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PRESENTED BY:
GOPAL KRISHAN DIXIT
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INTRODUCTION
In order to manufacture any product, it is necessary that materials
either move one step of the manufacturing process to another or
that operators to the materials. The most common practice ofcourse, is to move the materials. This movement of materials from
one processing area to another and from department to
department necessitates the use of much manpower and the
handling of tremendous tonnage of materials. It has been
estimated that : items are being worked on only 20% of the time
and 80% of the time the materials are either in storage or are
moved.
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INTRODUCTION
The handling of materials have always been an important factor in
manufacturing. But only recently has attention been focussed onthis problem with the view toward the improvement of equipment
and methods and the reduction of manufacturing costs. There has
been a growing realization of the magnitude of the problem and
recognition of the high ratio of materials handling costs to other
costs of manufacturing.
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INTRODUCTION
The importance of the handling function is greater in those
industries where the ratio of handling cost to the total processing
cost is considerably more. Material handling presents one of the
most potentially lucrative areas for improvement and reduction of
costs. A properly designed and integrated material handling system
provides tremendous cost saving opportunities and customer
services improvement potential. The significant impact of material
handling cost on total product cost has resulted in great deal of
attention and substantial resources being directed towards
discovering more efficient methods to reduce handling costs.
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Material handling is the picking up d putting down, moving of materials
and products in any plant or combination of plants, by any means, which
includes storage and all movements except processing operations and
consumption or end use of the material.
MATERIAL HANDLING:
Definition and Meaning
In a broad sense material handling includes all movements of materials
in manufacturing situation. I t has been defined by the American Material
Handling Society as Material Handling is the art and science involving
the movement, packaging, and storage of substances in any form .
So, we conclude that one accepted definition of scientificmaterial handling can be given as Scientific material handling isthe movement and storage of material at the lowest possible cost
through the use of proper methods and equipment.
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SCOPE OF MATERIAL HANDLING
Field of Activities :- Industrial Material Handling.
Transportation Industries.
Merchandising And Ware Housing.
Process Industries.
The movement of materials with the lowest expenditure of time and
effort is not only restricted to the industrial plant, but there is wide
application to the other fields of activities also.
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SCOPE OF MATERIAL HANDLING
(i) Industrial material handling :- The primary purpose of
materials movement in an industry is to provide an interrupted flow
of materials to, through, and from the manufacturing processes. In
spite of all the development that has taken place in this field, theindustry still has the greatest interest in the problem of moving and
storing materials and there is still a large scope for development in
this field.
(ii) Transportation Industries :- The primary consideration ofthe transportation industries is the movement of materials from
one place to another. The major part of the total cost is the
materials handling cost. More efficient movement of materials is
necessary for the growth of the industries concerned.
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Merchandizing and Ware hosing :- The cost of receiving. Processing, storing
and delivering of materials and products being sold forms a substantial part of the
operating cost of modern merchandizing units. By introduction of efficient methods
for the movement and handling of these materials, restriction of gross operatingmargin can be done.
The ware housing industry is almost entirely based upon the handling and
storage of materials . Many supplementary functions performed as part of the ware
house service are based entirely upon efficient handling techniques. Even a smallchange in the handling costs is related to the existence of the ware house.
Process Industries:- In these industries the handling function is regarded as
one of the most important aspects. The entire manufacturing process might be
build upon and designed around the handling system.
SCOPE OF MATERIAL HANDLING
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SYMPTOMS OF INEFFICIENTMATERIAL HANDLING
1. Back tracking in material flow path.
2. Built in hindrance to flow.
3. Cluttered aisles.
4. Confusion at the dock.
5. Disorganized storage.
6. Excess scrap.
7. Excessive handling of individual
pieces.
8. Excessive manual effort.
9. Excessive walking.
10. Failure to use gravity.
11. Fragmented operations.
12. High indirect labour costs.
13. Idle machines.
14. Inefficient use of skilled labour.
15. Lack of cube storage.
16. Lack of part and supplies.
17. Long Hauls.18. Material pilled up on the floor.
19. No standardization.
20. Over crowding.
21. Poor inventory control.
22. Product damage.
23. Repetitive Handling.
24. Service areas not conveniently located.
25. Trucks delayed or tied up.
26. Two man lifting job.
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BENEFITS OF A PROPEERLY PLANNED
MATERIAL HANDLING SYSTEM1. Reduce material handling time and indirect labour cost.
2. Makes better use of the existing floor space and facilities.
3. Increased plant capacity due to reduced manufacturing cycle time and faster
movement of material.
4. Increased volume of turnover.
5. Reduced volume of work in process.
6. Improved inventory control.
7. Reduced workers fatigue.
8. Enable workers to work at a consistent level of productivity leading to higher
wages fore the workers.
9. Increased productivity of workers lowers, product cost and increases profit.
10. Eliminate accident potential and disruption of work.
11. Promote greater industrial safety.
12. Create a better working operating condition and environment through an
improvement in house keeping conditions.
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13. Afford better protection top materials being handled, reduced damage to the finished products
and work in process.
14. Facilitates material control.
15. Help the maintenance of quality standards.
16. Provide an uninterrupted flow of material leading to increased operating efficiency and higher
production.
17. Reduced cost of transportation.
18. Increased capacity of distribution transport.
19. Improved design of shipping and storage units.
20. Reduced loading costs at the shipping prices.
21. Reduced time or labour of the receiving pieces.
22. Conserved skilled productive labour.
23. Improved morale of workers.
BENEFITS OF A PROPEERLY PLANNED
MATERIAL HANDLING SYSTEM
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Part I
LIMITATIONS AND NEGATIVE ASPECTS OFMATERIAL HANDLING SYSTEM
Some of the possible disadvantages of mechanical handling
system are :-
1. Additional capital investment.
2. Loss off flexibility.
3. Vulnerability of down time.
4. Maintenance.
5. Auxiliary equipment cost.
6. Space and special building requirement.
A careful evaluation of the total benefits and limitation
should be made, before one decides and go for any material
handling project.
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