MATERIAL HANDLING

MATERIAL HANDLING
Material

handling is the function of moving the right material to the right place in the right time, in the right amount, in sequence, and in the right condition to minimize production cost.

MATERIAL HANDLING
A

material-handling system can be simply defined as an integrated system involving such activities as handling, storing, and controlling of materials.

The

word material has very broad meaning, covering all kinds of raw materials, work in process, subassemblies, and finished assemblies.

MATERIAL HANDLING
The

primary objective of using a material handling system is to ensure that the material in the right amount is safely delivered to the desired destination at the right time and at minimum cost.

MATERIAL HANDLING
The

material handling system is properly designed not only to ensure the minimum cost and compatibility with other manufacturing equipment but also to meet safety concerns.
The cost of MH estimates 20-25 of total manufacturing labor cost in the United States

GOALS OF MATERIAL HANDLING

The

primary goal is to reduce unit costs of production or improve product quality, reduce damage of materials safety and improve working conditions

Maintain

Promote

GOALS OF MATERIAL HANDLING

Promote

increased use of

facilities
Reduce

tare weight (dead inventory

weight)
Control

GOALS OF MATERIAL HANDLING

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

GOALS OF MATERIAL HANDLING

Material

handling equipment includes:

Transport Equipment: industrial trucks, Automated Guided vehicles (AGVs), monorails, conveyors, cranes and hoists.

Storage Systems: bulk storage, rack systems, shelving and bins, drawer storage, automated storage systems.
Unitizing Equipment: palletizers Identification and Tracking systems

CONSIDERATIONS IN MATERIAL HANDLING SYSTEM DESIGN

1. Material Characteristics
Category Physical state Size Weight Shape Condition Safety risk and risk of damage Measures Solid, liquid, or gas Volume; length, width, height Weight per piece, weight per unit volume Long and flat, round, square, etc. Hot, cold, wet, etc. Explosive, flammable, toxic; fragile, etc.

2. Flow rate

Quantity of material moved

High
Conveyors Conveyors AGV train Powered trucks Unit load AGV

Manual handling Low Hand trucks

Short

Long

Move Distance

3. Plant Layout
Layout Type Fixed position Characteristics Large product size, low production rate Variation in product and processing, low and medium production rates Typical MH Equipment Cranes, hoists, industrial trucks

Process

Hand trucks, forklift trucks, AGVs

Product Limited product variety, high production rate Conveyors for product flow, trucks to deliver components to stations.

THE PLANNING PRINCIPLE

Large-scale material handling projects usually require a team approach.

Material handling planning considers every move, every storage need, and any delay in order to minimize production costs.
The plan should reflect the strategic objectives of the organization as well as the more immediate needs.

THE SYSTEMS PRINCIPLE

MH and storage activities should be fully integrated to form a coordinated, operational system that spans receiving, inspection, storage, production, assembly, , shipping, and the handling of returns.
Information flow and physical material flow should be integrated and treated as concurrent activities. Methods should be provided for easily identifying materials and products, for determining their location and status within facilities and within the supply chain.

SIMPLIFICATION PRINCIPLE
simplify handling by reducing, eliminating, or combining unnecessary movement and/or equipment.
Four questions to ask to simplify any job: Can this job be eliminated? If we cant eliminate, can we combine movements to reduce cost? (unit load concept) If we cant eliminate or combine, can we rearrange the operations to reduce the travel distance? If we cant do any of the above, can we simplify?

GRAVITY PRINCIPLE
Utilize gravity to move material whenever practical.

SPACE UTILIZATION PRINCIPLE

The better we use our building cube, the less space we need to buy or rent.

Racks, mezzanines, and overhead conveyors are a few examples that promote this goal.

UNIT LOAD PRINCIPLE

Unit loads should be appropriately sized and configured at each stage of the supply chain.
The most common unit load is the pallet

cardboard pallets
plastic pallets

wooden pallets
steel skids

AUTOMATION PRINCIPLE
MH operations should be mechanized and/or automated where feasible to improve operational efficiency, increase responsiveness, improve consistency and predictability, decrease operating costs.

THE STANDARDIZATION PRINCIPLE

standardize handling methods as well as types and sizes of handling equipment too many sizes and brands of equipment results in higher operational cost. A fewer sizes of carton will simplify the storage.

EQUIPMENT SELECTION PRINCIPLE

Why? What? Where? When? How? Who?
If we answer these questions about each move, the solution will become evident.

THE MAINTENANCE PRINCIPLE

Plan for preventive maintenance and scheduled repairs of all handling equipment. Pallets and storage facilities need repair too.

THE DEAD WEIGHT PRINCIPLE

Try to reduce the ratio of equipment weight to product weight. Dont buy equipment that is bigger than necessary. Reduce tare weight and save money.

THE CAPACITY PRINCIPLE

use handling equipment to help achieve desired production capacity i.e. material handling equipment can help to maximize production equipment utilization.

MATERIAL HANDLING EQUIPMENT

Industrial

trucks include hand trucks such as two-wheeled, four-wheeled, hand lift, and forklift and powered trucks such as forklift, tractor-trailer trains, industrial crane trucks, and side loaders. such as belt, chute, roller, wheel, slat, chain, bucket, trolley, tow, screw, vibrating, and pneumatic. hoists, and cranes such as bridge, gantry, tower, and stacker.

Conveyors

Monorails,

MATERIAL HANDLING EQUIPMENT

Automated

guided vehicle systems such as unit load carriers, towing, pallet trucks, fork trucks, and assembly line. storage and retrieval systems (AS/RS) such as unit load, mini-load, person-on-board, deep lane, and storage carousel systems.

Automated