Material Handling

MATERIAL HANDLINGModule 3

08.801. Facilities Planning & Management

College of Engineering, Thiruvananthapuram

2

Material Handling Handling of raw-materials, semi-finished parts and

finished products, mechanically or manually through the production as well as storage areas

In batches or one item at a time Horizontal, vertical or combinational movements About 25% of total cost A single component may be handled 50 times on an

average before it is transformed into final product

02/05/2023

02/05/2023College of Engineering, Thiruvananthapuram

3

Functions of Material Handling Internal movements Inter departmental transportation Movement and positioning

For storage For stocking and sale

Loading and unloading to and from transport vehicles


4

Material Handling Principles 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. Reduction in handling Plant layout aimed at eliminating MH as far as possible Plan developed in consultation between the planner(s)

and all who will use and benefit from the equipments Plan promoting concurrent engineering of product,

process design, process layout, and material handling methods as opposed to independent and sequential design practices.


5

Principle 2 - STANDARDIZATlON 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.

Less variety & customization in the methods and equipment employed.

Applies to sizes of containers, other load forming components, operating procedures and equipment

Select methods and equipment that can perform a variety of tasks under a variety of operating conditions and in anticipation of changing future requirements.

Standardization, flexibility, and modularity must not be incompatible.


6

Principle 3 - WORK PRINCIPLE Material handling work should be minimized without

sacrificing productivity or the level of service required of the operation.

Measure of material handling work is flow rate (volume, weight, or count per unit of time) multiplied by distance moved.

Simplifying processes by reducing, combining, shortening, or eliminating unnecessary moves will reduce work.

Where possible, gravity should be used to move materials or to assist in their movement while respecting consideration of safety and the potential for product damage.


7

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.

Material handling workplace and the equipment must be designed so they are safe for people.

Ergonomic principle embraces both physical and mental tasks.

Equipment that eliminates repetitive and strenuous manual labour and that effectively interacts with human operators and users


8

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.

Unit load- one which can stored or moved as a single entity Less effort & work are required to collect and move many individual

items as a single load than to move many items one at a time. Large unit loads are common in both pre- and post-manufacturing

in the form of raw materials and finished goods. Smaller unit loads - flexibility, continuous flow and just-in-time

delivery.


9

Principle 6 - SPACE UTILIZATION PRINCIPLE Effective and efficient use must be made of all

available space.

Space in material handling is three-dimensional and counted as cubic space.

In storage areas, the objective of maximizing storage density must be balanced against accessibility and selectivity.

Use of overhead material handling systems saves valuable floor space for productive purposes.


10

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, transportation, and the handling of returns.

Systems integration considering the entire supply chain, including reverse logistics

Inventory levels should be minimized at all stages of production and distribution

Methods should be provided for easily identifying materials and products, for determining their location and status


11

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 unsafe manual labor.

Items to be handled automatically must have standard shapes and/or features that permit such systems

Interface issues are critical to successful automation

Computerized MHS should be considered where appropriate for effective integration of material flow and information management.


12

Principle 9 - ENVIRONMENTAL PRINCIPLE Environmental impact and energy consumption should be

considered as criteria when designing or selecting alternative equipment and material handling systems.

Do not waste natural resources and to predict and eliminate the possible negative effects of our daily actions on the environment.

Containers, pallets, and other products used to form and protect unit loads should be designed for reusability and/or biodegradability

Materials specified as hazardous have special needs with regard to spill protection, combustibility, and other risks.


13

Principle 10 - LIFE CYCLE COST PRINCIPLE A thorough economic analysis should account for the entire life cycle of all material handling equipment and resulting systems.

Includes capital investment, installation, setup and equipment programming, training, system testing and acceptance, operating, maintenance and repair, reuse value, and ultimate disposal.

Plan for preventive & predictive maintenance should be prepared for the equipment. And the estimated cost of maintenance and spare parts should be included in the economic analysis.


14

Material Handling Devices

Three types Lifting & lowering devices ( vertical movements) Transporting devices ( horizontal movements) Devices which lift & transport ( combination

devices)


15

Lifting & lowering devices Block & tackle Hand & power winches Hoists Elevators Pillar crane Overhead crane


16

Transporting devices Wheel barrows Trucks Industrial narrow railways Tractors & trailers Pipelines Pumps Trams Automated guided vehicles (AGVs)


17

Devices which lift & transport Fork lift trucks Crane trucks Cranes Different types of Chutes Different types of Conveyors Spiral rollers


18

Conveyors

A conveyor is a mechanized device to move materials in relatively large quantities between specific locations over a fixed path.


19

Roller conveyors - Series of tube rollers perpendicular to motion direction, which can be powered or use gravity for motion.

Skate-wheel conveyors - Similar to rollers but use skate wheels parallel to motion direction.

Belt conveyors - Drives move flat or belts shaped into a trough.


20

Chain conveyors - Uses loops of chain that are typically moved by sprockets as driven by motors.

Overhead trolley conveyors - Items are moved in discrete loads by hooks or baskets suspended from overhead rails

Trolley


21

In-floor towline conveyors - Similar to overhead trolley but carts are pulled by hook to in-floor conveyor.

Cart on track conveyors - Items are moved by a cart attached to a rail system, which uses a rotating tube to move the cart along the rail.


22

Automated Guided Vehicle (AGV)

An AGV is an independently operated vehicle that moves material along defined paths between defined delivery points or stations. Typically the paths are defined by either using wires embedded in the floor or reflecting paint strips on the floor.


23

Automated Storage and Retrieval System (AS/RS) An AS/RS is a

combination of equipment and controls which handles, stores, and retrieves materials with precision, accuracy, and speed under a defined degree of automation.


24

Selection of MHS Nature of operations

Temporary or permanent Continous or intermittent Flow pattern – V/H Type of layout

Material to be handled Size and shape Quantity & weight Material characteristics Susceptibility to damage


25

Distance to be moved Fixed / long distance Workstations

Installation & operating cost Initial investment Operating & maintenance cost

Plant facilities Types of buildings Floor load capacity


26

Equipment reliability Use of standard components Service facilities Supplier reputation

Engineering factors Door & ceiling dimensions Floor condition & structural strength Traffic safety

Safety considerations


27

Designing MHS Define objectives & scope for the mhs Analyze the requirements for

Moving Storing Protecting Controlling

Generate alternate designs Evaluate alternate system designs Select preferred design Implement- Train – Install – Audit - Maintain


28

Riddler Suitable MHS for

Library Airport Textile industry Automobile assembly unit