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This paper aims to discuss some relevant issues in the design and operation of material handling and storage systems (MH&SS) characterized by complex material flows and high‐traffic intensity. The paper seeks to provide solution examples and an analysis methodology to face large increases of materials flows through a redesign of the material handling and storage system.

At first, possible strategies to improve system performances when facing strong increments of material flows are presented and discussed. A significant case study is then analyzed in order to present a practical application of the proposed methodology. Resorting to discrete‐events simulation, the alternatives are verified, correct design choices are identified, and the resources are properly sized to develop a streamlined layout.

The paper recognises that design and upgrade of intensive material handling systems is a complex task asking for a careful study of alternatives and detailed system analysis, otherwise capacity problems and bottleneck phenomena may not be effectively solved.

This work focuses on a specific case study. The paper, therefore, will be of interest mainly to managers and designers of similar plants and large – intensive material handling systems.

The paper shows how the correct planning and analysis of design alternatives integrated with a detailed system simulation enable a drastic reduction of bottleneck phenomena, thus meeting the required capacity improvement goals when upgrading and redesigning complex and high‐volume material handling systems.

The paper, while providing insights to practitioners engaged in design and management of complex MH&SS, outlines a methodological approach which can be useful when facing major capacity improvement projects.

Saudi Arabia's 2030 vision targets an increase of 34% in non-oil revenue participation in the GDP, thus the need for automation and digital transformation. The Company ER is a market leader producing high-quality dairy products in the Kingdom and is a pioneer in the production industry. The company has recently increased the capacity of its milk factory to meet its vision. An investment was made to automate the pallet handling procedures at the milk factory to provide increased production for daily consumption. The new automation transition in Company ER's milk factory provides a unique opportunity to utilize lean management tools to improve the current automated processes before commercialization.

OEE (overall equipment effectiveness) will monitor losses for different operational losses in the new automated system and indicate system improvements, with 85% as the target. Based on DMADV (design, measure, analyze, design and validate) methodology, this study analyzes the entire automated pallet handling system. It uses lean tools to identify areas for improvement, identify waste elements and propose solutions to achieve Company ER's OEE targets.

In this paper, the outcomes will be presented as documented solutions that address the losses encountered in the production system, showing a 12.8% increase in the system's OEE.

Owing the time and resource constraint, this study only involved automated pallet handling procedures in a milk production facility. Hence, the generalization of the result is slightly limited. More studies in several different processes and sectors are required.

This study provided a valuable tool for researchers for gaining deeper understanding regarding the lean manufacturing and its implementation. For practitioners, it is useful to evaluate the degree of lean manufacturing tools in their material handling systems.

This study is the first attempt to develop lean manufacturing constructs for evaluating the automated pallet handling procedures in a milk production facility.

The development of a generic flexible assembly system involves the design, selection and integration of a number of different mechanical systems in order to develop an assembly system, which is capable of assembling a wide variety of products having an unknown specification. A specific system configuration being dependent on a variety of factors such as, product size, weight, component insertion direction, and manipulator geometry. This paper examines each of the factors that should be considered when designing a generic flexible assembly system and presents a novel generic flexible assembly system design.

Taken very much for granted, the common or garden pallet is still one of the most versatile items of materials handling equipment. It comes in all shapes and sizes and there are countless variations on a theme: timber, metal and plastic are the most popular materials of construction, while post pallets, roll pallets, expendables, converters, collars and cages are just a few of the pallet's relations. As one of the most innovative sectors in the total handling/storage spectrum, palletisation still provides the vital link in the strength and well being of our distribution networks.

The purpose of this paper is to detail the design and prototyping of a smart automation solution for de-strapping plastic bonding straps on shipping pallets, which are loaded with multiple containers secured by a top-cover as they move on a conveyor belt.

The adopted design methodology to have the system perform its function entails using the least number of sensors and actuators to arrive at an economic solution from a system design viewpoint. Two prototypes of the robotic structure are designed and built, one in a research laboratory and another in an industrial plant, to perform localized cutting and grabbing of the plastic straps, with the help of a custom-designed passive localizing structure. The proposed structure is engineered to locate the plastic straps using one degree of freedom (DOF) only. An additional strap removal mechanism is designed to collect the straps and prevent them from interfering with the conveyor.

The functionality of the system is validated by performing full-process tests on the developed prototypes in a laboratory setting and under real-life operating conditions at BMW Group facilities. Testing showed that the proposed localization system meets the specified requirements and can be generalized and adapted to other industrial processes with similar requirements.

The proposed automated system for de-strapping pallets can be deployed in assembly or manufacturing facilities that receive parts in standard shipping pallets that are used worldwide.

To the best of the authors’ knowledge, this is the first mechanically smart system that is used for the automated removal of straps from shipping pallets used in assembly facilities. The two main novelties of the proposed design are the robustness of the strap localization without the need for computer vision and a large number of DOF, and the critical placement and choice of the cutting and gripping tools to minimize the number of needed actuators.

WHILST the operating life of modern airliners and the distances covered by them are ever increasing, the demands faced by aircraft manufacturrs for improved quality and safety standards are greater now than at any time in aviation history.

One of the first steps in designing a flexible assembly system is the selection of an appropriate manipulator. There are a number of different manipulator configurations which can be chosen depending on a variety of factors such as the assembly workspace layout, product size, weight, and component insertion direction.A number of methodologies have been written to help the selection of a manipulator for process cells. However, little work exists to aid the machine designer in the selection of an appropriate manipulator for flexible assembly. This paper examines the factors which affect this process.

The purpose of this paper is to provide a review of the most recent IMTS show in Chicago with emphasis on the new manufacturing automation innovations and applications on display.

The paper presents in‐depth interviews with exhibitors of automation equipment and system integrators of automation technology at the show.

Automation technology continues to address an ever increasing number of manufacturing tasks to improve quality and productivity at every step in the manufacturing and inspection process.

Customers may be surprised at the automation innovations and new applications which are appearing in the manufacturing environment.

The paper offers a review of some of the latest automation innovations and applications that one might have seen if they had been on the exhibition floor at the most recent Chicago IMTS show.

ALMOST from the beginning of design work on the VC10 it was clear that its high volumetric capacity combined with its advanced wing design, high power loading, modest approach speed and airfield performance could provide an excellent basis for a high work capacity economic freight transport.