MATERIAL HANDLING

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 Introduction
• Material handling can account for 30-75 % of the
total cost
• If we have efficient material handling, we can
primarily responsible for reducing a plant's
operating cost by 15-30 %.

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 1.1 Definition
• 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.
 MH is loading, moving & unloading of mts. or
 MH is the art & science involving the moving,
packaging and storing of substances in any form.
 It helps production, but not a production process

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 1.2 Objectives of Material Handling
• The primary goal is to reduce unit costs of
production
• To increase the efficiency of material flow by
ensuring the availability of materials when and
where they are needed.
• To improve facilities utilization.
• To improve safety and working conditions.
• To facilitate the manufacturing process.

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 Objectives cont….

• To increase 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

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 Functional Scope of MH
1. Bulk mtl and unit load material handling
 Bulk mtl : relevant in the processing, mining and
construction in industries.
 Unit load: handling of formed mrls in the initial,
intermediate and final storage.
2. Industrial packaging
3. Handling of mrls from storage or warehouse.

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 1.3 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.

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 MH EQUIPMENT TYPES

All Equipments in MH are classified in three main

types, i.e
1. Conveyors:
Conveyors are used for moving materials
continuously over a fixed path. Examples of
different conveyors are; roller, belt, & chute
conveyors

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 Conveyors

Belt type

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 Screw Type

Gravity Type

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 Chutes

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 Large Conveyors (2 axis)

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 MH EQUIPMENT TYPES (Cont..)

2. Cranes & Hoists

Cranes & Hoists are items of overhead
equipment for moving loads intermittently within
a limited area. Bridge cranes, monorail cranes, &
hoists are examples of this basic equipment type

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 Crane
Cable Crane
Overhead Crane

Rotary Crane Gantry crane

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 Lifts

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 MH EQUIPMENT TYPES (Cont..)
3. Trucks
Hand or Powered Trucks move loads over varying paths
Examples of such Trucks include Lift Trucks, Fork Trucks,
Trailer Trains, & Automated Guided Vehicles(AGVs)
• They are not require to follow a fixed path of movement &
therefore can be used any where on the floor where space
permits

• They are capable of loading, unloading, & lifting, in addition

to transferring material

• Because of their unrestricted mobility, which allows them to

serve different areas, trucks can achieve high utilization

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 Con‘t’d

• They cannot handle heavy loads

• They limited capacity per trip
• Aisles are require; other wise the trucks will
interfere with the work on the floor
• Most trucks have to be driven by an operator
• Trucks do not allow handling to be combined with
processing & inspection, as other type of eqpt do

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 MH EQUIPMENT TYPES (Cont..)

3. Trucks
Lift Trucks:

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 Tracks - Monorail

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 Lift truck
Computer Controlled Truck

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 Counter Balance AGV

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 Considerations in Material Handling System
Design
1. Material Characteristics

Category Measures
Physical state Solid, liquid, or gas
Size Volume; length, width, height
Weight Weight per piece, weight per unit volume
Shape Long and flat, round, square, etc.
Condition Hot, cold, wet, etc.
Safety risk and risk of Explosive, flammable, toxic; fragile, etc.
damage
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 Considerations …cont.

2. Flow rate
Quantity of
material
moved

Conveyors Conveyors
High AGV train

Manual handling Powered trucks

Low
Hand trucks Unit load AGV

Short Long Move Distance

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 Considerations …cont.
3. Plant Layout
Layout Type Characteristics Typical MH Equipment

Fixed – position Large product size, low Cranes, hoists, industrial

production rate trucks

Process Variation in product and

processing, low and medium Hand trucks, forklift trucks,
production rates AGVs

Product
Limited product variety, Conveyors for product flow,
high production rate trucks to deliver
components to stations.

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 1.4 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.

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 Principles cont…
2. The systems flow
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.

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 Principles cont…
3. Simplification
– 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 can’t eliminate, can we combine movements to
reduce cost? (unit load concept)
• If we can’t eliminate or combine, can we rearrange the
operations to reduce the travel distance?
• If we can’t do any of the above, can we simplify?

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 Principles cont…
4. Material flow
Provide an operation sequence and equipment layout
optimizing material flow.
5. Gravity principle
Utilize gravity to move material whenever practical.
6. Space utilization principle
– The better we use our building cube, the less space we
need to buy or rent.
– Overhead conveyors are a few examples that promote
this goal.

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 Principles cont…
7. Unit load (size) 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

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 Principles cont…
8. Mechanization
Mechanize handling operations.
9. 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.

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 Principles cont…
10.Equipment selection principle
– In selecting handling equipment, consider all aspects of
the material handled, the movement, and the method to be
used.
• Why? What? Where? When? How? Who?
• If we answer these questions about each move, the solution will
become evident.
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.
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 Principles cont…
12. Adaptability
– Use methods and equipment that can best perform a
variety of tasks and applications when special purpose
equipment is not justified.
13. The dead weight principle
– Try to reduce the ratio of equipment weight to product
weight. Don’t buy equipment that is bigger than
necessary.
– Reduce tare weight and save money.
14. Utilization
– Plan for optimum utilization of handling equipment
and manpower.

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 Principles cont…
15. The maintenance principle
– Plan for preventive maintenance and scheduled
repairs of all handling equipment.
– Pallets and storage facilities need repair too.
16. Obsolescence
– Replace obsolete handling methods and equipment
when more efficient methods of equipment will
improve operations.
17. Control
– Use material handling activities to improve control of
production, inventory and order handling.

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 Principles cont…
18. The capacity principle
– use handling equipment to help achieve desired
production capacity
– i.e. material handling equipment can help to maximize
production equipment utilization.
19. Performance
– Determine the effectiveness of handling performance
in terms of expense per unit handled.
20. Safety
– Provide suitable methods and equipment for safe
handling.

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 Material Handling System Equation

WHY?

WHAT? WHERE? WHEN? HOW? WHO? WHICH?

PREFERED
MATERIALS + MOVES + METHODS = SYSTEM

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 End!!!

Thank you !!!

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All the best!!!

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