PRODUCTION

SYSTEM DESIGN
MATERIAL HANDLING
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Introduction and Definition
Objectives of MH
1. Reduction of Handling Costs
Reduction of labor cost
Reduction of material cost
Reduction of overhead cost
2. Increase of Capacity
Increase of Production
Increase of storage capacity
Improved layout
3. Improvement of working condition
Increase safety
Reduction in fatigue
Strategic location of storage facilities


Materials Flow Diagram
MH system in the form of Flow Diagram:
Raw mat. supplier Transportation Receiving at
store
Storing Manufacturing/fabrication units
Flow of parts to
assembly line
Testing and
packaging
shipping
Warehouse
Dealers/consumers
Disposal/
recycling
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Functions of MH
1. Minimize the movements
2. Principle of containerization, palletization
3. Minimize the distance moved
4. Employ mechanical aids
5. Minimize back tracking and duplicate movement
6. Safe, standard, efficient, effective, appropriate,
flexible, and proper sized MH equipment
7. No interference with the production line
8. Utilize gravity
9. Design containers, drums, packages
10. MH equipments should be checked up, repaired and
maintained
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Principles of MH

Principles related to planning
1. Planning Principles
2. Systems Principles
3. Simplification Principle
4. Material Flow Principle
5. Gravity Principle
6. Use size principle
7. Space Utilization Principle
8. Safety Principle


MATERIAL HANDLING
Principles of MH

Principles related to equipment
1. Mechanization Principles
2. Flexibility Principles
3. Equipment Selection Principle
4. Standardization Principle
5. Light Weight Principle
6. Motion Principle
7. Idle Time Principle
8. Obsolescence Principle
9. Maintenance Principle
10. Control Principle
Factors to be considered in material handling problem
1 Engineering factors 2 Economic factors
Engineering factors to be considered:
Nature of materials and products (solid, gas, etc)
Production process and equipment (sequence of
operation, machine output per unit time)
Building construction (single or multi-storey)
Layout (layout and material handling are not
separable)
Existing material handling equipment
Production planning and control (sequence for
material flow and timing for processing)
Packaging (easy handling of packaged products)


Economic factors to be considered in MH
Initial cost of equipment
Cost of installation
Rearrangement of present equipment
Cost of alternation necessary to the building
Cost of maintenance, repairs, supplies etc
Cost of power, depreciation
Cost of labor to operate
Cost of auxiliary equipment (for example, charging
equipment for truck batteries, etc)
Flexible MH equipment help in reducing operating costs.

Material handling devices
1. Lifting and lowering devices (vertical
movement)
2. Transporting devices (horizontal
movement)
3. Devices with lift and transport (combination
devices)
4. Industrial Robots
5. Automatically guided vehicles

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Types of MH Equipments

Characteristics of MH equipment









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Classification of MH Equipments
1. Industrial Trucks
Manual / Powered Two Wheeled, Three Wheeled,
Four Wheeled Fork lift Truck
2. Cranes
3. Hoists Pneumatic/Electrical
4. Monorail
5. Conveyors Roller, Belt, Bucket, Chain,
Pipeline
6. Slides and Chutes
7. Lifts
8. Tractors and Trailers





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Industrial Robots
A robot is a reprogrammable multifunctional
manipulator designed to move material, parts,
tools, or specialized devices through variable
programmed motions for the performance of a
variety of tasks
Robots are like human workers
Robot application:
-to pick up hot steel ingots
-handling radioactive rods in nuclear power
plants
-spot welding and arc welding
Automated Guided Vehicle systems (AVGS)
Battery-powered, automatically steered
vehicles designed to follow defined pathways.
Capable of automatically loading and
unloading unit loads
Usually interfaced with other automated
systems to achieve full benefits of integrated
automation.
Examples: driverless trains, pallet trucks, unit
load carriers
Relation between plant layout and MH
Close relation
MH methods influence the layout and factory building
Integral part of plant layout to design low cost handling
system
Good MH is resulted based on the arrangement of
production equipment, location of departments, logical
sequence of operations, location of stores, tools
MH system/equipment can be selected only after the
appropriate floor plan
Plant layout considers the points for material receiving
and shipping of products
Careful arrangement of work centers and storage areas
Consider horizontal or vertical material transportation



Process layout and MH system

Need of flexibility-flexibility of path, and flexibility of size,
weight and shape of load
Mobile trucks, tractor trains, cranes, and forklift trucks, etc.
Loading and unloading time is very important for efficient
MH system
Quick pick up systems have developed around skids and
pallets
Material is loaded directly on skid or pallet by worker as
S/he completes his operation on the part
Heavy parts/loads are handled by overhead cranes
How much MH equipment is needed? Difficult question
because of random variations on demand for transporting
capacity in process layouts.

Line layout and MH

Nature of line layout requires direct means of transportation
between operations
Arrange the material flow so that each operator places the
unit down in such a position that it can be picked up by the
succeeding worker
Where possible gravity chutes can be used
Chutes are common in railway and air line terminal for
handling baggage.
Conveyers to lift all types of parts are available
Conveyers require a considerable amount of special design
to fit them into an effective overall design of a line layout



Task for self study

Review the literatures on material handling
equipment. Understand the basic physical
construction and application of major
material handling equipment used in
manufacturing and construction sector.
Participate actively in class room discussion
and demonstrate your knowledge and
understanding ability on material handling
equipment.
MATERIAL HANDLING

References:
Industrial Engineering and Management Dr.
O. P. Khanna Dhanpat Rai Publications
Industrial Engineering A. P. Verma S. K.
Kataria and Sons
Industrial Engineering and Production
Management M. Mahajan Dhanpat Rai and
Co.





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