MATERIAL
HANDLING
WEEK 1
What is material handling????
al Handling is the movement, storage, control and
ion of materials, goods and products throughout t
s of manufacturing, distribution, consumption and
l. The focus is on the methods, mechanical equipm
s and related controls used to achieve these functi
terial handling industry manufactures and distrib
uipment and services required to implement mater
ng systems. Material handling systems range from
ack and shelving projects, to complex conveyor be
ated Storage and Retrieval Systems (AS/RS).
al handling can also consist of sorting and picking
as automatic guided vehicles.
MATERIAL HANDLING
Material
handling is
the function of moving
the right material to
the right place in the
right time, in the right
amount, in sequence,
and in the right
condition to minimize
MATERIAL HANDLING
A
material-handling system
can be simply defined as an
integrated system involving
such activities as handling,
storing, and controlling of
materials.
The
word material has very
broad meaning, covering all
kinds of raw materials, work
Objectives
Main objective is to reduce the number
of handlings as well as the overall cost
of material handling equipment and
reducing the distances through which
the materials
are Costs
handled.
1) Reduced
2)
Increased Capacity
3)
Improved Working Condition
4)
Value Addition to Products
In brief, the primary objectives of Material Handling are;
1. To save money
2. To save time
3. To save men
objectives
primary
objective of using a
material handling
system is to ensure
that the material in the
right amount is safely
delivered to the
desired destination at
The
Objectives
The
material handling
system is properly
designed not only to
ensure the minimum cost
and compatibility with
other manufacturing
equipment but also to meet
safety concerns.
The cost of MH estimates
Other Objectives
Lower unit material handling costs
Reduction in manufacturing cycle time through
faster movement of materials and by reducing the
distance through which the materials are moved.
Reduction in manufacturing cycle time results in
reduced work in progress inventory costs.
Improved working conditions and greater safety in
movement of materials
Contribute to better quality by avoiding damage to
products by inefficient handling
Increased storage capacity through better
utilisation of storage areas
Higher productivity at lower manufacturing cost
GOALS OF MATERIAL HANDLING
The
primary goal is to
reduce unit costs of
production
Maintain
or improve
product quality, reduce
damage of materials
Promote
safety and
improve working
GOALS OF MATERIAL HANDLING
Promote
increased use
of facilities
Reduce
tare weight
(dead weight)
Control
inventory
GOALS OF MATERIAL HANDLING
Promote
productivity
material should flow in a
straight line
use gravity! It is free
power
move more material at
one time
mechanize material
GOALS OF MATERIAL HANDLING
Material
handling equipment
includes:
Transport Equipment:
industrial trucks, Automated
Guided vehicles (AGVs),
monorails, conveyors, cranes
and hoists.
Storage Systems: bulk
storage, rack systems,
shelving and bins, drawer
storage, automated storage
Scope of Material handling:
Manufacturing
Processing
Construction
Mining
Power
Machine Tools
Truck building
Rail road car builders
Barge and Ship building
Aircraft
Importance of M H
Efficient material handling is important to
manufacturing operations. Materials sent by vendors
must be unloaded, moved through inspections and
production operations to stores and finally to the
shipping department.
These movements do not add value to the product but
they do add value to the cost
Material handling is an integral part of any industrial
activity. With growing business, a greater emphasis is
laid on productivity, profitability as well as resource
conservation and ecological preservation. Material
handling plays a very crucial role in sustaining
efficiency in financial and human resources.
Importance of M H
Material handling analysis is a subset of
plant layout. Method study, plant layout
and material handling are all part of the
design of a production facility
Material handling system and plant layout
enhance effectiveness of each other.
Efficient operation of appropriate
material handling methods reduces costs
and enables maximum capabilities to be
derived from a given production facility
CONSIDERATIONS IN MATERIAL
HANDLING SYSTEM DESIGN
1. Material Characteristics
Category
Physical state
Size
Weight
Shape
Condition
Safety risk and risk of
damage
Measures
Solid, liquid, or gas
Volume; length, width, height
Weight per piece, weight per
unit volume
Long and flat, round, square,
etc.
Hot, cold, wet, etc.
Explosive, flammable, toxic;
fragile, etc.
2. Flow rate
Quantity of
material
moved
High
Conveyor
s
Manual
Low handling
Hand trucks
Short
Conveyor
s
AGV train
Powered
trucks
Unit load
AGVLong
Move Distance
3. Plant Layout
Layout Type
Characteristics
Typical MH
Equipment
Fixed position
Large product size,
low production rate
Cranes, hoists,
industrial trucks
Process
Variation in product
and processing, low
and medium
production rates
Hand trucks, forklift
trucks, AGVs
Product
Limited product
variety, high
production rate
Conveyors for
product flow, trucks
to deliver
components to
stations.
THE PLANNING PRINCIPLE
Large-scale material
handling projects usually
require a team approach.
Material handling planning
considers every move, every
storage need, and any delay
in order to minimize
production costs.
The plan should reflect the
strategic objectives of the
THE SYSTEMS PRINCIPLE
MH and storage activities should be fully
integrated to form a coordinated,
operational system that spans
receiving, inspection, storage,
production, assembly, shipping, and
the handling of returns.
Information flow and physical
material flow should be integrated and
treated as concurrent activities.
Methods should be provided for easily
identifying materials and products,
for determining their location and
SIMPLIFICATION PRINCIPLE
simplify handling by reducing,
eliminating, or combining
unnecessary movement and/or
equipment.
Four questions to ask to simplify any
job:
Can this job be eliminated?
If we cant eliminate, can we
combine movements to reduce cost?
(unit load concept)
If we cant eliminate or combine, can
we rearrange the operations to
GRAVITY
PRINCIPLE
Utilize gravity to move material
whenever practical.
SPACE
UTILIZATION
PRINCIPLE
The better we use our building cube,
the less space we need to buy or rent.
UNIT LOAD
PRINCIPLE
Unit loads should be
appropriately sized and
configured at each stage of
the supply chain.
The most common unit load
is the pallet
cardboard pallets
plastic pallets
AUTOMATION PRINCIPLE
MH operations should
be mechanized and/or
automated where
feasible to improve
operational efficiency,
increase responsiveness,
improve consistency and
predictability, decrease
operating costs.
THE
STANDARDIZATION
PRINCIPLE
standardize handling methods
as well as types and sizes of
handling equipment
too many sizes and brands of
equipment results in higher
operational cost.
A fewer sizes of carton will
EQUIPMENT SELECTION
PRINCIPLE
Why? What? Where? When? How?
Who?
If we answer these questions about
each move, the solution will become
evident.
THE MAINTENANCE
PRINCIPLE
Plan for preventive maintenance and
scheduled repairs of all handling
equipment.
THE DEAD WEIGHT
PRINCIPLE
Try to reduce the ratio of
equipment weight to product
weight. Dont buy equipment that
is bigger than necessary.
Reduce tare weight and save
money.
THE CAPACITY
PRINCIPLE
use handling equipment to help
achieve desired production
TYPES OF MATERIAL HANDLING EQUIPMENT
Conventional Material Handling Equipment
1. Storage Equipment
2. Bulk Material Handling
3. Industrial Trucks
Conventional Material Handling Equipment
1. Robotic Delivery System
2. Computer Controlled Conveyor System
3. Automated Guided Vehicles
MATERIAL HANDLING EQUIPMENT
Industrial
trucks include hand
trucks such as two-wheeled, fourwheeled, hand lift, and forklift
and powered trucks such as
forklift, tractor-trailer trains,
industrial crane trucks, and side
loaders.
Conveyors
such as belt, chute,
roller, wheel, slat, chain, bucket,
trolley, tow, screw, vibrating, and
pneumatic.
MATERIAL HANDLING EQUIPMENT
Automated
guided vehicle
systems such as unit load
carriers, towing, pallet
trucks, fork trucks, and
assembly line.
Automated
storage and
retrieval systems (AS/RS)
such as unit load, miniload, person-on-board,
Types of Material Handling
Equipment
Basically there are three types of
materials handling equipments.
1.
Static
Platforms
Pallets
Still ages
2. Fixed Types
Flat Conveyors
Roller Conveyors
Wheel Conveyors
Trolley
Conveyors
Bridge Crane
Electricity Hoist
Jib Crain
Chain Hoist
Gantry Crane
3. Vehicles
Pallets Trucks
Fork lift trucks
Industrial Vehicles
Pros and Cons of Using Material Handling Equipment
PROS:
CONS:
Lessen manual labor.
Require
Less shipping errors.
Minimal damage on
goods and materials.
Less shipping and
production costs.
Lessen employees
compensation claims
therefore allows you to
save more in the long
run.
fast data tracking and
processing.
Require
reliable and fool-proof
inventory management system.
Require
more free floor spaces
so that equipment can move
properly.
Buying
your own material
handling equipment may require
you to raise bigger funds or
initial capital.
Require
you to set aside funds
for maintenance and repair.
Factors Affecting the selection of
Material Handling Equipment
Adaptability
Flexibility
Load capacity
Power
Speed
Space requirements
Supervision required
Ease of maintenance
Environment
Cost
THANK YOU
