material handling systems

1. MATERIAL HANDLING
Module 3
08.801. Facilities Planning & Management

2. Material Handling
 Handling of raw-materials, semi-finished parts and
finished products, mechanically or manually through the
production as well as storage areas
 In batches or one item at a time
 Horizontal, vertical or combinational movements
 About 25% of total cost
 A single component may be handled 50 times on an average
before it is transformed into final product
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3. Functions of Material Handling
 Internal movements
 Inter departmental transportation
 Movement and positioning
 For storage
 For stocking and sale
 Loading and unloading to and from transport
vehicles
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4. Material Handling Principles
 Principle 1 - PLANNING 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.
 Reduction in handling
 Plant layout aimed at eliminating MH as far as possible
 Plan developed in consultation between the planner(s) and all
who will use and benefit from the equipments
 Plan promoting concurrent engineering of product, process
design, process layout, and material handling methods as
opposed to independent and sequential design practices.
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5.  Principle 2 - STANDARDIZATlON 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, and throughput.
 Less variety & customization in the methods and equipment
employed.
 Applies to sizes of containers, other load forming components,
operating procedures and equipment
 Select methods and equipment that can perform a variety of tasks
under a variety of operating conditions and in anticipation of
changing future requirements.
 Standardization, flexibility, and modularity must not be incompatible.
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6.  Principle 3 - WORK PRINCIPLE
Material handling work should be minimized without
sacrificing productivity or the level of service required of
the operation.
 Measure of material handling work is flow rate (volume,
weight, or count per unit of time) multiplied by distance moved.
 Simplifying processes by reducing, combining, shortening, or
eliminating unnecessary moves will reduce work.
 Where possible, gravity should be used to move materials or
to assist in their movement while respecting consideration of
safety and the potential for product damage.
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7.  Principle 4 - ERGONOMIC 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.
 Ergonomics is the science that seeks to adapt work or working
conditions to suit the abilities of the worker.
 Material handling workplace and the equipment must be designed
so they are safe for people.
 Ergonomic principle embraces both physical and mental tasks.
 Equipment that eliminates repetitive and strenuous manual labour
and that effectively interacts with human operators and users
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8.  Principle 5 - UNIT 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.
 Unit load- one which can stored or moved as a single entity
 Less effort & work are required to collect and move many
individual items as a single load than to move many items one at
a time.
 Large unit loads are common in both pre- and post-manufacturing
in the form of raw materials and finished goods.
 Smaller unit loads - flexibility, continuous flow and just-in-time
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9.  Principle 6 - SPACE UTILIZATION PRINCIPLE
Effective and efficient use must be made of all
available space.
 Space in material handling is three-dimensional and counted as
cubic space.
 In storage areas, the objective of maximizing storage density
must be balanced against accessibility and selectivity.
 Use of overhead material handling systems saves valuable
floor space for productive purposes.
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10.  Principle 7 - SYSTEM PRINCIPLE
Material movement and storage activities should be
fully integrated to form a coordinated, operational
system that spans receiving, inspection, storage,
production, assembly, packaging, unitizing, order
selection, shipping, transportation, and the handling of
returns.
 Systems integration considering the entire supply chain,
including reverse logistics
 Inventory levels should be minimized at all stages of
production and distribution
 Methods should be provided for easily identifying materials
and products, for determining their location and status
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11.  Principle 8 - AUTOMATION PRINCIPLE
Material handling operations should be mechanized and/or
automated where feasible to improve operational efficiency,
increase responsiveness, improve consistency and
predictability, decrease operating costs, and eliminate
repetitive or potentially unsafe manual labor.
 Items to be handled automatically must have standard shapes
and/or features that permit such systems
 Interface issues are critical to successful automation
 Computerized MHS should be considered where appropriate for
effective integration of material flow and information
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12.  Principle 9 - ENVIRONMENTAL PRINCIPLE
Environmental impact and energy consumption should be
considered as criteria when designing or selecting
alternative equipment and material handling systems.
 Do not waste natural resources and to predict and eliminate the
possible negative effects of our daily actions on the environment.
 Containers, pallets, and other products used to form and protect
unit loads should be designed for reusability and/or
biodegradability
 Materials specified as hazardous have special needs with regard
to spill protection, combustibility, and other risks.
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13.  Principle 10 - LIFE CYCLE COST PRINCIPLE
A thorough economic analysis should account for the
entire life cycle of all material handling equipment and
resulting systems.
 Includes capital investment, installation, setup and equipment
programming, training, system testing and acceptance,
operating, maintenance and repair, reuse value, and ultimate
disposal.
 Plan for preventive & 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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14. Material Handling Devices
 Three types
 Lifting & lowering devices ( vertical movements)
 Transporting devices ( horizontal movements)
 Devices which lift & transport ( combination devices)
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15. Lifting & lowering devices
 Block & tackle
 Hand & power winches
 Hoists
 Elevators
 Pillar crane
 Overhead crane
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16. Transporting devices
 Wheel barrows
 Trucks
 Industrial narrow railways
 Tractors & trailers
 Pipelines
 Pumps
 Trams
 Automated guided vehicles (AGVs)
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17. Devices which lift & transport
 Fork lift trucks
 Crane trucks
 Cranes
 Different types of Chutes
 Different types of Conveyors
 Spiral rollers
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18. Conveyors
 A conveyor is a
mechanized device to
move materials in relatively
large quantities between
specific locations over a
fixed path.
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19.  Roller conveyors - Series of tube rollers perpendicular to motion
direction, which can be powered or use gravity for motion.
 Skate-wheel conveyors - Similar to rollers but use skate wheels
parallel to motion direction.
 Belt conveyors - Drives move flat or belts shaped into a trough.
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20.  Chain conveyors - Uses
loops of chain that are
typically moved by sprockets
as driven by motors.
 Overhead trolley conveyors -
Items are moved in discrete
loads by hooks or baskets
suspended from overhead
rails
Trolley
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21.  In-floor towline conveyors -
Similar to overhead trolley but
carts are pulled by hook to in-
floor conveyor.
 Cart on track conveyors -
Items are moved by a cart
attached to a rail system,
which uses a rotating tube to
move the cart along the rail.
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22. Automated Guided Vehicle (AGV)
 An AGV is an
independently operated
vehicle that moves material
along defined paths
between defined delivery
points or stations. Typically
the paths are defined by
either using wires
embedded in the floor or
reflecting paint strips on the
floor.
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23. Automated Storage and Retrieval System
(AS/RS)
 An AS/RS is a combination
of equipment and controls
which handles, stores, and
retrieves materials with
precision, accuracy, and
speed under a defined
degree of automation.
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24. Selection of MHS
 Nature of operations
 Temporary or permanent
 Continous or intermittent
 Flow pattern – V/H
 Type of layout
 Material to be handled
 Size and shape
 Quantity & weight
 Material characteristics
 Susceptibility to damage
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 Distance to be moved
 Fixed / long distance
 Workstations
 Installation & operating cost
 Initial investment
 Operating & maintenance cost
 Plant facilities
 Types of buildings
 Floor load capacity

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 Equipment reliability
 Use of standard components
 Service facilities
 Supplier reputation
 Engineering factors
 Door & ceiling dimensions
 Floor condition & structural strength
 Traffic safety
 Safety considerations

27. Designing MHS
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 Define objectives & scope for the mhs
 Analyze the requirements for
 Moving
 Storing
 Protecting
 Controlling
 Generate alternate designs
 Evaluate alternate system designs
 Select preferred design
 Implement- Train – Install – Audit - Maintain

28. Riddler
 Suitable MHS for
 Library
 Airport
 Textile industry
 Automobile assembly unit
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