Unit09 Material Handling Principles (1)

8/10/2019 Unit09 Material Handling Principles (1)

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Facilities Planning- Unit 09

Material Handling Principles


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Material Handling Principles - 2

Hierarchy of Facility Planning

Facility

Planning

Structural Design

Facility

Location

Facility

Design

Handling SystemDesign

Layout

Design

Source for Figure: Tompkins and White,Facilities Planning, 2nd edition, Wiley


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Facility Layout

The physical arrangement of

production machines and equipment,

workstations, people, materials, and

material handling equipment.


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Material Handling Defined

Material handlingis 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.

The cost of MH is estimated to be 20-25% of total

manufacturing labor cost in the United States.Source: The Material Handling Industry of America (MHIA)



Nature of Material Handling

Material handling (MH) is the artand scienceinvolving

the moving, packing, and storing of substances in any

form.

The artof MH is the fact that there is no one rightanswer to a MH problem.

The scienceof MH encompasses a technical

understanding of the field.



The Value of Material Handling

MH does not change the shape or form of a good or

serviceit does not add value.

MH adds cost to the good or service and,

consequently, is something to be avoided. Material handling is the creation of timeand place

utility in a material.

Timeutilityhaving the proper good or service at the right

time. Placeutilityhaving the proper good or service at the right

place.



Objectives of Material Handling

Increase efficiency of material flow Reduce material-handling cost

Improve facility utilization

Improve safety and working conditions

Facilitate the manufacturing process

Increase productivity

Material handling can account for 30-75% of production costs and

can reduce operational costs by 15-30%. It affects building

requirements, departmental arrangements, and production time.Source: Manufacturing Facilities: Location, Planning, and Design [Sule, 94]



Scope of Material HandlingManufacturing

Raw materials receiving and shipping

Materials issue and distribution

Inter/intra departmental handling Workplace material handling

In-process storage

Finished goods storage

Stock picking and order assembly



Scope of Material HandlingHospitals

Patient handling

Staff personnel handling

Food handling Garbage handling

Laundry handling

Medication handling

Patient records handling



Scope of Material HandlingAirports

Passenger handling

Flight crew handling

Baggage handling

Fuel handling

Food handling (flight meals and terminal)

Air freight cargo handling


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Components of Material Handling

The Materialsproducts, items, substances and/or people

which are being moved, transported, or physically relocated.

The Move(origin, travel path, destination, frequency) to be

made.

The Method(equipment, people, procedures, physicalfacilities) to be used to make the move

Material Handling Equation


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Principles of Material Handling

A principle is a general rule, fundamental, or other

statement of an observed truth.

Over time certain fundamental truths of material

handling have been found to exist. The "principles" ofmaterial handling are often useful in analyzing, planning

and managing material handling activities and systems.

At the very least they form a basic foundation upon

which one can begin building expertise in materialhandling.

The Material Handling Industry of America (MHIA) is the major source used for compiling the remainder of this is unit


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The Principles of material Handlingserve as a starting

point to identifying potential problems and assessing

need, are:1. Planning

2. Standardization

3. Work4. Ergonomic

5. Unit Load

6. Space Utilization

7. System

8. Automation

9. Environment

10. Life Cycle Cost


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Principles of Material HandlingPlanning Principle

All material handling should be the result of a deliberate

plan where the needs, performance objectives and

functional specification of the proposed methods are

completely defined at the outset.

Definition: A plan is a prescribed course of action that is

defined in advance of implementation. In its simplest

form a material handing plan defines the material (what)and the moves (when and where); together they define

the method (how and who).


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The plan should be developed in consultation between

the planner(s) and all who will use and benefit from the

equipment to be employed.

Success in planning large scale material handling

projects generally requires a team approach involving

suppliers, consultants when appropriate, and end user

specialists from management, engineering, computer

and information systems, finance and operations.

Principles of Material HandlingPlanning PrincipleKey Points


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Principles of Material HandlingPlanning PrincipleKey Points

The material handling plan should reflect the strategic

objectives of the organization as well as the more

immediate needs.

The plan should document existing methods andproblems, physical and economic constraints, and

future requirements and goals.

The plan should promote concurrent engineering ofproduct, process design, process layout, and material

handling methods, as opposed to independent and

sequential design practices.


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Principles of Material HandlingStandardization Principle

Material handling methods, equipment, controls and

software should be standardized within the limits of

achieving overall performance objectives and without

sacrificing needed flexibility , modularity andthroughput.

Definition: Standardization means less variety and

customization in the methods and equipment employed.


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The planner should select methods and equipment thatcan perform a variety of tasks under a variety of

operating conditions and in anticipation of changing

future requirements.

Standardization applies to sizes of containers and

other load forming components as well as operating

procedures and equipment.

Standardization, flexibility and modularity must not be

incompatible.

Principles of Material HandlingStandardization PrincipleKey Points


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Principles of Material HandlingWork Principle

Material handling work should be minimized without

sacrificing productivity or the level of service required of

the operation.Definition: The measure of work is material handling

flow (volume, weight or count per unit of time) multiplied

by the distance moved.


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Simplifying processes by reducing, combining,

shortening or eliminating unnecessary moves will

reduce work.

Consider each pickup and set-down, or placingmaterial in and out of storage, as distinct moves and

components of the distance moved.

Process methods, operation sequences andprocess/equipment layouts should be prepared that

support the work minimization objective.

Principles of Material HandlingWork PrincipleKey Points


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Principles of Material HandlingWork PrincipleKey Points

Where possible, gravity should be used to move

materials or to assist in their movement while

respecting consideration of safety and the potential forproduct damage.

The shortest distance between two points is a straight

line.


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Principles of Material HandlingErgonomic Principle

Human capabilities and limitations must be recognized

and respected in the design of material handling tasks

and equipment to ensure safe and effective operations.

Definition: Ergonomics is the science that seeks to

adapt work or working conditions to suit the abilities of

the worker.


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Principles of Material HandlingErgonomic PrincipleKey Points

Equipment should be selected that eliminates repetitive

and strenuous manual labor and which effectively

interacts with human operators and users.

The ergonomic principle embraces both physical and

mental tasks.

The material handling workplace and the equipment

employed to assist in that work must be designed sothey are safe for people.


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Principles of Material HandlingUnit Load Principle

Unit loads shall be appropriately sized and configured in

a way which achieves the material flow and inventory

objectives at each stage in the supply chain.Definition: A unit load is one that can be stored or

moved as a single entity at one time, such as a pallet,

container or tote, regardless of the number of individual

items that make up the load.


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Principles of Material HandlingUnit Load PrincipleKey Points

Less effort and work is required to collect and move

many individual items as a single load than to move

many items one at a time.

Load size and composition may change as material

and product moves through stages of manufacturing

and the resulting distribution channels.

Large unit loads are common both pre and postmanufacturing in the form of raw materials and

finished goods.


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Principles of Material HandlingUnit Load PrincipleKey Points

During manufacturing, smaller unit loads, including asfew as one item, yield less in-process inventory andshorter item throughput times.

Smaller unit loads are consistent with manufacturingstrategies that embrace operating objectives such asflexibility, continuous flow and just-in-time delivery.

Unit loads composed of a mix of different items are

consistent with just-in-time and/or customized supplystrategies so long as item selectivity is notcompromised.

P i i l f M t i l H dli


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Principles of Material HandlingSpace Utilization Principle

Effective and efficient use must be made of all available

space.

Definition: Space in material handling is threedimensional and therefore is counted as cubic space.



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Principles of Material HandlingSpace Utilization PrincipleKey Points

In work areas, cluttered and unorganized spaces and

blocked aisles should be eliminated.

In storage areas, the objective of maximizing storage

density must be balanced against accessibility and

selectivity.

When transporting loads within a facility the use of

overhead space should be considered as an option.



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Principles of Material HandlingSystem Principle

Material movement and storage activities should be

fully integrated to form a coordinated, operational

system which spans receiving, inspection, storage,

production, assembly, packaging, unitizing, orderselection, shipping, transportation and the handling

of returns.

Definition: A system is a collection of interactingand/or interdependent entities that form a unified

whole.



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Principles of Material HandlingSystem PrincipleKey Points

Systems integration should encompass the entire

supply chain including reverse logistics. It should

include suppliers, manufacturers, distributors and

customers.

Inventory levels should be minimized at all stages of

production and distribution while respecting

considerations of process variability and customer

service.



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Principles of Material HandlingSystem PrincipleKey Points

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 locationand status within facilities and within the supply chain

and for controlling their movement.

Customer requirements and expectations regardingquantity, quality, and on-time delivery should be met

without exception.



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Principles of Material HandlingAutomation PrincipleKey Points

Material handling operations should be mechanized and/orautomated where feasible to improve operational efficiency, increase

responsiveness, improve consistency and predictability, decrease

operating costs and to eliminate repetitive or potentially unsafe

manual labor.

Definition: Automation is a technology concerned with the

application of electro-mechanical devices, electronics and

computer-based systems to operate and control production and

service activities. It suggests the linking of multiple mechanicaloperations to create a system that can be controlled by programmed

instructions.



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Pre-existing processes and methods should be

simplified and/or re-engineered before any efforts at

installing mechanized or automated systems.

Computerized material handling systems should be

considered where appropriate for effective integration

of material flow and information management.



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All items expected to be handled automatically must

have features that accommodate mechanized and

automated handling.

Treat all interface issues as critical to successfulautomation, including equipment to equipment,

equipment to load, equipment to operator, and control

communications.



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Principles of Material HandlingEnvironmental Principle

Environmental impact and energy consumption should

be considered as criteria when designing or selecting

alternative equipment and material handling systems.

Definition: Environmental consciousness stems from a

desire not to waste natural resources and to predict and

eliminate the possible negative effects of our daily

actions on the environment.



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Principles of Material HandlingEnvironmental PrincipleKey Points

Containers, pallets and other products used to formand protect unit loads should be designed forreusability when possible and/or biodegradability asappropriate.

Systems design should accommodate the handling ofspent dunnage, empty containers and other by-products of material handling.

Materials specified as hazardous have special needswith regard to spill protection, combustibility andother risks.



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Principles of Material HandlingLife Cycle Cost Principle

A thorough economic analysis should account for the

entire life cycle of all material handling equipment and

resulting systems.

Definition:Life cycle costs include all cash flows thatwill occur between the time the first dollar is spent to

plan or procure a new piece of equipment, or to put in

place a new method, until that method and/or

equipment is totally replaced.



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Principles of Material HandlingLie Cycle Cost PrincipleKey Points

Life cycle costs include capital investment,

installation, setup and equipment programming,

training, system testing and acceptance, operating

(labor, utilities, etc.), maintenance and repair, reusevalue, and ultimate disposal.

A plan for preventive and predictive maintenance

should be prepared for the equipment, and the

estimated cost of maintenance and spare parts should

be included in the economic analysis.



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Principles of Material HandlingLie Cycle Cost PrincipleKey Points

A long-range plan for replacement of the equipment

when it becomes obsolete should be prepared.

Although measurable cost is a primary factor, it iscertainly not the only factor in selecting among

alternatives. Other factors of a strategic nature to the

organization and which form the basis for competition

in the market place should be considered andquantified whenever possible.

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Unit09 Material Handling Principles (1)