric-Powered Pallet-Truck Concept 5.219 Tractor with a Train of Carts Concept 5.219 Tilt-Tray Concept 5.219 Tilt-Slat Concept 5.219 Lift Truck and Order Picker Truck Concept 5.220 Guli-Wing Concept 5.220 Flap Sorter Concept 5.220 SBIR Concept 5.22] AGV Concept 5.221 Cartrac or Shutile Car Concept 5.22] Air-Pallet Concept 5.221 Tele-Car Concept 5.22! Overhead Nonpowered Carton or Container Horizontal Transportation Concepts 5.222 Yarious Overhead Nonpowered Carton or Container Horizontal Transportation Concepts 5.222 Tubular-Rail or Inverted Bar Stock and Trolley witha Basket Concept 5.222 Nonpowered Skate Wheel or Roller Conveyor Concept 5.222 Slide and Chute Concept 5.223 Manual Monorail Concept 5.223 Overhead Powered Carton or Container Horizontal Transportation Concept 5.223 Vatious Overhead Powered Carton or Container Horizontal Transportation Concepts 5.223 Powered Conveyor Concept — 5.223CONTENTS xi Powered Chain with Trolley Basket Concept 5.224 Powered and Free Conveyor Concept 5.224 Overhead Towveyor Concept 5.224 Powered Monorail Concept 5.224 In-Floor Nonpowered Carton or Container Horizontal Transportation Concept 5.225 Various In-Floor Nonpowered Carton or Container Horizontal Transportation Concepts 5.225 Tn-Floor Powered Carton or Container Horizontal Transportation Concept = 5.225 Various In-Floor Powered Carton or Container Horizontal Transportation Concepts 5.225 Towline Concept 5.226 Powered Conveyor In-Floor or Below a Raised Floor Concept 5.226 Inverted Power and Free Conveyor Concept 5.226 Chapter 6. Carton Vertical Transportation Concepts 61 Introduction 6. Carton and Container Terms 6. Vertical Transportation Equipment.and Concept Objectives 6.3 Carton Vertical Transportation Equipment and Concept Design Parameters 6.3 Computer Simulation of the Carton Vertical Transportation Function 6.5 Nonpowered Vertical Transportation Design Factors 6.5 Various Vertical Carton Transportation Concepts 6.6 Above-Floor Nonpowered Vertical (Incline) Carton Transportation Group 6.6 Human Carry Concept 6.7 Ramp with a Nonpowered Mobile Vehicle Concept 6.7 Incline Powered Above-Floor Carton Transportation Concepts 6.7 Powered Belt Conveyor Concept 6.11 Continuous Vertical Lift Concept 6.36 Over a Ramp with a Powered Vehicle Concept 6.36 Whiz-Lift Concept 6.37 Vertical Reciprocating Lift Concept 6.37 Scissors Lift Concept 6.40 Freight ElevatorConcept 6.40 Lift-Truck or Order-Picker Truck Concept 6.40 Tele-Car Concept 6.40 Overhead Nonpowered Incline Carton Transportation Concepts 6.47 Overhead Powered Incline Carton Transportation Concepts 6.41 Powered Chain and Trolley with a Basket or Bag Concept 6.42 Powered Belt Conveyor Concept 6.42 Tele-Car Concept 6.42 Incline Nonpowered In-Floor Carton Transportation Concepts 6.42 Incline Powered In-Floor Carton Transportation Concepts 6.42 Tow-Line Concept 6.43 Powered Belt Conveyor in a Pit or Below a Raised Floor Concept 6.43 Dock LiftConcept 6.43 Above-Floor Nonpowered Decline Carton Transportation Concepts 6.44 Human Carry Concept 6.44 Slides and Chute Concept 6.44 Design Considerations: 6.44 Key Components 6.45 Gravity Roller or Skate Wheel Conveyor Concept 6.49 Ramp with a Nonpowered Mobile Vehicle or Cart Concept 6.60 Above-Floor Powered Decline Carton Transportation Concepts 6.60 Powered Belt Conveyor Concept 6.60 Continuous Vertical Lift 6.67 Over a Ramp with a Powered Vehicle Concept 6.61 Whiz-Lift Concept 6.67xii CONTENTS Vertical Reciprocating Lift Concept 6.62 Scissors-Lift Concept 6.62 Freight Elevator Concept _ 6.62 Lift-Truck or Order-Picker Truck Concept 6.02 Tele-Cart Concept 6.63 Overhead Nonpowered Incline Carton Transportation Concepts 6.63 Decline Nonpowered Overhead Carton Transportation Concepts 6.64 Gravity Slides or Chutes 6.64 Gravity Roller or Skate Wheel Conveyor Concept 6.64 Overhead Powered Decline Carton Transportation Concepts 6.64 Powered Belt Conveyor Concept 6.65 Trolley with a Basket or Bag Concept 6.65 Tele-Car Concept 6.65 In-Floor Nonpowered Decline Carton Transportation Concepts 6.65 Slide or Chute Concept 6.65 Gravity Roller or Skate Wheel Conveyor Concept 6.66 In-Floor Powered Decline Carton Transportation Concepts _ 6.66 Powered Belt Conveyor in a Pit or Below a Raised Floor Concept 6.66 Towline Concept 6.66 Dock Lift Concept 6.67 Chapter 7. Pallet or Unit-Load Horizontal Transportation Concepts 7.1 Introduction 7.1 Pallet or Unit-Load Terms 7.1 Pallet Board = 7.2 Slip Sheet 7.7 Container 7.8 Horizontal Pallet Transportation Equipment and Concept Objectives 7.10 Pallet or Unit-Load Horizontal Transportation Equipment and Concept Design Parameters 7.10 Computer Simulation of the Pallet Transportation Function = 7.12 Nonpowered Horizontal Pallet Transportation Design Factors 7.12 Various Pallet or Unit-Load Horizontal Transportation Concepts 7.13 Pallet Above-Floor Nonpowered Horizontal Transportation Group 7.13 Various Above-Floor Nonpowered Carton Horizontal Transportation Concepts 7.44 Dolly or Roller Pallet Concept 7.44 Nonpowered Roller Conveyor Concept 747 Platform-Truck Concept 7.17 Manually Powered or Hand-Pallet Truck or Jack Concept (7.21 Hand-Skid or Platform Truck — 7.31 Nonpowered Conveyor — 7.32 Above-Floor Powered Pallet Horizontal Transportation Concepts 7.32 Various Above-Floor Powered Pallet Horizontal Transportation Concepts 7.32 Powered Roller Conveyor Concept 7.33 Electric-Powered Pallet-Truck Concept 7.64 ‘Tractor witha Train of Carts Concept 7.88 Powered Forklift Truck and Order-Picker Concept 7.105 Automatic Guided Vehicles (AGVs) 7.128 Cartrac or Shuttle Car Concept 7.179 Air Pallet Load Concept 7.187 Bascule Bridge Concept 7.192 Overhead Nonpowered Pallet Horizontal Transportation Concepts 7.193 Various Overhead Nonpowered Pallet Horizontal Transportation Concepts 7.193 Manually Powered Monorail Concept 7.194 Pailet Flow Rack Concept 7.194 Overhead Powered Pallet Horizontal Transportation Concept 7. 200CONTENTS xiti Various Overhead Powered Pallet Horizontal Transportation Concepts 7.201 Powered Roller Conveyor Concept 7.207 Power and Free Conveyor Concept 7.201 Overhead Towveyor Concept 7.221 Powered Monorail Concept 7.225 Bridge Crane Concept 7.235 Air-Pallet Flow-Rack Concept 7.235 in-Floor Nonpowered Pallet Horizontal Transportation Concept 7.238 Various In-Floor Nonpowered Pailet Horizontal Transportation Concepts 7.238 In-Floor Powered Pallet Horizontal Transporatation Concept 7.239 Various In-Floor Powered Pallet Horizontal Transportation Concepts 7.239 Powered In-Floor Towline Concept 7.239 Powered Roller Conveyor in-Floor or Below a Raised Floor Concept 7.257 Inverted Power and Free Conveyor Concept 7.257 Chapter 8. Pallet or Unit-Load Vertical Transportation Concepts 31 Introduction 8. Vertical Transportation Equipment and Concept Objectives 8.2 Pallet or Unit-Load Vertical Transportation Equipment and Concept Design Parameters 8.2 Computer Simulation of the Pallet Vertical Transportation Function 8.4 Various Pallet Vertical Transportation Concepts 8.4 Pallet or Unit-Load Above-Floor Powered Incline Transportation Concepts 8.5 Various Pallet or Unit-Load Above-Floor Powered Incline Transportation Concepts 8.5 Ramp with Powered Mobile Vehicle Concept 8.5 Vertical Reciprocating Lift or Conveyor Concept 8.9 Continuous Vertical LiftConcept 8.21 Forklift Truck or Order-Picker Truck Concept 8.33 Freight Elevator Concept 8.39 Pallet or Unit-Load Overhead Powered Incline Transportation Concepts 8.54 Various Pallet or Unit-Load Overhead Powered Incline Transportation Concepts 8.54 Power and Free Conveyor Concept 8.55 Bridge Crane Concept 8.59 Overhead Towveyor with Ramp Concept 8.64 Pallet or Unit-Load Incline Powered In-Floor Transportation Concepts 8.64 Various Pallet or Unit-Load Incline Powered In-Floor Transportation Concepts 8.65 In-Floor Towline Concept 8.65 Inverted Power and Free Conveyor Concept 8.67 Scissors Lift or Dock Lift Concept 8.67 Pallet or Unit-Load Above-Floor Powered Decline Transportation Concepts 8.73 Various Pallet or Unit-Load Above-Floor Powered Decline Transportation Concepts 8.74 Ramp with Powered Mobile Vehicle Concept 8.74 Continuous Vertical Lift Concept 8,74 Vertical Reciprocating Conveyor Concept . 8.76 Lift-Truck and Order-Picker Truck Concept. 8.76 Scissors or Dock LiftConcept 8.76 Freight Elevator Concept . 8.76 Pallet or Unit-Load Overhead Powered Decline Transportation Concepts 8.77 Various Pallet or Unit-Load Overhead Powered Decline Transportation Concepts 8.77 Power and Free Conveyor Concept 8.77 Bridge Crane Concept 8.80 Overhead Towveyor Concept 8.80 Pallet or Unit-Load In-Floor Powered Decline Transportation Concepts 8.87 Various Pallet or Unit-Load In-Floor Powered Decline Transportation Concepts 88! Towline Concept 8.8 Inverted Power and Free Conveyor Concept 8.82xiv CONTENTS. Chapter 9. Outdoor Carton, Pallet-Load, or Unit-Load Horizontal and Vertical Transportation Concepts 9.1 Introduction 9.1 Ouitdoor Carton, Pallet-Load, or Unit-of-Product Horizontal or Vertical Transportation Equipment or Concept Objectives 9.1 Outdoor Carton, Pallet-Load, or Unit-Load Horizontal Transportation Equipment and Concept Design Parameters 9.2 Various Outdoor Horizontal and Vertical Carton, Pallet-Load, or Unit-Load Transportation Concepts 9.3 Outdoor Nonpowered Horizontal Carton Transportation Group 9.4 Outdoor Powered Horizontal Carton Transportation Concepts 9.4 Outdoor Powered Vertical Incline Carton Transportation Concepts 9.5 Outdoor Nonpowered Vertical Decline Carton Transportation Concepts 9.6 Outdoor Powered Vertical Decline Carton Transportation Concepts 9.7 Outdoor Nonpowered Horizontal Pallet-Load Transportation Concepts 9.8 Outdoor Powered Horizontal Pallet-Load Transportation Concepts 9.8 Outdoor Powred Vertical Incline Pallet-Load Transportation Concepts 9.19 Outdoor Powered Vertical Decline Pallet-Load Transportation Concepts 9.20 Chapter 10. How te Secure and Protect Your Product on Your Transportation Concept 10.1 Invoduction 10.7 Unitize or Palletize Your Loads as Soon as Possible 10.2 Stackable and Nonstackable Product 10.2 Product Transportation Design Parameters — [0.3 Objectives of Your Product Transportation Concept 10.3 What Determines Your Product Handling Container? 10.4 Transportation of Loose Single Items 10.4 Transportation of a Single Item in an Individual Bag = 10.5 Transportation of Loose Items in a Chipboard or Corrugated Box 10.6 Transportation of Single Items in Open Plastic Containers 10.16 Hanging Garment Transportation 10.26 ‘Transportation of a Carton by Itself, on a Tray, or in a Special-Design Container 10.29 How to Stabilize Product on a Pallet or Unit Load-Carrying Surface 10.62 Various Product Stabilization Techniques 10.63 Tix HiMethod 10.63 Stretch-Wrap Method 10.68 Shrink-Wrap Method 10.69 Steel or Plastic Banding Method = 10.70 Netting and Stretch Netting Method — 10.70 Glue and Adhesive Method — 0.70 Elastic or Rubber Band Method — 10.71 Self-Adhesive Tape Method = 10.71 String or Twine Method = 10.71 Chapter 11. Product Transportation Concept Project Management— Financial Justification to Impfementation 11.1 Introduction 71.1 Project Management Activities for Your Project Transportation Concept 71.1 How to Estimate Costs, Write Specifications, Review Bids, Administer Contracts, and Implement Your Product Transportation Concept 11.2 Cost Estimates 11.2CONTENTS xv Types of Cost Estimates 11.3 Preparation for a Materials Handling Concept Cost Estimate 11.4 Include a Contingency in Your Final Materials Handling or Project Transportation Project Budget Cost 11.5 Methods for Managing the Construction of a New Facility 17.5 Materials Handling (Product Transportation) Concept Budget Price Sources 11.6 Information on Your Company’s Building Drawing and Written Functional Specifications 11.6 Building, Land, and Site Preparation Budget Price Sources 11.7 Steps for Choosing Your Architect and Building Contractor 11.8 Preparation of Your Company's Bid Package 11.9 Materials Handling (Product Transportation} Concept and the Equipment Bid Process 11.18 Preparation of Your Bid Package or Request for Quote (RFQ) 11.19 Materials Handling or Product Transportation Equipment Vendor Payment Schedules 11.21 Steps to Ensure Three Accurate Bids 71.22 Materials Handling or Product Transportation Concept Bid Return Procedure 11.22 Bid Review or Bid Evaluation Process 11.23 Preparation of Your Company’s Purchase Order = 11.25 How to Issue Purchase Orders 11.25 Letter of Intent = 11.26 Other Important Project Factors 71.26 Materials Handling Equipment Supplier Drawing Review Process 11.26 Document All Changes = 11.27 Master Project Schedule 11.27 Contract Administration 11.30 Project Cost-Tracking Methods 1.30 Schedule Building Constmction and Materials Handling Equipment Vendor Installation Meetings = 72.31 Your Installation Office 11.33 What to Check and Inspect = 11.33 Contract Payment 11.37 Project Progress Report 11.37 Various Project Progress Reports 11.38 Keep Good Records 11.40 Materials Handling Equipment and Building Orientation Meetings — 11.40 Materials Handling Equipment or Concept Operational Test 11.42 Materials Handling Equipment or Concept Acceptance Test 11.43 Materials Handling Equipment or Concept and Building Punch List 71.44 Include Your Operational and Maintenance Staff as Part of the Punch List Team 11.44 Operational and Maintenance Training Sessions 71.46 Some Dos and Don’ts 11.47 How to Read Drawings (Blueprints), Convert Metric Standard Measurements, Use Military Time and Julian Dates, and Use Charts 11.47 Your Materials Handling or Building Concept Drawing (Blueprint) Is a Person’s View 11.48 Metric Measurements 11.60 Military Time and Julian Dates 11.60 Charts Are Important Tools for Building Construction and Materials Handling Concept Installation Schedules 11.60 When and How to Select and Use Your Internal or External Materials Handling (Product Transportation) Consultant 17.64 What Are Your Resources? 11.66 Where Do You Find Assistance for Your Materials Handling or Product Transportation Business? 1.66 Provide Accurate, On-Time Materials Handling Concept Design Information 11.67 What Are the Signals That Your Materials Handling Operation Needs a Consultant? 11.68xvi CONTENTS What Are Your Business Materials Handling Activities That Require an Extemal Consultant? 11.68 ‘What Your Materials Handling Consultant Should Look At 11.69 Who from Your Company Should Work on Your Materials Handling or Product Transportation Project? 11.69 Materials Handling Project Team Organization 11.69 Where Do You Find Materials Handling Consultants? = 71.72 Insights for Your Materials Handling Consultant Selection Process 14.71 Types of Materials Handling Projects That Involve Consultants 11.72 What Information Does Your Materials Handling Consultant Need for Your Project? = 1.73 Financial and Nonfinancial Justification Factors and Alternate Capital Expenditure Justification Methods = 11.73 Reasons for Economic Justification Factors 11.73 Economic Justification Process 11.74 Various Economic Justification Methods 11.76 Noneconomic Factors 11.91 How to Develop Your Employee Standards, Employee Productivity Program, and Annual Expense Budget for Your Materials Handling Operation 11.92 Why Is High Productivity Important? 17.92 What Is Employee Productivity? 11.93 What Business Factors Affect Your Materials Handling Employee Productivity? 11.93 Areas for Materials Handling Employee Productivity Improvement — 11.93 Guidelines for a Successful Employee Productivity Program — 11.96 Identify the Labor Activity with the Highest Numbers 11.97 How to Measure Your Employee Productivity 11.97 Employee Productivity Must Be Tied to Your Materials Handling (Product Transportation) Annual Expense Budget 11,108 How to Project Your Materials Handling Operating Budget 17.111 Various Methods for Your Annual Materials Handling Operating Expense Budget 14.117 Why Have Capital Investments? = 11.118 What Is the Justification for a Capital Expenditure? = 1.118 How Depreciation Expense Affects Your Company’s Income Statement and Balance Sheet 11.119 How Employee Productivity Affects Your Company's Income Statement 11.149 ‘What Good Employce Productivity Means to Your Company’s Income Statement 1. Lud Chapter 12. The Best Identification System for Your Product Transportation Concept 12.1 Introduction = 12.7 Components of an Automatic Identification System 12.1 Other Identification System Considerations 12.2 Various Smail-Product, Carton, or Pallet Transportation Load-Carrying Surface Identification Methods = /2.3 No Identification Method = 12.3 Manual Identification Method == 12.3 Automatic Identification Method = 12.5 index follows Chapter 12SAMPLE ILLUSTRATION Stringers {runners} Hand pallet truck openings Stringer board oleate and a Hand paltet FIGURE 10.12 Pallet-board components.