- Material Handling Systems

8/3/2019 - Material Handling Systems

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Material Handling Systems

Forexploiting productivity potential in logistics


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Material Handling

Material handling is the function ofmoving the right material to the right

place in the right time, in the rightamount, in sequence, and in the rightcondition to minimize production cost.

The cost of MH estimates 20-25 of totalmanufacturing labor cost in the UnitedStates [The Material Handling Industry of America (MHIA)]


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Goals of Material Handling

The primary goal is to reduce unit costsof production

Maintain or improve product quality, reduce damage ofmaterials

Promote safety and improve working conditions

Promote 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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Material Handling

Lifting/Lowering

Pushing/Pulling

Carrying Weights and Forces

Frequency of Activities

Load Center of Gravity


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Job Risk Factors

Weight of the Object

Location (position of load

w.r.t. worker) Frequency of Lifts

Stability of the Load

Hand Coupling Workplace Geometry

Twisting/Stooping

Environmental Factors


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Personal Risk Factors

Gender

Age

Lift technique Attitude

Strength

Training


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Calculator for Analyzing Lifting Operations


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Considerations in Material

Handling System Design1. Material Characteristics

Category Measures

Physical state

Size

Weight

ShapeCondition

Safety risk and risk ofdamage

Solid, liquid, or gas

Volume; length, width, height

Weight per piece, weight per unit

volumeLong and flat, round, square, etc.

Hot, cold, wet, etc.

Explosive, flammable, toxic; fragile,

etc.


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Considerations cont.

2. Flow rate

Manual handling

Hand trucks

Powered trucks

Unit load AGV

Conveyors Conveyors

AGV trainHigh

Low

LongShort Move Distance

Quantity of

material

moved


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Considerations cont.

3. Plant LayoutLayout Type Characteristics Typical MH Equipment

Fixedposition

Process

Product

Large product size, lowproduction rate

Variation in product andprocessing, low and medium

production rates

Limited product variety, highproduction rate

Cranes, hoists, industrialtrucks

Hand trucks, forklift trucks,AGVs

Conveyors for product flow,trucks to deliver componentsto stations.


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Manual

Mechanical

Semi-automatic

Automatic

Information guides

Material Handling Systems


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Volumes to be handled

Speed in handlingProductivityProduct characteristics

(weight, size, shape)

Nature of the product(hazardous, perishable, crushable)

Selection Criteria:Material Handling Systems


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Material Handling

Manual TrolleyVersatileFor smaller loadsFor short distance


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Material Handling

ForkliftManual or mechanizedPortableLarge distance travelMedium & large loads handlingVertical movement

Intermittent duty


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Material Handling

Overhead CraneCarry heavy loads

Continuous dutySize shape no bar


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Material Handling

Material handlingat sea ports


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Advanced MaterialHandling Systems

Pneumatic tube systemFor handling material in powered form

Semi-automatic system

Sorting devicesRobotics

Automatic guided vehicle systemMaterial handling on a fixed path

computer operated guided vehicleSpeed of operation 150-250 feet per minute

Automatic systemHuman factor eliminated

Operator required for to programming and controls

Productivity


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Standard equipment should be preferred to keep low capitalinvestments

Equipment designed for maximum continuous flow should bepreferred

Portable or movable equipment to be preferred

Ratio of dead weight to pay load should be minimum forhandling equipment

Gravity flow should be incorporated in the system design

Material Handling Guidelines


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Top 10 Principles of MaterialHandling

Principle 1. Planning Principle

All material handling should be the result of a deliberate plan where the needs,

performance objectives and functional specification of the proposed methods are

completely defined at the outset. The plan should be developed in consultation

between the planner(s) and all who will use and benefit from the equipment to be

employed.

Principle 2. Standardization Principle

Material handling methods, equipment, controls and software should be standardized

within the limits of achieving overall performance objectives and without sacrificing

needed flexibility, modularity, and throughput. Standardization means less variety

and customization in the methods and equipment employed.

Principle 3. Work Principle

Material handling work should be minimized without sacrificing productivity or the

level of service required of the operation.


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Top 10 Principles of Material Handling(cont.)

Principle 4. Ergonomic Principle

Human capabilities and limitations must be recognized and respected in the design

of material handling tasks and equipment to ensure safe and effective operations.

Ergonomics is the science that seeks to adapt work or working conditions to suit the

abilities of the worker.

Principle 5. Unit Load Principle

Unit loads shall be appropriately sized and configured in a way which achieves the

material flow and inventory objectives at each stage in the supply chain. A unit load

is one that can be stored or moved as a single entity at one time, such as pallet,

container or tote, regardless of the number of individual items that make up the

load.

Principle 6. Space Utilization Principle

Effective and efficient use must be made of all available space. Space in material

handling is three dimensional and therefore is counted as cubic space.


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Principle 7. System Principle

Material movement and storage activities should be fully integrated to form a

coordinated, operational system that spans receiving, inspection, storage,

production, assembly, packaging, unitizing, order selection, shipping, transportationand the handling of returns.

Principle 8. Automation Principle

Material handling operations should be mechanized and/or automated where feasible

to improve operational efficiency, increase responsiveness, improve consistency and

predictability, decrease operating costs, and eliminate repetitive or potentially unsafemanual labor.

Principle 9. Environmental Principle

Environmental impact and energy consumption should be considered as criteria

when designing or selecting alternative equipment and material handling systems.


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Principle 10. Life Cycle Cost Principle

A thorough economic analysis should account for the entire life cycle of all material

handling equipment and resulting system. Life cycle costs include all cash flows that

occur between the time the first dollar is spent to plan or procure a new piece ofequipment, or to put in place a new method, until that method and/or equipment is

totally replaced. Life cycle costs include capital investment, installation, setup and

equipment programming, training, system testing and acceptance, operating (labor,

utilities, etc.), maintenance and repair, reuse value, and ultimate disposal.


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Material Handling Checklist

Is the material handling equipment more than 10 years old?

Do you use a wide variety of makes and models which require a high spare parts

inventory?

Are equipment breakdowns the result of poor preventive maintenance?

Do the lift trucks go too far for servicing?

Are there excessive employee accidents due to manual handling of materials?

Are materials weighing more than 50 pounds handled manually?

Are there many handling tasks that require 2 or more employees?

Are skilled employees wasting time handling materials? Does material become congested at any point?

Is production work delayed due to poorly scheduled delivery and removal of

materials?

Is high storage space being wasted?

Are high demurrage charges experienced?


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Material Handling Checklist (cont.)

Is material being damaged during handling?

Do shop trucks operate empty more than 20% of the time?

Does the plant have an excessive number of re-handling points?

Is power equipment used on jobs that could be handled by gravity?

Are too many pieces of equipment being used because their scope of activity is

continued?

Are many handling operations unnecessary?

Are single pieces being handled where unit loads could be used?

Are floors and ramps dirty and in need of repair? Is handling equipment being overloaded?

Is there unnecessary transfer of material from one container to another?

Are inadequate storage areas hampering efficient scheduling of movement?

Is it difficult to analyze the system because there is no detailed flow chart?

Are indirect labor costs too high?

Documents

- Material Handling Systems