Material Handling 2009

7/28/2019 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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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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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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Material Handling 2009

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