Material handling

Anand dubey

MATERIAL HANDLING
Material handling is an integral function of the work to achieve the output. Statistics indicates that 40 to 100 tons of materials are handled for 1 ton of finished product. Further it adds cost to the finished products nearly 30% of production.

MATERIAL HANDLING
30-40% of the industrial accidents are caused due to material handling operation. So sufficient safety measures are to be adopted in handling of materials. The work performed by adopting appropriate method to handle appropriate material in appropriate quantity at appropriate place in appropriate time in appropriate order in correct position and by correct expenditure.

GROUPS OF M.H.
Material handling is divided in two groups. 1-Manual material handling. 2-Mehanical material handling.

SYSTEMATIC ANALYSIS OF M.H.

The key element for systematic handling analysis are PQRST P-Product (materials, parts, items to be
moved)

Q-Quantity (volume, weight) R-Route (0rigin to destination) S-Supportive (Dispatching procedures) T-Time (Timing, Regulatory,Duration,Urgency)

The Product (Physical characteristics)

Size (Length, Width, and Height) Weight (Wt. per item, carton, bundle,bin in which condition the mat.is to be moved.) Shape (Flat, Curved, Compact, Irregular) Risk of damage (Fragile, Contaminable etc Condition (Hot, Wet, Dirty, sticky, unstable)

The product (chemical characteristics)

Explosives, toxic and corrosive in nature Reactivate of chemical products with container. Compatibility of chemicals with other products. Deterioration of products or change in chemical properties due to weather condition.

The Quantity
Quantity per unit time, intensity of flows tons/ hour, pieces of skilled load per hour, per day or per week. Quantity per trip (per load)- the amount of material which can be carried per trip by truck. The capacity of handling equipment and its type can be decided only after knowing the quantity of material to be moved per unit time or per trip.

THE ROUTE
(ORIGIN TO DESTINATION OR PATH OF MOVEMENT)

The distance of the move, form the origin to destination. The physical situation of the route. i) horizontal, inclined, vertical bent curved. ii) Congestion and route condition, traffic congestion and obstructions on route paved surface, tarred road, muddy road. iii) Climate and surrounding indoor, outdoor, cold storages, sanitary area, explosion prone area.

SUPPORTING (SERVICES%,SURROUNDINGS)
Paper work, ordering movement of materials and dispatching procedures. Available speed for movement of the requirement of the surroundings within which material handling equipment have to operate.

TIME
Regulatory Continuous intermittent or occasional. Duration- how long the material handing work will continue. Speed Urgency, immediate or at convenience.

TOOLS USED IN MANUAL HANDLING

1. 2. 3. 4. 5. 6. 7. 8. Crowbar Hook Shovel Pliers Wrench Puller Axe Non- sparking tools.

SAFETY FOR MANUAL HANDLING OF MATERIALS

1.

2.
3. 4. 5. 6. 7. 8. 9.

Before lifting any material, remove projecting nails, sharp edges splinters if any. Wear suitable personal projective equipment like gloves safety shoes etc. Consider the weight of the load. As a trial lift, rise the load to a few centimeters. Do not carry a load which is too heavy for a single man. Always get help if the load too heavy. Do not carry a load that obstructs the in view ached Always keep the feet part on along side and on behind the load bend knees, relax back muscles. Always keep the back straight or nearly vertical. Always remember that a bend back is a week back. For lifting of material from lower level to higher level or vice versa, physical posture is very important, otherwise back injury may be inflicted.

SAFETY FOR MANUAL HANDLING OF MATERIALS (contd..)

10. Always remember during manual handling of materials.
a) Straight back as nearly vertical as possible. Elbows as straight as possible, knees bent till hand properly grip the load. b) Raise bead chin in. c) Proper feet position closed to the load for lobby balance. d) Proper hold. e) Arm close to the today f) Use your body weight. g) Keep the body weight on the feet but not on the back.

SAFETY FOR MANUAL HANDLING OF MATERIALS (contd..)

11. Always avoid awkward lift position. 12. Carry the load with steady watchful stops. 13. Never changes the position of load in motion.

Handling heavy or bulky objects

Take the help of co-workers. Let one man be out of the team for call/give signals. During carrying a long object with work mates in a team, be sure that the object is placed on the same side of each one of them.

LIFTING SPECIFIC TYPES OF ARTICLES

BOXES & CARTONS: Grasp them at opposite top an bottom center. Draw a corner between logs. Barrels & drums: Two men shall stand opposite. The chimes of the barrel shall be held firm an erect. While lowering down the bottom of the barrel shall be set down the ground and straight up. Handling of drum/ barrel in inclined plane: A rope around the barrel shall be passed through and one end shall be held by the person standing on the higher platform for controlling of motion. Object: long objects pipes, timber etc should be carried over the shoulders walking erect with front end held as high as possible to prevent striking other employee at corners.

MAXIMUM LOAD RECOMMENDED

Sl.no 1. 2. 3. 4. 5. Person Adult Male Adult Female Adolescent Male Adolescent Female Child Male Maximum load, kg. 55 30 20 20 16

6.

Child Female

14

FOLLOWING POINTS TO BE CONSIDERED

1. 2. 3. 4. 5. 6. 7. Age of worker Sex of worker. Body structure. Body weight. Physical health. Capacity. Trained or untrained.

MECHANICAL MATERIAL HANDLING

Mass production is impossible without highly mechanized material equipments. There are numerous types of mechanical equipments. We can divide them in following classes. Horizontal fixed type. Vertical Movement type. Fixed area type. Flexible path/Non flexible path type.

HORIZONTAL FIXED PATH TYPE

Belt conveyor. Wire Gauge conveyors. Gravity roller conveyors. Slant conveyors. Apron conveyors. Powered roller conveyors. Drag chain conveyors. Trolley conveyors moving on channel/Rail track. Vibrating conveyors. Closed channel conveyors. A) Screw conveyors B) Pneumatic tube conveyors.

VERTICAL MOVEMENT TYPE

Package lift elevator. Bucket elevator. Derricks and Booms. Mobile cranes. Fork lifts. Spiral chutes.

FIXED AREA TYPE

Revolving jib cranes. Derricks. Traveling Bridge cranes. Gantry cranes.

OVERHEAD MOVEMENT TYPE

Mono rail conveyors. Cable ways. Overhead chain conveyors. Overhead cranes.

FLEXIBLE PATH TYPE

Two wheel hand trucks. Three wheel hand trucks. Powered fixed Platform trucks. Fork lift trucks. Industrial Tractors. Side leading trucks. Straddle trucks. Dumper trucks.

RULES FOR SAFE OPERATION OF M.H.E.

A)-HAND TRUCKS: -Always load the truck in such a way that material will not slide or roll off. -Never load the truck so high that you can not look over it. -Do not use truck with broken wheel or damaged handle. -Never go ahead of your truck. -Wear safety shoes.

RULES FOR SAFE OPERATION OF M.H.E

B-Powered Equipment ;-Keep your load as low as possible while moving. -Avoid quick jerking stop. -If the truck has tilting device it should be used. -Go easy when approaching Danger points. -Do not cut corners. -Give ample warning when approaching Blind corners. -Observe Traffic rules. -Do not drive in the dark. -Never load inflammable liquid except approved container. Handle Hoist carefully.