Download - Material Handling 2009
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MATERIAL HANDLING
Farhin Panwala
MBA Sem-2
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DEFINITION
According to American Materials Handling SocietyMaterials handling is the art and science
involving the movement, packing, and storing of
substances in any form.
Material handling refers to the movement of
materials from the tore room to the machine and
from one machine to the next during the process of
manufacture.
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Objectives of Material Handling
Reduction in Wastage of Machine Time. Reduction in Manufacturing Cycle Time.
Avoid Disruption in Production Schedule.
Safety and Safe Working Conditions.
Customer Satisfaction.
Enhances Productivity and Avoids High Cost.
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Function of Material Handling
Using the principles of containerization, unit load, aim atmoving optimum number of pieces in one unit.
Safe, standard, efficient, effective appropriate, flexible
and proper-sized materials handling equipment should be
selected.
Employee mechanical aids in place of manual labour in
order to speed up the material movements.
Minimize the movement involved in a production
operation.
Changes in sequence of production operations may be
suggested in order to minimize back-tracking and
duplicate handling.
Minimize the distances moved by adopting shortest
routes.
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Function of Material Handling
Handling equipments arrangement should minimizedistances moved by products and, at the same time,
handling equipments should not interfere with the
production line.
Design containers, packages drums, etc. toeconomize handling and to reduce damage to the
materials in transit.
Utilize gravity for assisting materials movements
wherever possible. Materials handling equipments should periodically be
resorted to check ups, repairs and maintenance.
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Importance of Material Handling
1) Save Non-Value Added Time2) Reduces Wastage
3) Less congestion
4) Cost efficient
5) Better Customer Services
6) Good Housekeeping
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Factors Affecting Materials Handling
System
Production System Types of Products
Type of Building
Cost of Material Handling
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Principles of Material Handling
Developed by Moore, Apple and Murther Principles are divided in 5 categories.
1) Planning Principle
Material handling and production activity should
integrated to maximize overall operating efficiency.
- Delegation Principle
- Minimization of Re-handling
- Facility layout principle- Space saving principle
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Principles of Material Handling
2) Operating Principles- Material Flow Principle
- Unit Load Principle
- Use of Gravity
3) Principles Related to Equipment
- Standardization and Versatility
- Mechanization Principle
- Weight Ratio Principle- Maintenance Principle
- Principle of Speed
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Principles of Material Handling
4) Principle of Cost Reduction
- Carefully Equipment Selection Principle
- Replacement Analysis
- Costs Analysis
- Reduced Floor to Floor Time5) General Principles
- Education and Training
- Safety
- Principle of Identification- Location Principle
- Material Treatment Principle
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Material Handling Equipments
Material handling involves the movements ofmaterials, manually or mechanically in batches or
one item at a time within the plant. The movement
may be horizontal, vertical or the combination of
horizontal and vertical.1) Lifting and lowering devices
2) Devices which Lift and Transport
3) Transporting Devices
4) Storages Devices
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A)Lifting and Lowering Devices
These devices are used for lifting and lowering thematerial the material in a vertical direction only( up
and down).
1) Block and Tackle:
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2) Winches:
Winches are frequently
used in loading heavy
equipment in ships,construction
equipments into
building, and in similar
jobs.
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3) Hoists:
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4) Elevators:
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5) Cranes:
a) Pillar Crane
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b) Overhead Bridges Crane:
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c) Jib Crane:
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d) Gantry Crane:
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B) Transportating Devices
1) Hand Trucks and Wheel Barrows:
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2) Industrial Railways3) Tractors and Trailers
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3) Industrial Railways4) Railway Equipments
5) Aerial Tramways
6) Skids
7) Pipe Line
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C) Devices which Lift & Transport
1) Slides and Chutes:
Spiral Chute
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2) Monorails:
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3) Lifts: 4) Trucks:
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Pallet Truck
Fork Lift truck
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Crane Truck
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5) Conveyors
Roller Conveyors
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Belt Conveyor
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Chain conveyor
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Bucket Conveyor
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Screw Conveyor
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4) Storage Devices
1) Containers
- Containers are most commonly used in
manufacturing plants for in process materials
handling applications.
i. Welded Wire Containers
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ii Corrugated Metal Container
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iiiPlastic Containers
2) Automatic Storage & Retrieval System
C it i f S l ti f M t i l
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Criteria for Selection of Material
Handling Equipments
Low Maintenance Cost
Compliance with safety standards
Operational Environment
Buffer Storage
Effective Use of Operating Time
Nature of Operations
Engineering factors
Equipment Reliability
l i hi b l &
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Inter-Relationship between Plant Layout &
Material Handling There is a close connection between the concepts of plant layout and material
handling. A good plant structure can ascertain the least material handling process andinexpensive material handling equipment. The material handling factors to beconsidered while designing the plant layout are:
1) Excessive material movement damages the materials and causes loss of valuableman-hours in shifting materials. A layout should be designed such that it suits themanufacturing requirement of the products and reduces the material handling tominimum.
2) If the workers are compelled to search through the entire workshop for a particularmaterial, their productive time is bound to go wasted.
For maximum utilization of their time the plant should be equipped with:
a) Clearly identified and well-named functional areas.b) Distinct areas for raw materials, tools, work-in-process, inspection and finishedgoods.
3) For an effective and speedy movement of materials there should be an effectiveuse of:
a) Bins, trolleys, racks and trays to keep materials instead of placing them on floors
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b) Proper packaging techniques before dispatching
c) Conveyors, chutes, inclined planes and gravity feedbins to automate, materials movement.
4) Public utilities should be located at easily accessibledistances and should not require distant walks on part of
the workers5) Economical use of space should be aimed. Machinesand equipments should be placed in such a way thatthere is a minimal or no wastage of space and yet thereshould be optimum choice for expansion.
6) Maximum opportunity for greater width of aisles,heights of ceilings and other areas of storage so the needof later alterations will be reduced
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A good plant layout thus facilitates anefficient material handling system. It
offers minimum material handling by
making material movements shorter,faster and economical. Overcrowding is
prevented. Delays in supplying are avoided
due smooth manufacturing activity and
hence it is generally desirable to adopt agood plant layout that facilities minimum
handling.
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