Material handling involves the movement of materials and products throughout production processes and facilities. It aims to move the right materials, in the right quantities, to the right locations at the right times. Effective material handling can reduce costs and improve productivity, quality, safety and efficiency. It requires planning material flows and selecting appropriate equipment like conveyors, vehicles, robots and storage systems based on material characteristics, plant layout and other factors. Key principles include standardization, unit load handling, safety, and reducing unnecessary movement.

1. Material Handling
Chapter 11
Production
Operations management

2. Material Handling
Definition
™Material handling is the function of moving the
right material to the right place in the right time, in
the right amount, in sequence, and in the right
condition to minimize production cost.
™The cost of MH estimates 20-25 of total
manufacturing labor cost in the United States [The
Material Handling Industry of America (MHIA)]

3. Material Handling
Definition
Material handling is defined as the art & science of moving
Packing & storing of material in any form . The industry
comprises establishments primarily engaged in
manufacturing material handling equipment. This
definition includes :
•Aerial work platforms, hydraulic or electric truck or
carrier mounted, manufacturing
•Escalators and parts, manufacturing
•Automobile wrecker hoists, manufacturing
•Hoisting and lifting machinery, manufacturing
•Carts for moving goods (e.g., laundry, grocery),
manufacturing

4. Material Handling
Definition
•Industrial trucks, tractors, trailers and stackers and parts,
manufacturing
•Conveyors and conveying equipment, manufacturing
•Tackle blocks, metal, manufacturing
•Cranes, industrial, manufacturing
•Walkways, moving, manufacturing
•Dollies and hand trucks, manufacturing
•Wheelbarrows, manufacturing
•Elevators and parts, manufacturing
•Winches, manufacturing

5. Scope of
Material Handling
There are three perspectives about material
handling.
™The traditional point of view:Emphasis is on
material movement from one Location to another
within the confines of individual plant
™Plant wide concern:focuses on overall flow of
material.
™The system point of view:Requires visualization
of materials handling problem,the physical
distribution activities as a one encompassing
system.

6. The Importance
The Importance of
of
Material Handling
Material Handling
™Material handling is an important part of factory and
industrial processes. It covers the entire spectrum of
functions such as waste handling, assembly line
management, storage and material transport.
™A material handling system includes several smaller
components that work side by side, to make the everyday
business more efficient and cost effective.
™New advances in technology have revamped the entire
material handling system and function. Robotics and
automation techniques are increasingly becoming prevalent.
™ If you have an existing business, consider hiring a
consultant, to set up your material handling processes.

7. The Importance
The Importance of
of
Material Handling
Material Handling
™Such experts derive conclusions regarding overall
efficiency of operations, recommend appropriate safety
precautions and ensure regulatory acquiescence. Do an
adequate study and search for both a material handling
expert as also appropriate material handling systems
required for your purpose and set up an efficient and
effective material handling system for your organization.

8. The Objectives of
The Objectives of
Material Handling
Material Handling
™The primary Objective 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 handling

9. Material Handling
Material Handling
Principles
Principles
1. Orientation Principle
Study the system relationships thoroughly prior to
preliminary planning in order to identify existing methods
and problems, physical and economic constraints, and to
establish future requirements and goals.
2. Planning Principle
Establish a plan to include basic requirements, desirable
options, and the consideration of contingencies for all
material handling and storage activities.

10. Material Handling
Material Handling
Principles
Principles
3. Systems Principle
Integrate those handling and storage activities which are
economically viable into a coordinated system of operation
including receiving, inspection, storage, production,
assembly, packaging, warehousing, shipping and
transportation.
4. Unit Load Principle
Handle product in as large a unit load as practical.
5. Space Utilization Principle
Make effective utilization of all cubic space.
6. Standardization Principle
Standardize handling methods and equipment wherever
possible.

11. Material Handling
Material Handling
Principles
Principles
7. Ergonomic Principle
Recognize human capabilities and limitations by designing
material handling equipment and procedures for effective
interaction with the people using the system.
8. Energy Principle
Include energy consumption of the material handling
systems and material handling procedures when making
comparisons or preparing economic justifications.
9. Ecology Principle
Minimize adverse effects on the environment when selecting
material handling equipment and procedures.

12. Material Handling
Material Handling
Principles
Principles
10. Mechanization Principle
Mechanize the handling process where feasible to increase
efficiency and economy in the handling of materials.
11. Flexibility Principle
Use methods and equipment which can perform a variety of
tasks under a variety of operating conditions.
12. Simplification Principle
Simplify handling by eliminating, reducing, or combining
unnecessary movements and/or equipment.
13. Gravity Principle
Utilize gravity to move material wherever possible, while
respecting limitations concerning safety, product damage
and loss.

13. Material Handling
Material Handling
Principles
Principles
14. Safety Principle
Provide safe material handling equipment and methods
which follow existing safety codes and
regulations in addition to accrued experience.
15. Computerization Principle
Consider computerization in material handling and storage
systems, when circumstances warrant, for improved material
and information control.
16. System Flow Principle
Integrate data flow with the physical material flow in
handling and storage.

14. Material Handling
Material Handling
Principles
Principles
17. Layout Principle
Prepare an operational sequence and equipment layout for
all viable system solutions, then select the alternative system
which best integrates efficiency and effectiveness.
18. Cost Principle
Compare the economic justification of alternate solutions in
equipment and methods on the basis of economic
effectiveness as measured by expense per unit handled.
19. Maintenance Principle
Prepare a plan for preventive maintenance and scheduled
repairs on all material handling equipment.
20. Obsolescence Principle

15. Material Handling Costs
Material Handling Costs
The costs of material handling arises from two sources
™The cost of owning & maintaining the equipment.
™Cost of operating System
Every effort should be made to how to reduce the
material handling cost.There are three functional ways:
1.Eliminating handling itself,where ever & whenever
possible
2.Mechanizing largely by conveyors power driven trucks.
3.Making the necessary handling more efficient

16. Material Handling Costs
Material Handling Costs
•Unit load - number of items or bulk
material arranged so they can be picked
up and delivered as one load
•Large or small?
•If large, cost/unit handled decreases
•But, depending upon
–cost of unitizing, de-unitizing

17. Material Handling Costs
Material Handling Costs
–space required for material handling
– material handling carrier payload
– work-in-process inventory costs
–storage and return of empty pallets or containers used to
hold the unit load
•smaller unit load may be desired
–space required for material handling
– material handling carrier payload
– work-in-process inventory costs
- storage and return of empty pallets or containers used
to hold the unit load

18. Factors for consideration in planning Material
Material
Flow(
Flow(Material Characteristics)
Material Characteristics)
Category
Physical state
Size
Weight
Shape
Condition
Safety risk and risk
of damage
Measures
Solid, liquid, or gas
Volume; length, width, height
Weight per piece, weight per unit
volume
Long and flat, round, square, etc.
Hot, cold, wet, etc.
Explosive, flammable, toxic;
fragile, etc.

19. Factors for consideration in planning Material
Material
Flow
Flow(
( Plant Layout
Plant Layout)
Layout Type
Fixed – position
Process
Product
Characteristics
Large product
size, low
production rate
Variation in
product and
processing, low
and medium
production rates
Limited product
variety, high
production rate
Typical MH
Equipment
Cranes, hoists,
industrial trucks
Hand trucks, forklift
trucks, AGVs
Conveyors for
product flow, trucks
to deliver
components to
stations.

20. Material Handling Costs
Material Handling Costs
Seven steps to design a unit load
™Unit load concept applicable?
™Select the unit load type
™Identify most remote source of load
™Determine farthest practicable destination for
load
™Establish unit load size
™Determine unit load configuration
™Determine how to build unit load

21. Material Handling Devices
Material Handling Devices
•Material handling equipment includes:
–Transport Equipment: industrial trucks,
Automated Guided vehicles (AGVs), monorails,
conveyors, cranes and hoists.
–Storage Systems: bulk storage, rack systems,
shelving and bins, drawer storage, automated
storage systems.
–Unitizing Equipment: palletizers
–Identification and Tracking systems

22. Material Handling Devices
Material Handling Devices
•Conveyors
•Palletizers
•Pallet Lifting Devices
•Trucks
•Robots
•AGVs
•Jibs, Cranes and Hoists
•Warehouse MHSs

23. Material Handling Devices
Material Handling Devices
Conveyors:
•Accumulation,Belt,Bucket
•Can,Chain,Chute,Gravity
•Pneumatic or vacuum
•Power and free,Roller
•Screw,Skid,Slat
•Tow line,Trolley
•Wheel

24. Material Handling Devices
Material Handling Devices
Trucks
•Hand truck
•Fork-lift truck
•Pallet truck
•Platform truck
•Counterbalanced truck
•Tractor-trailer truck
•AGV

25. Material Handling Devices
Material Handling Devices
Robots:
•Point-to-point
•Contouring or continuous path
•Walkthrough or teach
•Lead through or teach pendant
•Hydraulic
•Servo-controlled

26. Material Handling Methods
Material Handling Methods
1. Inspect materials for slivers, jagged edges, burrs, rough
or slippery surfaces.
2. Get a firm grip on the object.
3. Keep fingers away from pinch points, especially when
setting down materials.
4. When handling lumber, pipe or other long objects, keep
hands away from the ends to prevent them from being
pinched.
5. Wipe off greasy, wet, slippery or dirty objects before
trying to handle them.
6. Keep hands free of oil and grease.

27. Material Handling Methods
Material Handling Methods
Lifting and Carrying
Before employees are assigned to jobs requiring heavy
and/or frequent lifting, make sure they are physically suited
for the job.
If a load is thought to be more than one employee can
handle, assign two employees to the operation or supply
materials handling equipment. Instruct employees in proper
ways to lift.
Proper Way To Lift
Here are six steps to safe lifting:
•Keep feet apart - one alongside, one behind the object;
•Keep back straight, nearly vertical; bend at the knees
instead of the waist;

28. Material Handling Methods
Material Handling Methods
1. Tuck your chin in;
2. Grip the object with the whole hand;
3. Tuck elbows and arms in;
4. Keep body weight directly over feet
When bulky objects are to be handled or when objects are to
be carried on the shoulder, employees shall be trained in
these techniques for special situations.
Handling Barrels and Drums
Whenever possible, use a dolly or other mechanical device
when moving barrels or drums.
If two employees are assigned to up-end a full drum, they
should use the following procedures:

29. Material Handling Methods
Material Handling Methods
1. Stand on opposite sides of the drum and face each other;
2. Grasp both chimes (rolled edges at both ends of the
barrel) near their high points, lift one end; press down on
the other;
3. As the drum is up-ended and brought to balance on the
bottom chime, release the grip on the bottom chime and
straighten the drum.
When two employees are to overturn a full drum, they
should use this procedure:
1. Make sure there is enough room. Cramped quarters can
result in badly injured hands.

30. Material Handling Methods
Material Handling Methods
1. Both stand near each other, facing the drum.
Grip the closest point of the top chime with both
hands, resting palms against the side of the
drum, push until the drum balances on the lower
chime.
2. Step forward a short distance, and each
employee releases one hand from the top chime
in order to grip the bottom chime. They ease the
drum down to a horizontal position until it rests
solidly on its side.

31. Plant Location
End Of
Chapter 11