Material handling involves the movement, storage, and control of materials throughout the manufacturing process. It aims to reduce costs and improve efficiency. The document discusses various types of material handling equipment like conveyors, industrial trucks, cranes, and automated guided vehicles. It also outlines objectives like minimizing costs and distances materials are handled. Key considerations in designing material handling systems include the material characteristics, flow rates, and plant layout.

2. MATERIAL
HANDLING
BY
DEV JAIN
MECHANICAL
DEPT
SURANA POWER
LIMITED

4. Material Handling is the movement, storage, control and
protection of materials, goods and products throughout the
process of manufacturing, distribution, consumption and
disposal. The focus is on the methods, mechanical equipment,
systems and related controls used to achieve these functions.
The material handling industry manufactures and distributes
the equipment and services required to implement material
handling systems. Material handling systems range from simple
pallet rack and shelving projects, to complex conveyor belt and
Automated Storage and Retrieval Systems (AS/RS).
Material handling can also consist of sorting and picking,
as well as automatic guided vehicles.

5. MATERIAL HANDLING
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.

6. MATERIAL HANDLING
A
material-handling system can be
simply defined as an integrated system
involving such activities as handling,
storing, and controlling of materials.
 The
word material has very broad
meaning, covering all kinds of raw
materials, work in process,
subassemblies, and finished assemblies.

7. Objectives
Main objective is to reduce the number of handlings
as well as the overall cost of material handling
equipment and reducing the distances through which
the materials are handled.
1)
Reduced Costs
2)
Increased Capacity
3)
Improved Working Condition
4)
Value Addition to Products
In brief, the primary objectives of Material Handling are;
1. To save money
2. To save time
3. To save men

8. objectives
The
primary objective of
using a material handling
system is to ensure that the
material in the right amount is
safely delivered to the desired
destination at the right time
and at minimum cost.

9. Objectives
The
material handling system is
properly designed not only to
ensure the minimum cost and
compatibility with other
manufacturing equipment but also
to meet safety concerns.
The cost of MH estimates 20-25
of total manufacturing labor cost.

10. Other Objectives

Lower unit material handling costs

Reduction in manufacturing cycle time through faster
movement of materials and by reducing the distance
through which the materials are moved. Reduction in
manufacturing cycle time results in reduced work –in –
progress inventory costs.

Improved working conditions and greater safety in
movement of materials

Contribute to better quality by avoiding damage to
products by inefficient handling

Increased storage capacity through better utilisation of
storage areas

Higher productivity at lower manufacturing cost

11. 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

12. GOALS OF MATERIAL HANDLING
Promote
increased use of
facilities
Reduce
tare weight (dead
weight)
Control
inventory

13. GOALS OF MATERIAL HANDLING
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

14. GOALS OF MATERIAL HANDLING
 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

15. Scope of Material handling:
o
Manufacturing
o
Processing
o
Construction
o
Mining
o
Power
o
Machine Tools
o
Truck building
o
Rail road car builders
o
Barge and Ship building
o
Aircraft

16. Importance of M H

Efficient material handling is important to manufacturing
operations. Materials sent by vendors must be unloaded,
moved through inspections and production operations to
stores and finally to the shipping department.
These movements do not add value to the product but they
do add value to the cost
Material handling is an integral part of any industrial
activity. With growing business, a greater emphasis is laid
on productivity, profitability as well as resource
conservation and ecological preservation. Material
handling plays a very crucial role in sustaining efficiency
in financial and human resources.

17. Importance of M H
•
Material handling analysis is a subset of plant layout.
Method study, plant layout and material handling are
all part of the design of a production facility
•
Material handling system and plant layout enhance
effectiveness of each other.
•
Efficient operation of appropriate material handling
methods reduces costs and enables maximum
capabilities to be derived from a given production
facility

18. CONSIDERATIONS IN MATERIAL
HANDLING SYSTEM DESIGN
1. 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. 2. Flow rate
Quantity of
material
moved
High
Conveyors
Manual handling
Low Hand trucks
Short
Conveyors
AGV train
Powered trucks
Unit load AGV
Long
Move Distance

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

21. THE PLANNING PRINCIPLE
Large-scale material handling projects
usually require a team approach.
Material handling planning considers
every move, every storage need, and
any delay in order to minimize
production costs.
The plan should reflect the strategic
objectives of the organization as well
as the more immediate needs.

22. THE SYSTEMS PRINCIPLE
MH and storage activities should be fully integrated to
form a coordinated, operational system that spans
receiving, inspection, storage, production,
assembly…, shipping, and the handling of returns.
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.

23. SIMPLIFICATION PRINCIPLE
simplify handling by reducing, eliminating, or
combining unnecessary movement and/or
equipment.
Four questions to ask to simplify any job:
Can this job be eliminated?
If we can’t eliminate, can we combine
movements to reduce cost? (unit load concept)
If we can’t eliminate or combine, can we
rearrange the operations to reduce the travel
distance?
If we can’t do any of the above, can we simplify?

24. GRAVITY PRINCIPLE
Utilize gravity to move material whenever
practical.
SPACE UTILIZATION
PRINCIPLE
The better we use our building cube, the less
space we need to buy or rent.
Racks, mezzanines, and overhead conveyors are a
few examples that promote this goal.

25. UNIT LOAD PRINCIPLE
Unit loads should be appropriately
sized and configured at each stage of
the supply chain.
The most common unit load is the
pallet
cardboard pallets
plastic pallets
wooden pallets
steel skids

26. AUTOMATION PRINCIPLE
MH operations should be
mechanized and/or automated
where feasible to improve
operational efficiency, increase
responsiveness, improve
consistency and predictability,
decrease operating costs.

27. THE STANDARDIZATION
PRINCIPLE
standardize handling methods as well as
types and sizes of handling equipment
too many sizes and brands of
equipment results in higher operational
cost.
A fewer sizes of carton will simplify
the storage.

28. EQUIPMENT SELECTION
PRINCIPLE
Why? What? Where? When? How? Who?
If we answer these questions about each move, the
solution will become evident.
THE MAINTENANCE
PRINCIPLE
 Plan for preventive maintenance and scheduled
repairs of all handling equipment.
 Pallets and storage facilities need repair too.

29. THE DEAD WEIGHT
PRINCIPLE
 Try to reduce the ratio of equipment weight
to product weight. Don’t buy equipment
that is bigger than necessary.
 Reduce tare weight and save money.
THE CAPACITY PRINCIPLE
 use handling equipment to help achieve
desired production capacity
 i.e. material handling equipment can help to
maximize production equipment utilization.

30. 






31. MATERIAL HANDLING EQUIPMENT
 Industrial
trucks include hand trucks such as
two-wheeled, four-wheeled, hand lift, and
forklift and powered trucks such as
forklift, tractor-trailer trains, industrial crane
trucks, and side loaders.
 Conveyors
such as
belt, chute, roller, wheel, slat, chain, bucket, t
rolley, tow, screw, vibrating, and pneumatic.
 Monorails,
hoists, and cranes such as
bridge, gantry, tower, and stacker.

32. MATERIAL HANDLING EQUIPMENT
Automated
guided vehicle systems
such as unit load carriers, towing,
pallet trucks, fork trucks, and
assembly line.
Automated
storage and retrieval
systems (AS/RS) such as unit load,
mini-load, person-on-board, deep
lane, and storage carousel systems.

33. 1.




34. 
Flat Conveyors

Roller Conveyors

Wheel Conveyors

Trolley Conveyors

Bridge Crane

Electricity Hoist

Jib Crain

Chain Hoist

Gantry Crane

35. 3. Vehicles

Pallets Trucks

Fork lift trucks

Industrial Vehicles

36. Pros and Cons of Using Material Handling Equipment

PROS:

CONS:

Lessen manual labor.

Require fast data tracking and
processing.

Less shipping errors.


Minimal damage on goods
and materials.
Require reliable and fool-proof
inventory management system.

Require more free floor spaces so
that equipment can move
properly.

Buying your own material
handling equipment may require
you to raise bigger funds or
initial capital.


Less shipping and production
costs.
Lessen employees
compensation claims therefore
allows you to save more in the
long run.
 Require you to set aside funds for
maintenance and repair.

37. Factors Affecting the selection of
Material Handling Equipment

Adaptability

Flexibility

Load capacity

Power

Speed

Space requirements

Supervision required

Ease of maintenance

Environment

Cost