Appendix IB. Course Syllabi

IE 443 Material Handling and Automation

Catalog Description:
Analysis and application of material handling systems and facility layouts including Systematic Layout Planning and computerized layout. Material handling methods and analysis. Application of sensors, PLC's, robots, AGV's, carousels other automated devices to material handling systems. Cellular manufacturing, focused factories and other current manufacturing system strategies.

Prerequisites: IE 312, IE 313, IE 348

Text:
Facilities Planning - Second Edition by Tompkins, White, Bozer, Frazelle, Tanchoco, and Trevino. John Wiley and Sons, Inc., 1996.

Course Objectives:

1. To learn, practice, and apply various methods of facility layout and optimization.
1. To learn about the theory, analysis methods and application of material handling devices in the industrial and service industries.
2. To be able to evaluate and suggest improvements to current material handling practice through knowledge and the appropriate application of automated equipment.
3. To practice and develop teamwork and group collaboration skills.
4. To practice and refine communication and presentation skills.

Topics Covered:

1. Introduction and overview of facility layout, materials handling, and automated devices.
1. Flow, space, and activity relationships
2. Systematic Layout Planning and Quadratic Assignment Problem methods
3. Various types of layouts-product, process, fixed material, group technology
4. Various types of production - job shop, batch, mass production
5. Computer-aided facility layout and optimization
6. Material handling principles
7. Material handling equipment selection and utilization
8. Group technology and machine layout within cells
9. Part family determination-Tabular method, Rank-Ordered Clustering, Direct Clustering Algorithm
10. Storage and warehousing
11. Manufacturing methods - Traditional, Cellular, Focused Factories, Lean, etc.
12. Assembly for electronics manufacture, use of robots and automation
13. Automation - Sensors, PLC's, RFID, Barcodes
14. Automation - AGV's, ASRS, Carousels, Control Systems, CIM

Class/Laboratory Schedule:
The course meets three times per week for 50 minutes. The learning environment is active and varied (small groups, in-class activities, discussions, peer presentations, etc.). Students complete eight homework assignments, three mini-projects, and an end-of-semester project. Some homework and projects are assigned to individuals others are completed with 1 or 2 other students in a team. There are two in-class exams plus a final exam. Students are expected to participate in class and present material assigned that day. Four laboratory days are used to familiarize students with AGV’s, conveyors, PLC’s and robots and their material handling applications. Also, a plant tour is taken to a local industrial facility.

Professional Component Contributions:
Students learn how to both construct and optimize a facility layout. They must consider the appropriate mix of data and assumptions and be sensitive to other constraints such as management, personnel and costs. Most problems are open-ended requiring both quantitative and subjective analysis. Implementation of changes and improvements are discussed in the context of the human element, culture, and global viewpoint.

Relationship to Program Objectives:

Objectives 1, 3, and 6 - Facilities and workplace design is essential to the course. Layouts require that the appropriate mix of people, materials, machines and information are in place to effectively design and control a system.

Objectives 2 and 7 - Students learn that the best design or material handling device is not always feasible due to constraints and limitations imposed by other sectors of the business or environment. They must effectively bridge the gaps between engineering and business interests.

Objectives 1, 2, 3, 6 ,7 - All layouts, material handling, and automation are designed with the final process in mind. The integration of people, materials, equipment, information and control are the driving principles of the course.

Objectives 2 and 7 - Industrial engineers will be involved in the design and optimization of facilities across the globe. In addition, students will gain an understanding of the importance of each functional unit of an enterprise as well as how they relate and interact with one another.

Objectives 3, 5, 7 - Students will work with every other member of the course through assigned and in-class projects. They will provide the essential leadership and initiative to meet the objectives of each team project.

How Assessed:
Assessment of the instructor is performed at midterm by Alpha Pi Mu and at the end of the semester by the department. This permits me to receive feedback which I incorporate into the course.

Actions Taken to Improve the Course:
I have modified the course to meet overall program objectives and lists of topics to correspond with other required IE courses. I continue to add more content on electronics manufacturing and hands-on experiences (laboratories) for the students. The final project is intended to allow students to apply course content to industrial settings. I have worked with a number of IE 441 student teams and industrial partners to solve warehousing, material handling, and layout problems which extend the material covered in this course. I am also exploring the use of virtual reality in facility and workstation design.

Prepared by: Cheryl Moller-Wong

Date Prepared: December 10, 1999