Material Handling

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MATERIAL HANDLING
Definition of material handling Material handling is defined as the art and science of moving, packaging and storing of substances in a form. Other definitions include: a) Creation of time and place utility b) Movement and storage of material at the lowest possible cost through the use of proper methods and equipments. c) Lifting, shifting and placing of material which effect in a saving in money, time and place. d) Art and science of conveying, elevating, packaging and storing of materials.
SCOPE OF MATERIALS HANDLING

The scope of materials handling activity within an organization depends on the type of product manufactured, the size of organization, the value of the product and the value of the activity being performed and the relative importance of materials handling to the enterprise. There are three perspectives about materials handling viz: a) The traditional point of view. b) Plant wide concern for overall flow of materials. c) The system point of view. In the traditional point of view of materials handling, the emphasis is on the movement of materials from one location to another within the confines of the individual plant. The concern is to find the best way to move the materials from one place to another within the planrt.
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Plant wide concern focuses the attention on the overall flow of materials in the plant. The main concern is te hinter-relationship between all the handling problems and the possibility of establishing an overall materials handling plan. The systems point of view of material handling requires visualization of material handling problems, the physical distribution activities, and all closely related functions as one, an all encompassing system. This point of view involves a much broader considerations of materials handling activities involving the movement of material from all sources of supply (vendors), all handling activities witin and around the plant and the activities involved in the distribution of finished goods to all customers of thr firm.
IMPORTANCE OF MATERIAL HANDLING

1. Efficient materials 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 departments. This movements donot add value to the product but, they do add to the cost. 2. materials handling analysis is a subset to plant layout and materials handling are all part of design of a production facility and can hardly be treated as separate. Materials handling system and plant, enhance effectiveness of each other. A good plant layout enables an operation to use the most effective handling method. Efficient operation of appropriate materials handling methods reduces costs and enables maximum capabilities to be derived from a given production facility.
OBJECTIVES OF MATERIALS HANDLING

Even though the best solution to the materials handling problem, is no handling, it is hardly practicable in the manufacturing process. Hence, the main objective of materials handling is to reduce the number of handling equipments and reducing the distances through which the materials are handled. Other objectives of materials handling are: 1. lower unit materials handling costs. 2. reduction in the manufacturing cycle time through faster movements 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. 3. contribution towards a better control of the flow of materials through the manufacturing facility. 4. improved working conditions and the greater safety in the movement of materials. 5. contribute to better quality by avoiding damage to products by inefficient handling. 6. increases storage capacity through better utilisation of storage areas. 7. higher productivity at lower manufacturing cost.
MATERIAL HANDLING PRINCIPLES

Certain principles have evolved to guide facility layout to ensure efficient handling of materials. Although, there are no hard and fast rules, they do provide effective guidelines for the efficient movement of materials in most facility layouts. Principle 1: Materials should move through the facility in direct flow pattern, minimizing zigzagging or backtracking.
Principle 2: Related production processes should be arranged to provide for direct material flows. Principle 3: Mechanized materials handling devices should be designed and located so that human effort is minimized. Principle 4: Heavy and bulk materials should be moved the shortest distance during processing. Principle 5: The number of times each material is handled should be minimized. Principle 6: Systems flexibility should allow for unexpected breakdowns of materials handling equipments, changes in production system technology, etc. Principle 7: Mobile equipments should carry full loads all the times. These seven principles can be summarized as follows: 1. Eliminate Handling: If not, make the handling distance as short as possible. 2. Keep Moving: If not, reduce the time spent at the terminal points of a route as short as possible. 3. Use simple patterns of material flow (the simplest path is a straight line path of flow which minimizes the handling distance between two points). If not, reduce backtracking, crossovers and other congestion producing patterns as much as possible. 4. Carry pay loads both ways: If not, minimize the time spent in transport empty by speed changes and route locations. 5. Carry full loads: If not, consider increasing the size of unit loads, decreasing carrying capacity, lowering speed, or acquiring more versatile equipment. 6. Use Gravity: if not, try to find another source of power that is reliable and inexpensive.
In addition to the above guidelines, there are certain other very important aspects of materials handling, such as the following: a. Materials handling consideration should include the movement of men, machine, tools and information. b. The flow system must support the objectives of receiving, sorting, inspecting, inventorying, accounting, packaging and assembling. Since the consideration and objectives do conflict, it is essential to take a systems decision followed by delicate diplomacy to establish a material movement plan that meets service requirement without subordinating safety and economy.
MATERIAL HANDLING COSTS

The costs of materials handling arise from two sources: 1. the cost of owning and maintaining equipment. 2. the cost of operating the system. While the costs of owning the equipment are generally known since entries are available in the books of accounts, the cost of operating the handling system are hard to pin down as records are not generally maintained. Every effort has to be made to reduce materials handling costs, particularly because they do not add any value to a product. The product will not be worth any more toi the consumer simply because it was moved, but it will still cost the consumer more.
How to reduce handling costs? There are three fundamental ways of minimizing the costs: a) eliminating the handling itself whenever and wherever possible. b) Mechanizing, largely by conveyors and power driven trucks, whatever handling still remains. c) Making the necessary handling more efficient. Primary requisite for any action to be taken towards minimizing handling costs is to have a record maintained for them. It is here that majority of the companies are not doing the right thing. Factors affecting the selection of materials handling equipments The selection of materials handling equipments requires consideration of and attaining of proper balance between the following factors: i. ii. iii. Production problem. The capabilities of the handling equipment available. The human element involved.
The ultimate aim is to arrive at the lowest cost per unit of materials handled. (i) The production problem factors are: a. Volume of the production t obe attained. b. Class of materials to be handled. c. The layout of plant and building facilities. For example: the handling equipment which can be economically justified for the manufacture of 1000 TV sets per day would be entirely different from the handling equipment needed in a plant
manufacturing 20 steam turbine generators I na year as the production rate, weight and class of materials needed are different. (ii) Capabilities of the handling equipments available are: a. Adaptability: The load carrying and movement characteristics of the equipment should fit the material-handling problem. b. Flexibility: Wherever possible, the equipment should have the flexibility to handle more than one material, class or size. c. Load Capacity: Equipment selected should have enough load-carrying characteristics to do the job effectively. d. Power: The equipment should have enough power available to do this job. e. Speed: The speed of movement of the handling equipment should be as high as possible, within the limits of production process and plant safety. f. Space Requirements: The required to install or operate materials handling equipment is also an important consideration. g. Supervision required: The degree of automation in the handling equipment decides the amount of supervision required. h. Ease of maintenance: Equipment selected should be capable of easy maintenance at reasonable cost. i. Environment: Equipment selected must conform to any environmental regulations. j. Cost: The cost of the equipment (capital investment) is an obvious factor in the selection. The various kinds of costs to be considered in addition to the initial purchase price of the handling equipment are: a. Operating Costs b. Installation Costs c. Maintenance Costs d. Power Requirements e. Insurance Requirements f. Space Cost
g. Depreciation Cost h. Salvage Value i. Time Value of money invested j. Opportunity Cost (iii) The human elements/factors cannot be overlooked in the selection of materials handling equipment. They are: a. The capabilities of the available manpower to operate the equipment. b. Safety of personnel (those who operate it or come in contact with it)
TYPES OF MATERIAL HANDLING SYSTEMS

The materials handling systems can be classified according to the type of handling equipment used, type of material handled and the methods, need or functions performed. The Classifications are: 1. Equipment oriented systems depending upon the type of equipment used. They are: a) Overhead Systems b) Conveyor Systems c) Tractor Transfer Systems d) Fork-lift Truck and Pallet Truck Systems e) Industrial Truck Systems f) Underground Systems 2. Material oriented systems consisting of the following types: a) Unit handling Systems b) Bulk Handling Systems
c) Liquid handling Systems 3. Method oriented systems can be of the following types: a) Manual Systems b) Mechanized or automated Systems c) Job-Shop Handling Systems d) Mass Production Handling Systems 4. Function oriented Systems: a) Transportation systems b) Conveying Systems c) Transferring Systems d) Elevating Systems The materials handling equipments are classified into four basic types, viz. conveyors, cranes and hoists, trucks and auxiliary equipment.
TYPES OF MATERIALS HANDLING SYSTEMS

1. CONVEYORS These are gravity or powered devices, commonly used for moving loads from point to point over fixed paths. The various types of conveyors are: a) b) slide base. c) Roller conveyor: Boxes, large parts or unit lands roll on top of a series of rollers mounted on a rigid frame. Belt Conveyor: Motor driven belt, usually made of rubberized fabric or metal fabric on a rigid frame. Chain Conveyor: Motor driven chain that drags materials along a metal
d) Pneumatic Conveyor: high volume of air flows through a tube, carrying materials along with the airflow. The other types of conveyors are bucket conveyor, screw conveyor, pipeline conveyor, vibratory conveyor, trolley conveyor, and chute or gravity conveyors. Advantages of conveyors are that they do not require operators, will move a large volume of products and inexpensive to operate. 2. CRANES, ELEVATORS AND HOISTS These are overloaded devices used for moving various loads intermittently between points within an area, fixed by supporting and binding rails. a) Cranes are devices mounted on overhead rails or ground level wheels or rails. They lift, swing and transport large and heavy materials. Examples are Gantry Crane, Jib Crane and Electrically Operated Overhead Crane (EOTC). b) Elevators are a type of cranes that lift materials usually between floors of buildings. c) Hoists are devices, which move materials vertically and horizontally in a limited area. Examples are Air Hoists, electric hoists and chain hoists. 3. INDUSTRIAL TRUCKS
These devices are used for moving mixed or uniform loads intermittently over variable paths. They are electric, diesel, gasoline or liquefied petroleum, gas powered vehicles equipped with beds, forks, arms or other holding devices. Examples are forklift trucks, pallet trucks, tractor with trailers, hand trucks and power trolleys. 4. AUXILIARY EQUIPMENTS
These are devices or attachments used with handling equipment to make their use more effective and versatile. Examples are ramps, positioners, pallets, containers and turn-tables.
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MISCELLANEOUS HANDLING EQUIPMENTS

1. Pipe Lines, which are closed tubes that transport liquids by means of pumps or gravity. 2. Automatic transfer devices, which automatically grasp materials, hold them firmly while operations are being performed and move them to other locations. 3. Automated guided vehicle (AGV) Systems: These devices do not require operations and provide a great deal of flexibility in the paths they travel and the functions they perform and the AGVs are controlled by signals sent through the wires embedded in the floor or inductive tape on the floor surface. A remote control computer is needed to control the movement of AGVs. 4. Industrial Robots: a robot is a mechanism that has a movable armlike projection with a gripper on the end that can perform a variety of functions with the control that can be reprogrammed and hence they are very versatile. The process design and the principles of efficient materials handling provide the framework for selecting specific materials handling devices as the core of the materials handling system. Each of the handling devices has its own unique characteristics and advantages and disadvantages.
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Material Handling

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Material Handling

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SCOPE OF MATERIALS HANDLING

IMPORTANCE OF MATERIAL HANDLING

OBJECTIVES OF MATERIALS HANDLING

MATERIAL HANDLING PRINCIPLES

MATERIAL HANDLING COSTS

TYPES OF MATERIAL HANDLING SYSTEMS

TYPES OF MATERIALS HANDLING SYSTEMS

MISCELLANEOUS HANDLING EQUIPMENTS

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