Chapter 5

Material Handling
BY: JOSH CONLEY
Introduction

Without proper handling techniques, the product will never achieve

full potential.
Systems have been put in place to minimize defects.
Having the proper equipment can increase product value.
It requires the proper systems in order to produce quality products.
Scope and Definitions of Material
Handling
Material handling usually accounts for:
25% employees
55% factory space
87% production time
15-70% cost of product
The handling phase is one that can be greatly improved upon by
eliminating movement.
Definitions

Material handling involves:

Movement
Storage
Control
Protection of goods throughout process
Material handling is both a science and an art.
Definitions (Continued)

Proper material handling includes having the right:

Amount
Material
Condition
Sequence
Orientation
Place
Time
Cost
Method
Scope of Material Handling

The three views of material handling:

Conventional
Contemporary
Progressive
Material Handling Principles

There are ten principles of material handling:

Planning
Standardization
Work
Ergonomic
Unit load
Space utilization
System
Automation
Environmental
Life Cycle Cost
Material Handling Checklists

Checklists have been made to better material handling.

These are check sheets that can show if there are better
opportunities in the process.
It shows that everything has been accounted for.
These checklists include:
Supervisory attention
Management attention
Analytical study
Capital investment
Designing Material Handling
Systems
Six-step engineering design process:
1.) Define objectives and scope
2.) Analyze the requirements
3.) Generate alternative designs
4.) Evaluate alternative designs
5.) Select proffered design
6.) Implement design
Developing Alternative Material
Handling System Designs
Ideal systems approach
1.) Aim for the most ideal system
2.) Conceptualize the system
3.) Design a working technology system
4.) Install the system
The Material Handling System
Equation
Materials + Moves + Methods = Recommended System
Ask questions about the materials and their handling in the form of:
What
Where
When
How
Who
Which
Material Handling Planning Chart

This is a chart that is used to detect a problem in the handling

process.
It is broken into:
Operation
Transport
Storage
Inspection
This is to show where the fault is located in the chart.
Unit Load Design

Unit load is an item(s) that is too large to be handled or either too

many items to hold.
These are to be arranged into a single mass to be easily transported.
The most common methods of movement is:
Picking up underneath
Inserting a lifter into the unit
Squeezing and moving the load
Suspending in air
Efficiency of Returnable Containers

When choosing the method of movement, the best method should

be chosen.
This can be done efficiently by knowing the:
Container space needed
Storage space provided
Container nesting ratio
Container stacking requirements
Trailer return rate
Unit Load Interactions with
Warehouse Components
Two main factors are specifications of carton and pallet size.
These determine the:
Equipment used
Pattern of storage
Configuration of facility
Material Handling Equipment

The four main categories of material handling equipment include:

Containers and unitizing
Material transport
Storage and retrieval
Automatic data collection and communication
Each of these four parts are broken into more specific types of each
category.
Material Handling Equipment
Classifications
Once each of the previous categories have been classified, they
are broken down again to get the most classifications as possible.
There are many options and the designer should have access to
knowing them all.
Different alternatives can be seen this way.
The best option can then be chosen.
Estimating Material Handling Costs

Knowing the costs of different methods is crucial to making the most

efficient process.
With cost fluctuation today, it is hard to be certain of prices.
Use of a complex pricing model is best to see best option.
The end result is one that should be most optimal for the operations.
Safety Considerations

Safety should be the number one concern when planning any part
of a facility.
The key to this is a good interface between workers and the
equipment.
If the equipment is in a proper location, with adequate safety
precautions, there should be no injury.
However due to human error, there will be some.
This should be taken into consideration and be avoided at all costs.
Summary

Proper material handling can achieve a much more cost efficient

facility.
Choosing the right equipment and storage is crucial.
Poor material handling can be devastating to the end product.
Safety is a main concern when designing this process.