The document outlines 10 principles for effective material handling systems and operations. The principles cover planning, standardization, minimizing work, ergonomics, unit loads, space utilization, treating the overall system as integrated, automation, environmental impact, and life cycle cost analysis. For each principle, a definition is provided along with 2-3 key points on how to apply that principle for optimal material handling.
Materials handling in lexible manufacturing systems 121MatAbramMartino96
Materials handling in lexible manufacturing systems 121
Materials handling in lexible manufacturing systems
Dr. Tauseef Aized
X
Materials handling in flexible
manufacturing systems
Dr. Tauseef Aized
Professor, Department of Mechanical, Mechatrnics and Manufacturing Engineering, KSK
Campus, University of Engineering and Technology, Lahore, Pakistan
1. Introduction
Material handling can be defined as an integrated system involving such activities as
moving, handling, storing and controlling of materials by means of gravity, manual effort or
power activated machinery. Moving materials utilize time and space. Any movement of
materials requires that the size, shape, weight and condition of the material, as well as the
path and frequency of the move be analyzed. Storing materials provide a buffer between
operations. It facilitates the efficient use of people and machines and provides an efficient
organization of materials. The considerations for material system design include the size,
weight, condition and stack ability of materials; the required throughput; and building
constraints such as floor loading, floor condition, column spacing etc. The protection of
materials include both packaging and protecting against damage and theft of material as
well as the use of safeguards on the information system to include protection against the
material being mishandled, misplaced, misappropriated and processed in a wrong
sequence. Controlling material includes both physical control as well as status of material
control. Physical control is the orientation of sequence and space between material
movements. Status control is the real time awareness of the location, amount, destination,
origin, ownership and schedule of material. Maintaining the correct degree of control is a
challenge because the right amount of control depends upon the culture of the organization
and the people who manage and perform material handling functions.
Material handling is an important area of concern in flexible manufacturing systems because
more than 80 % of time that material spends on a shop floor is spent either in waiting or in
transportation, although both these activities are non-value added activities. Efficient
material handling is needed for less congestion, timely delivery and reduced idle time of
machines due to non-availability or accumulation of materials at workstations. Safe
handling of materials is important in a plant as it reduces wastage, breakage, loss and
scrapes etc.
6
www.intechopen.com
Future Manufacturing Systems122
2. Principles of material handlings
The material handling principles provide fundamentals of material handling practices and
provide guidance to material handling system designers. The following is a brief description
of material handling principles.
2.1 Planning principle
All material handling should be the result of a deliberate plan where the needs, performance
objectives and fu ...
Materials handling in lexible manufacturing systems 121MatAbramMartino96
Materials handling in lexible manufacturing systems 121
Materials handling in lexible manufacturing systems
Dr. Tauseef Aized
X
Materials handling in flexible
manufacturing systems
Dr. Tauseef Aized
Professor, Department of Mechanical, Mechatrnics and Manufacturing Engineering, KSK
Campus, University of Engineering and Technology, Lahore, Pakistan
1. Introduction
Material handling can be defined as an integrated system involving such activities as
moving, handling, storing and controlling of materials by means of gravity, manual effort or
power activated machinery. Moving materials utilize time and space. Any movement of
materials requires that the size, shape, weight and condition of the material, as well as the
path and frequency of the move be analyzed. Storing materials provide a buffer between
operations. It facilitates the efficient use of people and machines and provides an efficient
organization of materials. The considerations for material system design include the size,
weight, condition and stack ability of materials; the required throughput; and building
constraints such as floor loading, floor condition, column spacing etc. The protection of
materials include both packaging and protecting against damage and theft of material as
well as the use of safeguards on the information system to include protection against the
material being mishandled, misplaced, misappropriated and processed in a wrong
sequence. Controlling material includes both physical control as well as status of material
control. Physical control is the orientation of sequence and space between material
movements. Status control is the real time awareness of the location, amount, destination,
origin, ownership and schedule of material. Maintaining the correct degree of control is a
challenge because the right amount of control depends upon the culture of the organization
and the people who manage and perform material handling functions.
Material handling is an important area of concern in flexible manufacturing systems because
more than 80 % of time that material spends on a shop floor is spent either in waiting or in
transportation, although both these activities are non-value added activities. Efficient
material handling is needed for less congestion, timely delivery and reduced idle time of
machines due to non-availability or accumulation of materials at workstations. Safe
handling of materials is important in a plant as it reduces wastage, breakage, loss and
scrapes etc.
6
www.intechopen.com
Future Manufacturing Systems122
2. Principles of material handlings
The material handling principles provide fundamentals of material handling practices and
provide guidance to material handling system designers. The following is a brief description
of material handling principles.
2.1 Planning principle
All material handling should be the result of a deliberate plan where the needs, performance
objectives and fu ...
Materials handling in lexible manufacturing systems 121MatAbramMartino96
Materials handling in lexible manufacturing systems 121
Materials handling in lexible manufacturing systems
Dr. Tauseef Aized
X
Materials handling in flexible
manufacturing systems
Dr. Tauseef Aized
Professor, Department of Mechanical, Mechatrnics and Manufacturing Engineering, KSK
Campus, University of Engineering and Technology, Lahore, Pakistan
1. Introduction
Material handling can be defined as an integrated system involving such activities as
moving, handling, storing and controlling of materials by means of gravity, manual effort or
power activated machinery. Moving materials utilize time and space. Any movement of
materials requires that the size, shape, weight and condition of the material, as well as the
path and frequency of the move be analyzed. Storing materials provide a buffer between
operations. It facilitates the efficient use of people and machines and provides an efficient
organization of materials. The considerations for material system design include the size,
weight, condition and stack ability of materials; the required throughput; and building
constraints such as floor loading, floor condition, column spacing etc. The protection of
materials include both packaging and protecting against damage and theft of material as
well as the use of safeguards on the information system to include protection against the
material being mishandled, misplaced, misappropriated and processed in a wrong
sequence. Controlling material includes both physical control as well as status of material
control. Physical control is the orientation of sequence and space between material
movements. Status control is the real time awareness of the location, amount, destination,
origin, ownership and schedule of material. Maintaining the correct degree of control is a
challenge because the right amount of control depends upon the culture of the organization
and the people who manage and perform material handling functions.
Material handling is an important area of concern in flexible manufacturing systems because
more than 80 % of time that material spends on a shop floor is spent either in waiting or in
transportation, although both these activities are non-value added activities. Efficient
material handling is needed for less congestion, timely delivery and reduced idle time of
machines due to non-availability or accumulation of materials at workstations. Safe
handling of materials is important in a plant as it reduces wastage, breakage, loss and
scrapes etc.
6
www.intechopen.com
Future Manufacturing Systems122
2. Principles of material handlings
The material handling principles provide fundamentals of material handling practices and
provide guidance to material handling system designers. The following is a brief description
of material handling principles.
2.1 Planning principle
All material handling should be the result of a deliberate plan where the needs, performance
objectives and fu ...
Materials handling in lexible manufacturing systems 121MatAbramMartino96
Materials handling in lexible manufacturing systems 121
Materials handling in lexible manufacturing systems
Dr. Tauseef Aized
X
Materials handling in flexible
manufacturing systems
Dr. Tauseef Aized
Professor, Department of Mechanical, Mechatrnics and Manufacturing Engineering, KSK
Campus, University of Engineering and Technology, Lahore, Pakistan
1. Introduction
Material handling can be defined as an integrated system involving such activities as
moving, handling, storing and controlling of materials by means of gravity, manual effort or
power activated machinery. Moving materials utilize time and space. Any movement of
materials requires that the size, shape, weight and condition of the material, as well as the
path and frequency of the move be analyzed. Storing materials provide a buffer between
operations. It facilitates the efficient use of people and machines and provides an efficient
organization of materials. The considerations for material system design include the size,
weight, condition and stack ability of materials; the required throughput; and building
constraints such as floor loading, floor condition, column spacing etc. The protection of
materials include both packaging and protecting against damage and theft of material as
well as the use of safeguards on the information system to include protection against the
material being mishandled, misplaced, misappropriated and processed in a wrong
sequence. Controlling material includes both physical control as well as status of material
control. Physical control is the orientation of sequence and space between material
movements. Status control is the real time awareness of the location, amount, destination,
origin, ownership and schedule of material. Maintaining the correct degree of control is a
challenge because the right amount of control depends upon the culture of the organization
and the people who manage and perform material handling functions.
Material handling is an important area of concern in flexible manufacturing systems because
more than 80 % of time that material spends on a shop floor is spent either in waiting or in
transportation, although both these activities are non-value added activities. Efficient
material handling is needed for less congestion, timely delivery and reduced idle time of
machines due to non-availability or accumulation of materials at workstations. Safe
handling of materials is important in a plant as it reduces wastage, breakage, loss and
scrapes etc.
6
www.intechopen.com
Future Manufacturing Systems122
2. Principles of material handlings
The material handling principles provide fundamentals of material handling practices and
provide guidance to material handling system designers. The following is a brief description
of material handling principles.
2.1 Planning principle
All material handling should be the result of a deliberate plan where the needs, performance
objectives and fu ...
Compiled By: Mr. Gokul O
Assistant Professor
Department of Mechanical Engineering
Sree Buddha College of Engineering, Pattoor
According to APJ Abdul Kalam Technological University Syllabus
Subject- Industrial Engineering
Course code- ME404
Social development club is a leading course content provider of India with a key focus on skilling courseware development. We deliver complete package required to deliver the Skill development program effectively. We develop NCVT and SSC aligned courses of all the domains and for all the schemes.
Contact: sdccourses@gmail.com, http://www.socialdevelopment.club
Material handling is unavoidable and is very cost in terms of accidents & damage when serious measures are not taken.
Materials should be handled by a right person in a right place under a thorough supervision of a right person.
Chapter 16. Facility Layout DecisionAfter selecting a facility.docxrobert345678
Chapter 16. Facility Layout Decision
After selecting a facility's location, the next major decision is to design the best physical layout for the facility. The available space needs to be assessed with workstations, equipment, storage, and other amenities need to be arranged. The goal is to create the most efficient workflow produce necessary to produce its goods or services at the highest level of quality with the lowest possible cost.
Layout planning is organizationally important not only for efficient operations, but other functions are impacted as well such as marketing which is affected by layout when clients come to the site, human resources as layout impacts people and finance as layout changes can be costly endeavors.
The layout decision can determine how efficient a facility is. In the case of the supply chain this is primarily focused in the warehousing function, in both the warehouse itself and various other areas including office and maintenance areas.
Layout should be considered in a variety of situations including when a new facility is being constructed, when there is a significant change in demand or through put volume, when a new good or service is introduced to the customer benefit package or different processes, equipment, and/or technology are installed.
The focus of layout improvements are to minimize delays in materials handling and customer movement, maintain flexibility use labor and space effectively, promote high employee morale and customer satisfaction, provide for good housekeeping and maintenance and enhance sales as appropriate in manufacturing and service facilities .
Types of Layouts
There are five primary types of workflow layouts that managers can choose from:
1. Product layout - Production line (e.g., an automobile assembly plant).
2. Process layout - Arranged in departments (e.g., hospitals, printer).
3. Hybrid layout – A combination of both product and process layouts.
4. Fixed-position layout: building a large item (e.g., airplane, cruise ship).
5. Cellular layout - Reorganizes people and machines into groups to focus on single products or product groups
We will now discuss each in some detail.
Product Layouts
Product arrangements are based on the sequence of operations that are performed during the manufacturing of a fairly standardized good or delivery of a service. Typically, work stations and equipment are located along the line of production, as with an assembly line for example. Batches of semi-finished (i.e. work in process) goods are passed to the next station in a production line.
Some examples of this type of layout include: winemaking industry, credit card processing, Subway sandwich shops, paper manufacturers, insurance policy processing, and automobile assembly lines.
Advantages of product layouts include lower work-in-process inventories, shorter processing times, less material handling, lower labor skills and relatively simple planning and contr.
What Is Materials Handling? Logistics Glossarykumarjamiy
The importance of the supply chain has been highlighted by recent shortages, reminding us of its crucial role in our daily lives. Although we often take for granted the seamless delivery of products to our doorsteps and store shelves, the supply chain network is actually a highly intricate system encompassing various processes such as sourcing raw materials, transportation, storage, and distribution.
Within the supply chain, material handling plays a significant role. This article explores the concept of material handling, emphasizing its significance and discussing the fundamental principles, processes, and equipment required for its efficient operation.
It is a presentation on facility layout which covers the definition of layout, objectives of good layout, factors affecting layout and types of layout.
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Compiled By: Mr. Gokul O
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Sree Buddha College of Engineering, Pattoor
According to APJ Abdul Kalam Technological University Syllabus
Subject- Industrial Engineering
Course code- ME404
Social development club is a leading course content provider of India with a key focus on skilling courseware development. We deliver complete package required to deliver the Skill development program effectively. We develop NCVT and SSC aligned courses of all the domains and for all the schemes.
Contact: sdccourses@gmail.com, http://www.socialdevelopment.club
Material handling is unavoidable and is very cost in terms of accidents & damage when serious measures are not taken.
Materials should be handled by a right person in a right place under a thorough supervision of a right person.
Chapter 16. Facility Layout DecisionAfter selecting a facility.docxrobert345678
Chapter 16. Facility Layout Decision
After selecting a facility's location, the next major decision is to design the best physical layout for the facility. The available space needs to be assessed with workstations, equipment, storage, and other amenities need to be arranged. The goal is to create the most efficient workflow produce necessary to produce its goods or services at the highest level of quality with the lowest possible cost.
Layout planning is organizationally important not only for efficient operations, but other functions are impacted as well such as marketing which is affected by layout when clients come to the site, human resources as layout impacts people and finance as layout changes can be costly endeavors.
The layout decision can determine how efficient a facility is. In the case of the supply chain this is primarily focused in the warehousing function, in both the warehouse itself and various other areas including office and maintenance areas.
Layout should be considered in a variety of situations including when a new facility is being constructed, when there is a significant change in demand or through put volume, when a new good or service is introduced to the customer benefit package or different processes, equipment, and/or technology are installed.
The focus of layout improvements are to minimize delays in materials handling and customer movement, maintain flexibility use labor and space effectively, promote high employee morale and customer satisfaction, provide for good housekeeping and maintenance and enhance sales as appropriate in manufacturing and service facilities .
Types of Layouts
There are five primary types of workflow layouts that managers can choose from:
1. Product layout - Production line (e.g., an automobile assembly plant).
2. Process layout - Arranged in departments (e.g., hospitals, printer).
3. Hybrid layout – A combination of both product and process layouts.
4. Fixed-position layout: building a large item (e.g., airplane, cruise ship).
5. Cellular layout - Reorganizes people and machines into groups to focus on single products or product groups
We will now discuss each in some detail.
Product Layouts
Product arrangements are based on the sequence of operations that are performed during the manufacturing of a fairly standardized good or delivery of a service. Typically, work stations and equipment are located along the line of production, as with an assembly line for example. Batches of semi-finished (i.e. work in process) goods are passed to the next station in a production line.
Some examples of this type of layout include: winemaking industry, credit card processing, Subway sandwich shops, paper manufacturers, insurance policy processing, and automobile assembly lines.
Advantages of product layouts include lower work-in-process inventories, shorter processing times, less material handling, lower labor skills and relatively simple planning and contr.
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The importance of the supply chain has been highlighted by recent shortages, reminding us of its crucial role in our daily lives. Although we often take for granted the seamless delivery of products to our doorsteps and store shelves, the supply chain network is actually a highly intricate system encompassing various processes such as sourcing raw materials, transportation, storage, and distribution.
Within the supply chain, material handling plays a significant role. This article explores the concept of material handling, emphasizing its significance and discussing the fundamental principles, processes, and equipment required for its efficient operation.
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1. The Ten Principles
of Material Handling
The Key to Greater Productivity, Customer Service
and Profitability
2. 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.
3. PLANNING PRINCIPLE
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).
4. PLANNING PRINCIPLE
Key Points
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.
The material handling plan should reflect the
strategic objectives of the organization as well as the
more immediate needs.
5. PLANNING PRINCIPLE
KEY 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
and problems, physical and economic
constraints, and future requirements and
goals.
6. PLANNING PRINCIPLE
KEY POINTS
The plan should promote concurrent
engineering of product, process design,
process layout, and material handling
methods, as opposed to independent and
sequential design practices.
7. STANDARDIZATION 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.
9. STANDARDIZATION PRINCIPLE
Key Points
The planner should 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 applies to sizes of
containers and other load forming
components as well as operating procedures
and equipment.
11. WORK PRINCIPLE
Material handling work should be
minimized without sacrificing productivity
or the level of service required of the
operation.
12. WORK PRINCIPLE
Definition: The measure of work is
material handling flow (volume, weight or
count per unit of time) multiplied by the
distance moved.
13. WORK PRINCIPLE
Key Points
Simplifying processes by reducing,
combining, shortening or eliminating
unnecessary moves will reduce work.
Consider each pickup and set-down, or
placing material in and out of storage, as
distinct moves and components of the
distance moved.
14. WORK PRINCIPLE
Key Points
Process methods, operation sequences and
process/equipment layouts should be
prepared that support the work
minimization objective.
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.
16. 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.
18. ERGONOMIC PRINCIPLE
Key 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 so they are safe for
people.
19. 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.
20. UNIT LOAD PRINCIPLE
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.
21. UNIT LOAD PRINCIPLE
Key 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
post manufacturing in the form of raw
materials and finished goods.
22. UNIT LOAD PRINCIPLE
Key Points
During manufacturing, smaller unit loads,
including as few as one item, yield less in-
process inventory and shorter item
throughput times.
Smaller unit loads are consistent with
manufacturing strategies that embrace
operating objectives such as flexibility,
continuous flow and just-in-time delivery.
23. UNIT LOAD PRINCIPLE
Key Points
Unit loads composed of a mix of different
items are consistent with just-in-time and/or
customized supply strategies so long as item
selectivity is not compromised.
26. SPACE UTILIZATION
Key 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.
27. SYSTEM 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,
order selection, shipping, transportation
and the handling of returns.
28. SYSTEM PRINCIPLE
Definition: A system is a collection of
interacting and/or interdependent entities
that form a unified whole.
29. SYSTEM PRINCIPLE
Key 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.
30. SYSTEM PRINCIPLE
Key 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 location and status
within facilities and within the supply
chain and for controlling their movement.
31. SYSTEM PRINCIPLE
Key Points
Customer requirements and expectations
regarding quantity, quality, and on-time
delivery should be met without exception.
32. 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 to eliminate repetitive
or potentially unsafe manual labor.
33. AUTOMATION PRINCIPLE
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 mechanical
operations to create a system that can be
controlled by programmed instructions.
34. AUTOMATION PRINCIPLE
Key Points
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.
35. AUTOMATION PRINCIPLE
Key Points
All items expected to be handled
automatically must have features that
accommodate mechanized and automated
handling.
Treat all interface issues as critical to
successful automation, including equipment
to equipment, equipment to load, equipment
to operator, and control communications.
36. ENVIRONMENTAL PRINCIPLE
Environmental impact and energy
consumption should be considered as
criteria when designing or selecting
alternative equipment and material
handling systems.
37. ENVIRONMENTAL PRINCIPLE
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.
38. ENVIRONMENTAL PRINCIPLE
Key Points
Containers, pallets and other products used
to form and protect unit loads should be
designed for reusability when possible
and/or biodegradability as appropriate.
Systems design should accommodate the
handling of spent dunnage, empty
containers and other by-products of
material handling.
40. LIFE CYCLE COST PRINCIPLE
A thorough economic analysis should
account for the entire life cycle of all
material handling equipment and resulting
systems.
41. LIFE CYCLE COST PRINCIPLE
Definition: Life cycle costs include all
cash flows that will 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.
42. LIFE CYCLE PRINCIPLE
Key Points
Life cycle costs include capital investment,
installation, setup and equipment
programming, training, system testing and
acceptance, operating (labor, utilities, etc.),
maintenance and repair, reuse value, 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.
43. LIFE CYCLE PRINCIPLE
Key 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 is certainly not the only factor in
selecting among nature alternatives. Other
factors of a strategic to the organization
and which form the basis for competition in
the market place should be considered and
quantified whenever possible.