Material Handling

1. K.RAJ MOHAN

2. MATERIAL HANDLING MEANS
 LOADING
 UNLOADING
 TRANSPORTATION
 PUSH
 PULL
 HOLD
 CARRY & LIFT

3. Why Material Handling Plays Vital Role
in Engineering Industry ?
 30 To 40% Of Accidents due to M.H.
 45% Of Production Time due to M.H.
 30% Of Production Cost due to M.H.
 50 To 100 Times Handled before Shipping.

5. Manual Handling Operation means
Any transporting or supporting of a load including
Lifting, putting down, pushing, pulling, carrying or
moving by hand or bodily force.
Background
34 % of ALL accidents reported are manual
handling
Most Manual Handling injuries are accumulative
46% affect the BACK
64% are sprains / strains

6. Manual Handling & Lifting
• Everyone lifts and carries most of the times
through out their lives.
• The more you lift successfully the more
complacent you become.
• Many back injuries are caused to people who
have a great deal of experience.
• Prevention is better than cure.
• Correct training followed by a high standard of
discipline throughout life is the only answer.

8. Stop & Think
- Assess – Where, How Long,
How Complicated, Can Manual
Handling Be Avoided Etc
Place The Feet
Apart to Give a Balanced and
Stable Base for Lifting.

9. Adopt A Good Posture
• Bend the knees so that the hands are
as near to the waist as possible.
• Keep the back straight, chin tucked in,
lean over the load if necessary.
[ Shoulders in same direction as hips ]

10. Get A Firm Grip
• Try to keep, the arms within the
boundary formed of the legs.
Don’t Jerk
• Carry out lifting smoothly

11. Move The Feet
• Don’t twist the trunk when turning to the
side.
Keep Close To The Load
Keep the load close to the trunk for as
long as possible.

12. Put Down
• Then adjust,
• If precise positioning is necessary.
Team Lifting
• When team lifting, we have to include the
words “prepare to “ before any command to
gain the attention of the whole group,
thereby, ensuring a team effort and
preventing one or more members of the
team from day-dreaming. - Alertness

13. ADDITIONAL SAFETY PRACTICES IN
MANUAL HANDLING.
1. Restrict the load to be lifted and carried
by a single person to 50 Kg.
2. A trial lift is recommended before actual
lifting of the load, if the load is not within
one’s capacity, suitable help should be
provided.
3. Before lifting ascertain that intended path
of movement is free from obstacles

14. When lifting a object to a high level use a bench or
support and make the lift in two stages.
• Use personal protective equipment as the
situation warrants.
• While carrying a load, if a change in direction is
desired do not twist the body. Instead, change
the direction of entire body including feet in the
intended direction.
• Use manual handling aids such as crow bars,
hand hooks etc. Keep these tools in good state
of repair.

15. MANUAL HANDLING
As per Factory Act Sec. 34 & Rule 57 Max. weight that can be
carried.
 Adult Male 50 Kg.
 Adult Female 30 Kg.
 Adolescent Male 30 Kg.
 Adolescent Female 20 Kg.
 Male child 16 Kg.
 Female child 13 Kg.

17. MATERIALS HANDLING EQUIPMENT
1. Eot Cranes
2. Gantry Cranes
3. Semi Gantry
4. Pillar Type
5. Fork Lifts
6. Jambos
7. Mobile Cranes
8. Loco
9. Front End Loader
• Lorries, Trailors.

18. SAFE OPERATION OF CRANE DEPENDS ON
 Rigger
 Crane Operator
 Maintenance Persons
 Competent persons
 Statutory Authority

19. GENERAL SAFETY INSTRUCTION
1. When not in use crane should be parked with load
hook raised, control switches to neutral & main
switch open.
2. No crane shall be used for the purpose of
transportation of passengers.
3. Cranes on same runways should be avoided from
collision.
4. The Crane Operator should ensure the availability &
serviceable condition of fire extinguishers.

20. 5. Crane should not be used for dragging & pulling.
6. Impact load should be avoided.
7. The condition of ropes, slings are to be checked before
loading.
8. Notify the shift in charge for and special lifts.
9. Spreader beam to be used for lengthy objects.
10.Operator should follow signal from only one person.
But he should respond for stop signal from any persons.
11.For any maintenance work on crane, runway “Permit
to work” system to be followed.

21. STATUES
FACTORIES ACT 1948 – SECTION 29.
Lifting machines, chains, ropes, lifting tackles to be
tested by competent person.
Register to be maintained with all particulars.

22. SAFETY PROVISIONS (EOT CRANES)
Bumpers on trolley, bridges & rails to prevent shock
over travel.
Limit switches to cut off supply in longitudinal, cross
travel, hoist & Lowering the hook.
Guard iron to clear the track.
Automatic brake – Electromagnetic, electric &
Hydraulic.
Warning Device – Alarm while moving load.
System lock – To switch off power supply for
maintenance work.

23. Speed control – 10%, 25%, 50%,75% & full
increase of speed in steps.
Walkways & ladders with hand rails.
Gantry Cranes are provided with anchorages to
prevent sliding due to wind pressure.
Emergency push button to switch off power supply.
Fire extinguisher at operator cabin.
Emergency rope ladders at cabin.

24. ERGONOMIC DESIGN
 Operator cabin location for better Arial view
 Sufficient lighting at bottom of the bridge.
 Wheel type controls for easy operation.
 Indicator lamp on 3 phase.
 Circuit breakers, limit switches, speed
controls are provided to minimize the operator
error.

25. 1. Allowing the rope to lie upon ashes. Wet or damp ground,
near rusty steel or corrosive substances.
2. Dragging the rope from under a load.
3. Allowing the rope to contact sharp corners.
4. Over loading and shock loading.
5. Over heating or damaging during flame cutting or Welding
operations.
6. Jamming under load.
7. Allowing the rope to run over by heavy vehicles.
8. Kinking.
9. Using the ropes for other than lifting operation.

26. Mobile Crane
1. Maintain specified tyre pressure
2. Travel speed must be low
3. Use a tagline to control the load
4. Avoid sudden stops and starts
5. When carrying load over 50% capacity, Don’t move the
crane away from load.
Major Causes for failure
1. Failure to use out riggers
2. Failure to fully extend out riggers beams and get wheels
off the ground.
3. Failure to level the crane.
4. Poor ground conditions & incorrect blocking beneath
the out rigger floats.

27. TOWER CRANE
Tower Cranes are used whenever
- in long term need ; the site is congested
- lift heights are extreme and reach may be deep.
- lift frequency is high ; little need for mobility
- long term rental of tower cranes are less than for mobile crane.
Operation
1. A meter to be mounted on to measure wind load.
2. At < - 18°C (0°F) structural members can fail suddenly without
warning.
3. Only the driver should be on the crane.

28. • Load is to be free before lifting.
• Always keep the slew path clear.
• Never drag loads sideways.
• Avoid jerk while lift & movement
• SWL not to be exceeded.
• Minimum 3 wounds left out in drum.
•Keep load as close to the ground as possible while
traveling.
•Never travel with full capacity load.
•Keep the jib in line with direction of motion.
•Set the slew brake.