BY

EP JOHN

I MBA

B SEC

11397044

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

MATERIAL HANDLING

GOALS OF MATERIAL HANDLING

The primary goal is to reduce unit costs of production

Maintain or improve product quality, reduce damage of materials

Promote safety and improve working conditions

Promote increased use of facilities

Reduce tare weight (dead weight)

Control inventory

GOALS OF MATERIAL HANDLING

Promote productivitymaterial 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

GOALS OF MATERIAL HANDLING

CONSIDERATIONS IN MATERIAL HANDLING SYSTEM DESIGN

1. Material CharacteristicsCategory Measures

Physical stateSizeWeight

Shape

ConditionSafety risk and risk of damage

Solid, liquid, or gasVolume; length, width, heightWeight per piece, weight per unit volumeLong and flat, round, square, etc.Hot, cold, wet, etc.Explosive, flammable, toxic; fragile, etc.

2. Flow rate

Manual handlingHand trucks

Powered trucksUnit load AGV

Conveyors

ConveyorsAGV train

High

Low

LongShort Move Distance

Quantity of material moved

Layout Type Characteristics Typical MH Equipment

Fixed – position

Process

Product

Large product size, low production rate

Variation in product and processing, low and medium production rates

Limited product variety, high production rate

Cranes, hoists, industrial trucks

Hand trucks, forklift trucks, AGVs

Conveyors for product flow, trucks to deliver components to stations.

3. Plant Layout

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 PRINCIPLEMH 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 PRINCIPLEsimplify 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 can’t eliminate, can we combine movements to reduce cost? (unit load concept)

If we can’t eliminate or combine, can we rearrange the operations to reduce the travel distance?

If we can’t do any of the above, can we simplify?

GRAVITY PRINCIPLEUtilize 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 PRINCIPLEUnit loads should be appropriately sized and configured at each stage of the supply chain.

The most common unit load is the palletcardboard palletsplastic palletswooden palletssteel 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

PRINCIPLEstandardize 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. Don’t 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.

Conveyors such as belt, chute, roller, wheel, slat, chain, bucket, trolley, tow, screw, vibrating, and pneumatic.

Monorails, hoists, and cranes such as bridge, gantry, tower, and stacker.

Automated guided vehicle systems such as unit load carriers, towing, pallet trucks, fork trucks, and assembly line.

Automated storage and retrieval systems (AS/RS) such as unit load, mini-load, person-on-board, deep lane, and storage carousel systems.

MATERIAL HANDLING EQUIPMENT

THANK YOU