Material management by kailash vilegave shivajirao S. Jondhle college of pharmacy
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Material management by kailash vilegave shivajirao S. Jondhle college of pharmacy

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Selection of material handling

Selection of material handling
Maintenance of material handling equipment
Unit-load, palletization & containerization
Types of material handling

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Material management by kailash vilegave shivajirao S. Jondhle college of pharmacy Material management by kailash vilegave shivajirao S. Jondhle college of pharmacy Presentation Transcript

  • MATERIAL MANAGEMENT Mr. Kailash Vilegave. Dept. of Pharmaceutics, Shivajirao S Jondhle college of Pharmacy Asangaon, Thane9/2/2012 1
  • CONTENTS Selection of material handling Maintenance of material handling equipment Unit-load, palletization & containerization Types of material handling References9/2/2012 2
  • Materials Handling Material handling is an activity that uses the right method to provide the right amount of the right material at the right place, at the right time, in the right sequence, in the right position and at the right cost9/2/2012 3
  • 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 productivity  material should flow in a straight line  use gravity! It is free power  move more material at one time  mechanize material handling  automate material handling9/2/2012 4
  • Goals of Material Handling Promote increased use of facilities Reduce tare weight (dead weight) Control inventory9/2/2012 5
  • Importance of Material management Increase in cost of raw materials & finished products Delay in production schedule & long cycle Increase in in-process inventories Damage or loss of material & employee safety liabilities Employee frustration & reduced morale Customers dissatisfaction9/2/2012 6
  • Applications of material managementequipment in pharmaceutical industry Production department Stores department9/2/2012 7
  • Functions of material handling Handling of unit load :-the principle of containerization, unit-load & palletization are employed for moving an optimum number of pieces at a time to their ultimate destinations. Placement of equipment :-In production operations, appropriate plant layout & proper placement of equipment minimizes the movement of materials. Appropriate material handling equipment :- Mechanical aids should be employed in place of manual handling.9/2/2012 8
  • Selection of material handling systems The best equipment is one that : Permits smooth & continuous production flow Involves less number of accidents Reduces production cycles time Promotes better working condition Lessens fatigue to the operators Brings down total material handling cost9/2/2012 9
  •  Nature of material to be moved :- the size, weight, delicacy, nature (solid, liquid, gas) of material & chances of getting damaged during handling should be considered. Plant building & layout :-A multi-storeyed building facilitates the use of gravity for material flow. The door locations,sizes,ceiling heights, roof& floor strenghts,columns,etc.. Production machines :-Different machines have different outputs per unit time.9/2/2012 10
  •  Type of material flow patterns :-A vertical flow pattern requires elevators,conveyors,pipes etc.,whereas horizontal flow patterns need trucks, overhead bridges, cranes, conveyors etc. Type of production :-Conveyors are more suitable for fixed routes for continuous process & powered trucks are suitable for batch operation.9/2/2012 11
  •  Cost of material handling equipment :-The initial cost of handling equipment are high. when human contact with product must be minimized, equipment is the alternative, hence cost does not limit the installation. Handling costs :-Economy in material handling can be achieved by employing gravity-aided movements & minimizing the distance of material travel. A system that allows the product directly fall over the material handling equipment is more ideal.9/2/2012 12
  •  Life of equipment :-Proper periodic insepection,repairs & maintaences of equipment increases its life. smoothen the flow of materials & economize the production system.9/2/2012 13
  • Maintenance of material handlingequipment Inspection :-all parts, open or covered are inspected for wear & tear. Worn out or unworkable components such as wire ropes, bearing & bolts, are identified & remedial measures are taken. Breaks are adjusted & lubricated wherever & whenever necessary. Repairs :-After inspection, all repairable parts are corrected & minor defected are rectified. open gear transmission, coupling, riveted & bolted joints, trolleys, breaks, guards etc., require frequent repairs.9/2/2012 14
  •  Overhaul:-involves dismantling the complete mechanism & replacing the damage components. Crane structure, buffers, rails, open gear transmission, pulley blocks etc., may be overhauled & various sub mechanisms may be aligned & adjusted.9/2/2012 15
  • Unit-load, palletization & containerization It is easier & faster to move a hundred small parts by grouping them into one unit than moving them individually one by one. these are collectively known as unit-load. For example, each formulation of tablet contains a number of ingredients. For a lot size, ingredients(raw materials) are weighed & packed individually & loaded onto a pallet.9/2/2012 16
  •  Pallet is one unit load Unit load & palletizaton these are moved to the production department by suitable handling system. Depending on the types of item to be transferred, a suitable pallet can be designed. for example, items of irregular in shape are liable to be damaged by crushing, for such items, a post pallet is useful. small items can be placed in a wire mesh- box.9/2/2012 17
  •  Containerization uses  Containerization the principle of unit load. in this system, a big metal container is filled with a number of small products. many such containers are placed on a truck or trailer that is pulled by tractor or truck. such containers can be loaded on railway trailers & transported.9/2/2012 18
  • Types of material handling systems Conveyors:-are employed for transporting materials in a fixed path, which may be horizontal, vertical or inclined to different locations of a factory. these prove economical, if the flow of material is continuous.9/2/2012 19
  • Belt conveyors It is used in transporting containers (bottles) for filling, capping, sealing, labeling, visual inspection etc.,in production of injectables,liquid orals, ointments & jellies. Several types of other conveyor are available. example are roller conveyor, slat conveyor, wheel conveyor, apron conveyor, pusher bar conveyor, & bucket conveyor.9/2/2012 20
  •  Belt Conveyors  Conveys materials along horizontal, and slightly inclined paths  Driven by power operated roll mounted underneath the conveyor or at the one end of the conveyor.  supported on either rollers or on metal slider pan and we call them roller conveyor and slider conveyor respectively9/2/2012 21
  • Belt conveyors-advantages Belt can be made of asbestos fibers, neoprene, Teflon, & vinyl polymer. cord belt are also used. Belt conveyors are for general purpose installation & available in relatively large sizes. these can travel several kilometers as in case of coal mines. Routine maintenance is easy. It is economical. Disadvantage-it is expensive.9/2/2012 22
  • Pneumatic conveyor Pneumatic conveyor or pipeline conveyor is one of the most commonly used handling techniques in chemical industry. it is employed when the material is light & bulky, for example, formulation of powder insufflations. This type of conveyor is a closed system, handling of unpleasant & injurious substance is easy. it is used for transporting of granular(example,wheat)or pulverized material(example,salt)through the pipes.9/2/2012 23
  • Pneumatic Conveyors Involves the transportation of a wide variety of dry powdered and granular solids in a gas stream. In most cases the gas is normally air. Where special conditions prevail, different gases are used.9/2/2012 24
  • Why Pneumatic Conveying? Advantages  Dust free transportation of a variety of products.  Flexibility in routing.  Low maintenance and low manpower costs.  Multiple use.  Security.  Ease of automation and control.9/2/2012 25
  • Why Pneumatic Conveying? Disadvantages  High power consumption  Wear and abrasion of equipment  Incorrect design can result in particle degradation  Limited distance  By virtue of the complex flow phenomenon which take place, there is a requirement for high levels of skill to design, operate and maintain systems9/2/2012 26
  • Fork-lift trucks It consist of forks attached to a column of the truck. fork can be lifted upto the desired height with material(boxes) on them. the material can be stacked at the proper place very close to the roof in warehousing & shinning area. fork-lift trucks are used for short distance(40 to 70 meters) travel. these are used for indoor applications.9/2/2012 27
  •  Platform truck (low-lift) is used for transporting the palletised raw materials of a lot-size manually from the warehouse to the production area. Platform trucks (high lift) is used for loading the tablet granules into double cone blender.9/2/2012 28
  •  Three wheel engine powered Electric fork-lift fork-lift9/2/2012 29
  • cranes Cranes are employed for lifting & lowering of bulky items, packages & boxes. these find applications in heavy engineering industry & generally in intermittent type of production.9/2/2012 30
  • Hoists Hoists means lift or pull something up to higher place (overhead position) with ropes. this equipment is mounted on single rail fixed at the height nearer to the roof. hence, material are transferred along fixed path. hoists find application in industries employing chemical cleaning. Cranes are used for heavy items & hoists are employed for small items.s9/2/2012 31
  •  Air-operated hoist electric hoist9/2/2012 32
  • Slides, chutes & lifts Slides can be straight, spiral & vibrating, & made up of wood or steel. these transfer small jobs that can slide down under gravity. vibrating slides transport material up & inclined.(example,cigar- ette factories)9/2/2012 33
  • chutes Chutes have sheet metal or roller base for transferring components down the incline. chutes generally deliver the feed material directly onto the conveyor to reach the destination further. Spiral chutes are used for transporting sealed vials from aseptic area to packing section using gravity principle.9/2/2012 34
  • Lifts Lifts are used to transport material up in multi- storeyed plants. it is a fast & flexible equipment for floor to floor travel. buckets or trays are mounted on the endless chain running from the ground floor to the top floor. the material can be loaded into trays automatically.9/2/2012 35
  • Tractors & trailers Three wheeled or four wheeled tractors are employed & fitted with an IC engine drive. these are used for outdoor applications. Trailers are loaded with the material & attached to the tractor. it can be either uncoupled from the tractor or the material can be dumped in respective stations.9/2/2012 36
  • References Pharmaceutical Production & Management by C.V.S. Subrahmanyam, Vallabh Prakashan, first edition, pg. no. 260-267. Modern business organization & Management systems approach by Prof.S.A.Sherlekar,V.S.Sherlekar, Himalaya publishing house, 5th edition,pg.no.5.38–5.58. Applied production & operation management by Evans, Anderson, Sweemey & Williams, 3rd edition, West publishing company ltd. Management (Task, responsibility & practices) by Peter F. Ducker, Allied publication, Bangalore. The eastern pharmacist-1993 www.google.com9/2/2012 37
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