The document discusses material handling, which involves moving materials efficiently through the production process. It defines material handling and lists its goals as reducing costs, maintaining quality, and promoting safety, productivity and facility usage. The document outlines principles for effective material handling system design, such as considering material characteristics, plant layout, simplification, use of gravity, standardization, and maintenance. It also discusses various material handling equipment options.

1. MATERIAL
HANDLING

2. 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.

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

4. MATERIAL HANDLING
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.

5. MATERIAL HANDLING
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
in the United States

6. 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

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

8. 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

9. 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

10. CONSIDERATIONS IN MATERIAL
HANDLING SYSTEM DESIGN
1. Material Characteristics
Category Measures
Physical state Solid, liquid, or gas
Size Volume; length, width, height
Weight Weight per piece, weight per
unit volume
Shape Long and flat, round, square,
etc.
Condition Hot, cold, wet, etc.
Safety risk and risk of Explosive, flammable, toxic;
damage fragile, etc.

11. 2. Flow rate
Quantity of
material
moved
Conveyors Conveyors
High AGV train
Manual handling Powered trucks
Low Hand trucks Unit load AGV
Short Long Move Distance

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

13. 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.

14. 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.

15. 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?

16. 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.

17. 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

18. 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.

19. 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.

20. 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.

21. 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.

22. 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, trolley, tow, screw,
vibrating, and pneumatic.
 Monorails, hoists, and cranes such as bridge,
gantry, tower, and stacker.

23. 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.