*AGV

EXAMPLE 1: Consider the AGVS layout in Figure . Vehicles travel counterclockwise around
the loop to deliver loads from the load station to the unload station. Loading time at the load
station : 0.75 min, and unloading time at the unload station : 0.50 min. The following
performance parameters are given:
• vehicle speed : 50 m/min, availability : 0.95, and traffic factor : 0.90.
• Operator efficiency does not apply, so Ew : 1.0. Determine
• (a) travel distances loaded and empty,
• (b) ideal delivery cycle time, and
• (c) number of vehicles required to satisfy the delivery demand if a total of 40 deliveries
per hour must be completed by the AGVS

TL = 0.75 min
TU = 0.5 min
v = 50m/min
A = 0.95
Ft = 0.9
Ew =1
a) Ignoring effects of slightly shorter distances around the curves at corners of the loop, the
values of Ld and Le are readily determined from the layout to be 110 m and 80 m,
respectively.
b) Ideal cycle time per delivery per vehicle :

Ld Le ❑
Tc =T L + +T U + = (min)
vc Ve ❑

c) To determine the number of vehicles requires to make 40 delivers/hr, compute the

workload of AGVS and the available time per hour per vehicle:

WL = Rf . Tc = (min/hr)
AT = 60 A Ft Ew = ( min/hour per vehicle)

Therefore, the number of vehicles required is:

WT
nc = = 3.94 (vehicles)
AT
This value should be rounded up to 4 vehicles, since the number of vehicles must be an
integer

EXAMPLE 2: The layout for this example is shown in Figure, and the from-to chart is
presented in table. The AGVS includes load station 1 where raw parts enter the system
for delivery to any of three production stations 2, 3, and 4. unload station 5 receives
finished parts from the production stations. Load and unload times at stations 1 and 5 are
each 0.5 min. Production rates for each workstation are indicated by the delivery
requirements in Table. A complicating factor is that some parts must be transshipped
between stations 3 and 4. Vehicles move in the direction indicated by the arrows in the
figure.
Determine the average delivery distance, Ld

To determine the value of Ld, a weighted average must be calculated based on the
number of trips and corresponding distances shown in the from-to chart for the Problem:

9 ( 50 ) +5 (120 )+ 6 ( 205 )+ 9 ( 80 ) +2 ( 85 ) +3 ( 70 ) +8(85) 4360

Ld = = = 103.8 (m)
9+5+6+ 9+2+3+8 42

EXERCISE 1: An automated guided vehicle system has an average travel distance per
delivery : 220 m and an average empty travel distance : 160 m. Load and unload times
are each24 sec and the speed of the AGV : 1 m/sec. Traffic factor : 0.9 and availability :
0.94. How many vehicles are needed to satisfy a delivery requirement of 35 deliveries/hr?

Ld : average travel distance per delivery: 220 m

Le : distance the vehicle travels empty: 160 m
TL = TU = 24 sec.
Vc : AGV velocity: 1m/sec
Traffic factor : 0.9
Availability : 0.94
Rf : total delivery requirements: 35 deliveries/hr
• How many AGV?

Solution:
Ideal cycle time per delivery per vehicle :

Ld Le
Tc =T L + +T U + (min)
vc Ve

To determine the number of vehicles requires to make 40 delivers/hr, compute the

workload of AGVS and the available time per hour per vehicle:

WL = Rf . Tc = (min/hr)
AT = 60 A Ft Ew = ( min/hour per vehicle)

Therefore, the number of vehicles required is:

WT
nc = = (vehicles)
AT

This value should be rounded up to 4 vehicles, since the number of vehicles must be an
integer

EXERCISE 2: In Example.2, suppose that the vehicles operate according to the

following scheduling rules: (1) vehicles delivering raw work parts from station 1 to
stations 2,3, and 4 must return empty to station 5; and (2) vehicles picking up finished
parts at stations 2,3, and 4 for delivery to station 5 must travel empty from station 1.
(a) Determine the empty travel distances associated with each delivery and develop a
from-to chart in the format of Table.
(b) The AGVs travel at a speed of 50 m/min and the traffic factor: 0.90. Assume
reliability:100%. From Example .2, the delivery distance Ld: 103.8m. Determine the
value of Le.
(c) How many automated guided vehicles will be required to operate the system?
Solution:
a) Determine the empty travel distances associated with each delivery and develop a
from-to chart in the format of Table
From to chart table:

To 1 2 3 4 5
From 1 0/0
2 0/0
3 0/0
4 0/0
 5 0/0

Deliveries Associated empty trips Frequency Empty distance

1 to 2 2 to 1 9 110
2 to 5 1 to 2 and 5 to 1 9 50+30
1 to 3 3 to 1 5 200
3 to 5 1 to 3 and 5 to 1 3 120+30
1 to 4 4 to 1 6 115
3 to 4 1 to 3 and 4 to 1 2 120+115
4 to 5 1 to 4 and 5 to 1 8 205+30

b) The AGVs travel at a speed of 50 m/min and the traffic factor: 0.90. Assume
reliability:100%. From Example .2, the delivery distance Ld: 103.8m. Determine the
value of Le.

9(50)+5(120)+8(205)+9( 110)+ 5(200)+8(115)+20 (30)

Le = =
42
c) How many automated guided vehicles will be required to operate the system?
Cycle time:
Ld Le
Tc =T L + +T U + (min)
vc Ve
- Available time (AT):
𝐴𝑇 = 60 𝐴 𝐹t= 60.(0.9)(1.0) = 54 𝑚𝑖𝑛/ℎ𝑟
- Delivery rate per hour per vehicle:
AT
𝑅𝑑𝑣 = = (𝑑𝑒𝑙𝑖𝑣𝑒𝑟𝑖𝑒𝑠/ℎ𝑟 per vehicles)
Tc

- Total delivery rate

𝑅𝑓 = 9 + 9 + 5 + 3 + 6 + 2 + 8 = 42 𝑑𝑒𝑙𝑖𝑣𝑒𝑟𝑖𝑒𝑠/ℎ
- the number of vehicles required is:

WT
nc = = (vehicles)
AT
 QUIZ1: Mon
An AGVs has an average loaded travel distance per delivery =400ft. The average empty travel
distance is not known. Required number of deliveries per hour = 60. Load and unload times are
each 0.6 min and the AGVs speed = 125ft/min. Anticipated traffic factor =0.80. Availability
=0.95. Develop an equation that relates the number of vehicles required to operate the system as
a function of the average empty travel distance Le.
Ld = 400 ft
Le ?
Rf =60 del/hr
Tl = Tu = 0.6 min
Vc = 125 ft/min
Ft = 0.8;
A = 0.9;
Solution:
Ld Le
Tc =T L + +T U + (min)
vc Ve

Total ideal cycle time per delivery Tc = 4.4 + Le / 125

AT = 60 A Ft Ew = 45.6 min/hr/vehicle
Rf ∗Tc 60∗(4.4 +¿/125)
nc = = ) = 1.315 (4.4 + Le/125) = 1.315*4.4 + (1.315/125) Le = 5.8 +
AT ¿¿
(1.315/125) Le → Le = (125/1.315)(np - 5.8) ( ft)
QUIZ 1: Wed
Five forklift trucks are used to deliver pallet loads of parts between works cells in the factory
Average travel distance loaded is 400ft, and the travel distance empty is estimated to be the
same. The trucks are driven at an average speed of 3m/hr when loaded and 4.5m/hr when empty.
Terminal time per delivery average 1 min (load =0.5min and unload =0.5min) If the traffic factor
is assumed to be 0.95, availability = 0.95 and work efficiency = 0.90, what is the maximum
hourly delivery rate of the five trucks? (1 m = 3.28 feet)
Solution:
Given data: Number of forklift truck nc = 5
Average travel distance Ld = 400ft,
Le =400ft
Vd = 3 m/hr = 9.84 feet/hr = 9.84/60 feet/min(loaded)
Ve = 4.5 m/hr = 14.76 feet/hr = 14.76/60fett/min (unload-empty)
Loading and unloading time = Tu = TL =0.5 min
Ft = 0.95 ;
A= 0.95,
Ew=0.90
- Ideal cycle time per delivery per vehicle :

Ld Le
Tc =T L + +T U + (min)
vc Ve
Tc = 0.5 + (400/(9.84/60)) + 0.5 + (400/(14.76/60)) = 4066.041 min

- The number of vehicles required is:

WT
nc =
AT
WL = Rf * Tc
WL = nc * AT
Rf * Tc = nc * AT
(nc∗AT ) nc∗(60∗A∗Ft∗Ew)
Rf = =
Tc Tc
AT = 60*A*Ft*Ew = 60 * 0.95 * 0.95 * 0.90 = 48.735
nc∗AT
Rf = = 5 * (48.735/4066) = 0.0599 parts/min = 3.595 parts/hrs
Tc
Therefore,...
QUIZ 1: Friday
Give AGVs layout shown in figure. Vehicle travel counterclockwise around the loop to deliver
loads from the load station. Loading time at the load station = 0.75 min, and unloading time at
the unload station = 0.50 min. It is desired to determine how many vehicles are required to
satisfy demand for this layout if a total of 40del/hr must be completed by the AGVs. The
following performance parameter are given vehicle velocity = 50m/min, Availability = 0.95,
traffic factor =0.90 and operator efficiency does not apply. Determine: (a) travel distance loaded
and empty
Solution:
Tl = 0.75 min
Tu = 0.50 min
Rf = 40 del/hr
Vc = 50m/min
A = 0.95 ;
Ft = 0.90;
Ew = 1
(a) Ignoring effect of shorter distances around the curve at corners of the loop.
Ld = 35 + 40 + 35 = 110 m
Le = 20 + 40 + 20 = 80 m
(b) Ideal cycle time per delivery per vehicle is given by
Ld Le
Tc =T L + +T U + (min)
vc Ve

= 0.75 + 110/50 + 0.50 + 80/50 = 5.05 min

(c) To determine the number of vehicles required to make 40del/hr,
WL = Rf * Tc
WL = 40× (5.05) = 202 min/hr
AT = 60*A*Ft*Ew
AT = 60 × (0.95) × (0.90) × (1.0) = 51.3 min/hr per vehicle
The number of vehicle required is
WT
nc =
AT
= 202/51.3 = 3.94 = 4 vehicles (value should be integer)

*CONVEYOR
 Ld = 35m ,
vc= 40m/min,
np= 20 parts ,
5
TL= 25 sec = min
12
A. The spacing between tote pans along the conveyor:
vc 1 5
= => sc= vc* TLType equation here .= (40 m/min)* ( min)= 16.67 m
sc T L 12

n p v c ( 20 parts )∗( 40 m / min )

B. The flow rate: Rf= = = 48 parts/min
sc ( 16.67 m )
20 parts
The loading rate of 20 parts in 25 sec: RL= =0.8 parts/sec = 48 parts/min
25 sec
Because RL= Rf, the maximum possible flow rate is 48 parts/min
C. The minimum time required to unload the tote pan in the assembly department:
TU ≤ TL = 25 sec

2, A recirculating conveyor has a total length of 700 ft and a speed of 90 ft/min. Spacing of part
carriers = 14 ft. Each carrier holds one part. Automated machines load and unload the conveyor
at the load and unload stations. Time to load a part is 0.10 min and unload time is the same. To
satisfy production requirements, the loading and unloading rates are each 2.0 parts per min.
Evaluate the conveyor system design with respect to the three principles developed by Kwo
• Ld = length of conveyor = 700 ft, vc = 90 ft/min, np = 1, Sc = 14 ft/ carrier
• TL = loading time = TU = Unloading time = 0.1 min
RL =RU= 2 parts/min
(1) Speed rule:
 np vc
Lower limit: ≥ Max { RL,RU}
sc

( 1 parts/carrier )∗( 90 ft / min )

= 6.43 parts/min ≥ Max{2,2} = 2 ( satisfied)
( 14 ft /carrier )
vc 1 1
Upper Limit: ≤ Min{ , }
sc T L TU

( 90 ft / min ) 1 1
= 6.43 carrier/min ≤ Min{ , } = Min{ 10, 10} = 10-> (satisfied)
( 14 ft /carrier ) 0.1 0.1

So, the speed rule is satisfied

(2) Capacity constraint: In this case, The required loading and unloading rates are both
defined by the specified flow rate : Rf= RU= RL= 2 parts/min
np vc
≥ Rf
sc
( 1 parts/carrier )∗( 90 ft / min )
= 6.43 parts/min ≥ 2 parts/min ( satisfied)
( 14 ft /carrier )
So, the capacity constraint is satisfied
(3) Uniform principle: the conveyor is assumed to be uniformly loaded throughout its
length since RL =RU and the flow rate capacity (=25 parts/min) is significantly greater
than RL and RU.
Conclusion: the system is feasible

3, A closed loop overhead conveyor must be designed to deliver parts from one load station to
one unload station. The specified flow rate of parts that must be delivered between the two
stations is 600 parts/hr. The conveyor has carriers spaced at a center-to center distance that is to
be determined. Each carrier holds two parts. Forward and return loops will each be 135 m long.
Conveyor speed = 0.75 m/sec. Times to load and unload parts at the respective stations are each
= 9 sec. Is the system feasible and if so, what is the appropriate number of carriers and spacing
between carriers that will achieve the specified flow rate?
Rf= 600 parts/hr = 0.167 parts/sec , Ld=Le= 135 m , vc= 0.75 m/ sec, TU= TL= 9 sec
np= 2 parts/ carrier
n p v c ( 2 parts/carrier )∗( 0.75 m/sec )
We have the flow rate: Rf= = = 0.167 parts/sec (1)
sc sc

( 0.167 parts /sec)

From (1) , The spacing between carriers is : sc = = 0.11
( 2 parts /carrier )∗( 0.75 m/sec )
( m/carrier)
 1
We have: Rf ≤
TL

1
0.167 ≤
TL

1
 TL ≤ = 6 (sec)
0.167
L 135+135
The total number of carriers: nc= = = 2454.54( carriers)
sc 0.11
The system is feasible
4, An overhead trolley conveyor is configured as a closed 1oop. The delivery loop has a length
of 150 m and the return loop is 100 m. All parts loaded at the load station are unloaded at the
unload station. Each hook on the conveyor can hold one part and the hooks are separated by 3 m.
Conveyor speed : 0.3 m/sec. Determine
a) Number of parts in the conveyor system under normal operations,
b) parts flow rate; and
c) Maximum loading and unloading times that are compatible with the operation of the conveyor
system.
Ld= 150 m, Le= 100 m, sc= 3 m/ carrier , vc= 0.3 m/sec, np= 1 part/carrier
A, Total length of conveyor: L= Ld+Le= 150+100= 250 (m)
L 250 m
Total number of carriers: nc= = = 83.3 (carriers)
sc 3m
n p nc Ld ( 1 parts/carrier )∗( 83.3 carriers )∗(150 m)
Number of parts in the conveyor = = = 49.98
L ( 250 m )
parts
B,Parts flow rate:
n p v c ( 1 parts/carrier )∗( 0.3 m/sec )
Rf= = = 0.1 parts/ sec
sc (3 m/carrier )
C, Maximum loading and unloading times are:
Ld 150 m
Td= = = 500 sec
v c 0.3 m/sec

5, A 300-ft long roller conveyor operates at a velocity : 30 ft/min and is used to move parts in
containers between load and unload stations. Each container holds 20 parts. One worker at the
load station is able to load parts into containers and place the containers onto the conveyor in 30
sec. It takes 20 sec to unload at the unload station. Determine
 (a) center-to-center distance between containers,
(b) number of containers on the conveyor at one time, and
(c) hourly flow rate of parts. (d) By how much must conveyor speed be increased in order
to increase flow rate to 3,600 parts/hr?
Ld= 300 ft ,
vc= 30 ft/min,
TU= 30 sec = 0.5 min,
TL=20 sec= 0.33 min
np= 20 parts/ container
a, center-to-center distance between containers:
vc 1
Rf= RL= ≤ => sc= T L∗v c = (0.33 min) *(30 ft/min)= 9.9 ft/container
sc T L

L 300 m
B, number of containers on the conveyor at one time: nc= = = 100 containers
sc 3m
C, ) hourly flow rate of parts:
n p v c ( 20 parts/container )∗( 30 ft /min )
Rf= = = 60.6 parts/min= 3636 parts/hr
sc (9.9 ft /container )
D, increasing flow rate to 3,600 parts/hr, The conveyor speed is:
Vc= Rf *sc = (3600 parts/hr) ( 9.9 ft) = 35640 ft/hr
6, A roller conveyor moves tote pans in one direction at 300 ft/min between a load station and an
unload station, a distance of 450 ft. With one worker, the time to load parts into a tote pan at the
load station is 5 sec per part. Each tote pan holds 15 parts. In addition, it takes 12 sec to load a
tote pan of parts onto the conveyor. Determine
(a) spacing between tote pan centers flowing in the conveyor system and
(b) flow rate of parts on the conveyor system.
(c) Consider the effect of the Unit Load Principle. Suppose the tote pans were smaller and
could hold only one part instead of 15. Determine the flow rate of parts in this case if it takes 5
sec to load a tote pan onto the conveyor (instead of 12 sec for the larger tote pan), and it takes the
same 5 sec to load the part into the tote pan.

Ld= 450 ft , vc= 300 ft/min , TL=( 5*15+12) sec= 87 sec= 1.45 min/tote pan
np= 15 parts/tote pan
a, spacing between tote pan centers flowing in the conveyor system:
sc= T L∗v c = (1.45 min/tote pan) *(300 ft/min)= 435 ft/tote pan
b, flow rate of parts:
n p v c ( 15 parts/tote pan )∗(300 ft /min )
Rf= = = 10.35 parts/ min
sc ( 435 ft /container )
C, The delivery time on the forward loop: TL= 5*15 +5= 80 sec/tote pan= 1.33 min/tote pan
Center-to-center spacing between tote pan centers flowing in the conveyor system :
sc= T L∗v c = (1.33 min/tote pan) *(300 ft/min)= 399 ft/tote pan
n p v c ( 15 parts/tote pan )∗(300 ft /min )
flow rate of parts: Rf= = = 11.28 parts/ min
sc (399 ft /container )