Production and Operations Management

PRODUCTION AND OPERATIONS MANAGEMENT
Chapter 22 Stores Management and Materials Handling
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Chapter 22
STORES MANAGEMENT AND MATERIALS HANDLING

Himalaya Publishing House Production and Operations Management By K. Aswathappa & K. Shridhara Bhat
II. Materials Handling
Materials handling is the art and science of moving, packing and storing of substances in any form.
Himalaya Publishing House
Production and Operations Management By K. Aswathappa & K. Shridhara Bhat
Scope of Material Handling

Depends on type of the product manufactured, the size of the organization, the value of the product and the value of the activity being performed and relative importance of material handling to the enterprise :
3 Perspectives of Material Handling
The traditional point of view Movement of material from one place to another within the plant Plant-wide concern for overall flow of materials Interrelationship between all handling problems and possibility of establishing an overall materials handling plan. The systems point of view. The movement of material from all sources of supply, all handling activities within an around the plant, all handling activities in distribution of finished goods to all customers of the firm
Importance of Material Handling
Efficient materials handling is important to manufacturing operations. Material handling analysis is a subset of plant layout.
1.
Objectives of Materials Handling
Lower unit materials handling cost Reduction in mfg cycle time Better control of the flow of materials Better working conditions Better quality Enhanced storage capacity Higher productivity
2.
3.
4.
5.
6.
7.
Material handling principles
Materials should move through the facility in direct flow patterns, minimizing zigzagging or backtracking Related production processes should be arranged to provide for direct material flows Mechanized materials handling devices should be designed and located so that human effort is minimized
Cont..
Heavy and bulk materials should be moved to the shortest distance during processing The number of times each material is handled should be minimized. Systems flexibility should allow for unexpected breakdowns of materials handling equipments Mobile equipments should carry full loads all the times. Production and Operations Management
By K. Aswathappa & K. Shridhara Bhat
Summary of 7 Principles
Eliminate handling Keep moving
Use simple patterns of material flow Carry pay loads both ways Carry full loads Use gravity
Selection and Design of Handling System
Selection and design of the materials handling system should be done along with the development of the layout, as each one affects the other.
Materials Handling Costs
Materials handling costs include

cost of owning and maintaining equipment and cost of operating the system. Eliminating the handling itself whenever and wherever possible Mechanising, largely by conveyors and power driven trucks, whatever handling still remains Making the necessary handling more efficient Have a record maintained of them.
Cost can be reduced by
Organization for Material Handling
It vary with the industry, manufacturing process, product manufactured, its bulk and its value. Unit load concept
The number of items so arranged that the mass can be picked up and moved as a single object. It helps reduce or lower the cost per unit handled.
Cont..
Disadvantages of Unit Load

Cost of unitising and de-unitising Equipment and space requirements Bare weight of unitising medium Problem of returning empty pallets or container Transfer equipment often not available on both ends of the move.
Material flow pattern
Will help efficient movement of materials at best cost When drawn on paper, it is a flowchart. Once areas of unwanted movement are known, steps can be taken to eliminate or reduce such moves.
Cont..
Advantages

Increased efficiency of production Better utilisation of floor space Simplified handling activities Better equipment utilisation, less idle time Reduced in-process time and inventory More efficient utilisation of work force Reduced product damange
reduced walking distances Minimal accident hazards Basis for an efficient layout Faster supervision Simplified production control Minimal back tracking Smooth production flow Reduced crowded conditions Logical work sequence Improved scheduling process better housekeeping
Factors for consideration in planning material flow

Material or product Moves Handling methods Process Building\ Site Personnel Miscellaneous
checklist
Factors affecting the selection of Materials Handling Equipment

Production problem Capabilities of the handling equipment available Human element involved
1. 2. 3.
Types of Materials Handling Systems
Types of material handling systems: a. Equipment oriented systems b. Material oriented systems c. Methods oriented systems d. Functions oriented systems
Selection and Design of Handling System
Selection and design of the materials handling system should be done along with the development of the layout, as each one affects the other.
Types of Materials Handling Equipment

Conveyers Cranes, Elevators and Hoists Industrial Trucks Auxiliary Equipments Miscellaneous Handling Equipments
1. 2. 3. 4. 5.

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PRODUCTION AND OPERATIONS MANAGEMENT

Chapter 22 Stores Management and Materials Handling

Click to edit Master subtitle style

STORES MANAGEMENT AND MATERIALS HANDLING

Chapter 22 Stores Management and Materials Handling

II. Materials Handling

Himalaya Publishing House