Ch 8 material handling


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Ch 8 material handling

  1. 1. <ul><li>Important concepts in Material Handling </li></ul><ul><li>Material Handling </li></ul><ul><li>Unitization </li></ul><ul><li>Palletisation </li></ul><ul><li>Containerization </li></ul><ul><li>Inter-modal transportation and related benefits </li></ul><ul><li>Lead-time </li></ul><ul><li>Cost </li></ul>
  2. 2. <ul><li>Material handling </li></ul><ul><li>Definition: “the art & science of moving, packing & storing substances in any form” </li></ul><ul><li>Receiving, moving, storing, dispatching activities </li></ul><ul><li>Impact on Quality, cost [capital as well as running], Delivery & Safety </li></ul><ul><li>Objectives of material handling </li></ul><ul><li>Movement minimization </li></ul><ul><li>Cost minimization </li></ul><ul><li>Time minimization </li></ul><ul><li>Commonly used equipment - forklifts, EOT Cranes, hoists, pulley blocks, trolleys, railroad cars, conveyers, ropes, slings, carousels, sortations, robotics </li></ul>
  3. 3. Unitization, unit loads
  4. 4. <ul><li>Benefits of Unitization & unit loads </li></ul><ul><li>Ease of movement </li></ul><ul><li>Standardization of handling equipment, </li></ul><ul><li>methods and training </li></ul><ul><li>Reduction in time and cost of handling </li></ul><ul><li>Inbound shipment checking is simplified </li></ul><ul><li>product protection is improved </li></ul><ul><li>Examples: bottles in crates, steel sheets in coils, steel ropes in coils etc. container is an example of unit load. </li></ul>
  5. 5.
  6. 6. Palletization Pallet is a Unit load platform
  7. 7. <ul><li>Benefits of Palletization </li></ul><ul><li>Unit load is secured on a pallet, pallet provides a secure base for the unit load </li></ul><ul><li>Leads to containerization, container is a (unit load) self contained, ie., unitized and palletized, shipping unit </li></ul><ul><li>Facilitates use of standardized handling equipment like a forklift or a crane </li></ul><ul><li>Palletized unit loads bring down time of handling and cost of handling </li></ul><ul><li>Ensures safe handling </li></ul><ul><li>Product is well protected </li></ul>
  8. 8. <ul><li>Types of pallets </li></ul><ul><li>Wooden pallets </li></ul><ul><li>Plastic pallets </li></ul><ul><li>Composite pallets </li></ul><ul><li>Refrigerated pallets: self-contained shipping units for refrigerated materials </li></ul><ul><li>Pallet pools </li></ul><ul><li>central pools to collect pallets and issue pallets to global business </li></ul>
  9. 9. HOIST EOT
  10. 10. pulley block forklift
  11. 11. conveyers
  12. 12. Automatic Guided Vehicles
  13. 13.
  14. 14. <ul><li>Principles of material handling </li></ul><ul><li>Planning - high impact on cost </li></ul><ul><li>Integration – material handling decision should be part the corporate strategy-foundation, floors, layout, product </li></ul><ul><li>Standardization – handling methods, equipment, software </li></ul><ul><li>Work – minimum handling </li></ul><ul><li>Ergonomics – tasks, equipment and human beings </li></ul><ul><li>Use of gravity- always use gravity to advantage </li></ul>
  15. 15. <ul><li>Unit load- handle only in unit loads </li></ul><ul><li>Space utilization- use space and not area, EOT rather than F/Ls </li></ul><ul><li>System – integrate handling & storage (O/H tanks and pipe lines) and form Operational Material Handling System </li></ul><ul><li>Auomation - need based </li></ul><ul><li>Environment - explosive? </li></ul>
  16. 16. <ul><li>Signs of Poor Material Handling </li></ul><ul><li>Cluttered floor </li></ul><ul><li>Accidents </li></ul><ul><li>Excess inventory </li></ul><ul><li>High waiting time, high Through Put Time, poor flow of material </li></ul><ul><li>Excessive handling </li></ul><ul><li>Poor quality of product, high scrap </li></ul><ul><li>Lack of standardization </li></ul><ul><li>Poor use of skilled labor </li></ul>
  17. 17. <ul><li>Material handling system </li></ul><ul><li>Types of Material Handling Systems: Manual, mechanized, automatic, computerized </li></ul><ul><li>Elements of the system: human, equipment, storage, packaging </li></ul><ul><li>Equipment selection & Purchase </li></ul><ul><li>Full utilization of existing equipment </li></ul><ul><li>Overall cost reduction </li></ul><ul><li>Standardization </li></ul><ul><li>Integration with current system </li></ul><ul><li>Alternate methods – production should not halt </li></ul>
  18. 18. <ul><li>Facility limitation, building, floors etc </li></ul><ul><li>Future plan </li></ul><ul><li>Maintenance support </li></ul><ul><li>Life cycle cost </li></ul>