MATERIAL HANDLING

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 production 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 conditions
Promote productivity

material should flow in a straight line

use gravity! It is free power
move more material at one time
mechanize material handling
automate material handling

Goals of Material Handling

Promote increased use of facilities
Control inventory

Overview of Material Handling Equipment

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 systems.
Unitizing Equipment: palletizers
Identification and Tracking systems

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.

Considerations cont.
2. Flow rate
Quantity of
material
moved

High
Low

Conveyors

Conveyors
AGV train

Manual handling
Hand trucks

Powered trucks
Unit load AGV

Short

Long

Move Distance

Considerations cont.
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

Limited product variety, high

production rate

Conveyors for product flow,

trucks to deliver components to
stations.

Product

Principles of Material Handling

1. 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
organization as well as the more immediate needs.

2. 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 status within facilities and within the supply chain.

3.

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 reduce the travel distance?
If we cant do any of the above, can we simplify?

4. Gravity principle
Utilize gravity to move material whenever practical.

5. Space utilization principle

The better we use our building in cube, the less space
we need to buy or rent.
Racks, mezzanines, and overhead conveyors are a few
examples that promote this goal.

6. 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
wooden pallets
steel skids

8. 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.
Automated Storage and Retrieval
System (ASRS or AS/RS) is a perfect example.

10. Equipment selection principle

Why? What? Where? When? How? Who?
If we answer these questions about each move, the
solution will become easily seen or understood.

11.

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 simplify the storage.

12. 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.

13. The maintenance principle

Plan for preventive maintenance and scheduled repairs of all

handling equipment.
Pallets and storage facilities need repair too.

14. The capacity principle

use handling equipment to help achieve desired production

capacity
i.e. material handling equipment can help to maximize production
equipment utilization.

Example
A punch press can cycle every 0.03 minute, but our time
standard for manually loading and unloading this press is
only 300 pieces per hour.

Press capacity = 60 min / 0.03 = 2000 pieces/hr

Utilization = 300 / 2000 = 15%
Should we buy a new press?
If we can purchase a coil-feeding material handling
system, we could approach 100% press utilization.

MATERIAL HANDLING EQUIPMENT

1. Conveyors
Belt conveyorsairport baggage handling
Chain/cable conveyorscoal mines
Gravity roller conveyorspower plant coal handling
system
Live roller conveyorsPetroleum companies
Elevating conveyorsfertilizer factories
Screw/spiral conveyorscement factories
Pipeline conveyors

MATERIAL HANDLING EQUIPMENT

2. Cranes

Fixed cranessteel factory

Travelling cranesturbine shop
Electric hoistautomobile factories
Winches and capstans

MATERIAL HANDLING EQUIPMENT

3. Mobile
Industrial vehicles
Fixed platform type
Lift platform typeto transport bricks, books, etc.
Fork lift trucks

Motor vehicles or trucksto transport petroleum products

Rail road cars or goods trainto transport coal, ores, sheet,
rods, etc.
Cargo shipsto carry oil, food supply, etc.
Cargo planesto transport passengers baggage, equipment, etc.