Lecture for Module ThreeUnit Loads

A unit load is a combination of items into a single mass that can be moved as one unit. It must not exceed the size, weight, and economic constraints of the system that handles it.1. Size constraints are determined by the minimum door openings through which the unit load must pass, the area in which the unit load will be stored, and the type of truck on which the unit load will be transported.2. The maximum weight allowance is determined by the weakest link in the material handling system that will be transporting the unit load.3. The economic constraint (or maximum quantity) is determined by how much inventory the company is willing to purchase and transport at one time. In most cases, companies will not purchase more than a two month supply of any item in advance of need.There are four general considerations for the design of a unit load:1. Materials should be assembled into a unit load at the first possible opportunity.2. The unit load should be as large as possible without exceeding the physical limitations of the building (door heights, aisle widths, rack sizes), the material handling equipment, and the interior dimensions of the common carrier on which it will be transported between plants.3. The unit load should minimize the number of times the product is handled.4. The unit load should be maintained as long as possible.In addition to the above general design considerations, there are also a variety of specific questions that must be answered in order to properly select an effective design for the unit load:1. What is the size of the item?2. What is the weight of the item?3. Is the item of an unusual or irregular shape?4. Is the item loose or is it already packaged inside a container of some type?5. Can the items be stacked without crushing? If so, how high can they be stacked?6. How will the items be shipped (boat, rail, or truck)?7. Does the item require special temperature or humidity controls?There are five basic options for creating the unit load:1. A large self-contained unit: This type of load is feasible when the unit is exceptionally large or heavy. Examples would be automobiles, refrigerators, and washing machines. These loads are handled one item at a time.2. Bulk containers: Used to unitize bulk materials, such as powders, granular substances, or liquids. They may be either open or closed, and are made of rubber, plastic, metal, wood, or cardboard. They may or may not be lined with a plastic interliner. Some containers are stackable and some are reusable. The most common dimensions for bulk containers are:

3. Tote box or container: Any size of container that is used to transport two or more items at the same time. The items may be neatly arranged inside the container or randomly jumbled together. These containers may be made of wood, plastic, metal, wire, or cardboard. Most can be stacked. They provide a method for consolidating a lot of small parts into one unit and they also provide protection for the parts.4. Portable rack: A frame-like structure with dimensions that correspond to the materials stored on it. The rack may or may not have wheels. A common example would be the wheeled rack used to move bread into a grocery store so it can be stacked on the store shelves.5. Pallet: A horizontal platform used as a base for assembling, transporting, storing, and handling materials as a unit load. It usually consists of one or two flat surfaces separated by cross members. The criteria for selecting the optimal pallet size are:

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