VAIBHAV PATHAKB.TECH 4 YEAR MECHANICAL

MATERIAL HANDLING SYSTEMS AND THEIR CLASSIFICATION.

PRINCIPLE OF EFFECTIVE MATERIAL HANDLING

CONTENTS INTRODUCTION OBJECTIVES OF MATERIAL HANDLING CLASSIFICATION OF MATERIAL HANDLING SYSTEM PRINCIPLES OF MATERIAL HANDLING

Material handling means providing the right amount of the right material, in the right condition, at the right place, at the right time, in the right position and for the right cost, by using the right method

It applies to the movement of raw materials, parts in process, finished goods, packing materials, and disposal of scraps.

The cost of material handling contributes significantly to the total cost of manufacturing.

A properly designed and integrated material handling system provides tremendous cost saving opportunities and customer services improvement potential.

INTRODUCTION

OBJECTIVES OF MATERIAL HANDLING

The primary objective of a material handling system is to reduce the unit cost of production.

The other subordinate objectives are:1. Reduce manufacturing cycle time2. Reduce delays, and damage3. Promote safety and improve working conditions4. Maintain or improve product quality

5. Promote productivity Material should flow in a straight line. Material should move as short a distance as possible. Use gravity. Move more material at one time Automate material handling.6. Promote increased use of facilities Promote the use of building cube Purchase versatile equipment Develop a preventive maintenance program Maximize the equipment utilization etc.7. Reduce tare weight8. Control inventory.

Classification Of Material Handling Equipment

It constitute a group of equipment which are employed mainly for lifting or lowering of unit load or piece goods in batches. This group of equipment can be further sub classified into:

1. Pure Hoisting Machineries•Jack•Hand Hoists•Pulley Blocks2. Cranes

3. Elevators•Lift•Bucket Elevators

HOIST MATERIAL HANDLING EQUIPMENT

CONVEYING EQUIPMENT

It comprises of a number of equipment which are employed for handling principally bulk load (occasionally piece goods or unit load may also be handled) in continuous flow. Such machines do not have separate lifting or lowering gear. This group of equipment also can have further sub classifications as:1. Belt conveyor2. Roller conveyor3. Skate wheel conveyor4. Overhead trolley conveyors5. In floor taw line.

These are the group of equipment which are employed for handling unit load or bulk load in batches on a horizontal surface. This group of equipment may be further sub classified into:1. Truck and Lorries2. Railway Cars and Wagons3. Fork Lifts4. Overhead mono-rail / Equipment5. Scrapers and Skidders

SURFACE / OVERHEAD EQUIPMENT

ROBOTICS IN MATERIAL HANDLING

A computer-controlled overhead conveyor system is provided wherein all conveyor vehicles substantially continually communicate with a control system to be routed through the track network.

The track is conceptually divided into zones each identified by an optically read marker; and the vehicles include scanners for reading the markers as the vehicles traverse the track. The marker information is communicated to the control system which controls track switches and vehicle velocities to prevent collisions and to direct the vehicles to desired destinations

COMPUTER CONTROLLED CONVEYORS

An automated guided vehicle or automatic guided vehicle (AGV) is a mobile robot that follows markers or wires in the floor, or uses vision, magnets, or lasers for navigation

AUTOMATED GUIDED VEHICLE

•Repetitive movement of materials over distance•Regular delivery of stable loads•Medium throughput/volume•When on-time delivery is critical and late deliveries are causing inefficiency•Operations with at least two shifts•Processes where tracking material is important

Types of Material Handling Equipment Loads:It usually classified into:1. Unit Load2. Bulk Load

Unit Load: Unit loads are those which are counted by numbers or units. A component of a machine, a complete machine, a structural element, a beam, a girder, building block are some examples of unit load.

Sometimes certain quantities of free flowing materials can be placed in a container and can be handled as unit load. Hoisting equipment are primarily used for handling unit load. Unit loads are usually specified by it’s weight.

Bulk Load:When the load is in the form of particles or lumps of homogeneous materials or powder like materials, which cannot be counted by numbers, it is called as Bulk load.Examples are:Sand, Cement, Coal, Mineral, Stone, Clay etc.,

A bulk material may be classified by the following properties:1. Bulk Density2. Lump-Size3. Flowability4. Abrasiveness5. Miscellaneous Characteristics

LIMITATIONS OF AUTOMATED MATERIAL HANDLING SYSTEMS:

A good management practice is to weigh benefits against the limitations or disadvantages before contemplating any change.Material handling systems also have consequences that may be distinctly negative. These are:1. Additional investment2. Lack of flexibility3. Vulnerability to downtime whenever there is breakdown4. Additional maintenance staff and cost5. Cost of auxiliary equipment.6. Space and other requirements.

Principles of Material HandlingMaterial handling principles are as follows:

Orientation Principle: It encourages study of all available system relationships before moving towards preliminary planning. The study includes looking at existing methods, problems, etc.

Planning Principle: It establishes a plan which includes basic requirements, desirable alternates and planning for contingency.

Systems Principle: It integrates handling and storage activities, which is cost effective into integrated system design.

Unit Load Principle: Handle product in a unit load as large as possible Space Utilization Principle: Encourage effective utilization of all the space

available

Standardization Principle: It encourages standardization of handling methods and equipment.

Ergonomic Principle: It recognizes human capabilities and limitation by design effective handling equipment.

Energy Principle: It considers consumption of energy during material handling.

Ecology Principle: It encourages minimum impact upon the environment during material handling.

Flexibility Principle: Encourages of methods and equipment which are possible to utilize in all types of condition.

Simplification Principle: Encourage simplification of methods and process by removing unnecessary movements

Gravity Principle: Encourages usage of gravity principle in movement of goods.

Safety Principle: Encourages provision for safe handling equipment according to safety rules and regulation

Computerization Principle: Encourages of computerization of material handling and storage systems

System Flow Principle: Encourages integration of data flow with physical material flow

Layout Principle: Encourages preparation of operational sequence of all systems available

Cost Principle: Encourages cost benefit analysis of all solutions available Maintenance Principle: Encourages preparation of plan for preventive

maintenance and scheduled repairs Obsolescence Principle: Encourage preparation of equipment policy as to

enjoy appropriate economic advantage.