1 INTRODUCTION TO MATERIAL HANDLING

COURSE OBJECTIVES: To provide knowledge on materials handling equipment.

SYLLABUS:
Unit-1 Introduction
Types of industrial transport – classification and characteristics of materials –
classification and selection of materials handling.
LEARNING OUTCOMES:
Students will be able to
 understand the basic concepts of material handling equipment.
 select appropriate material handling system.
1.1 Introduction
 Materials handling is loading, moving and unloading of materials.
 To do it safely and economically, different types of tackles, gadgets and
equipment are used, when the materials handling is referred to as
mechanical handling of materials.
Since primitive men discovered the use of wheels and levers, they have been
moving materials mechanically. Any human activity involving materials need
materials handling. However, in the field of engineering and technology, the term
materials handling is used with reference to industrial activity. In any industry,
be it big or small, involving manufacturing or construction type work, materials
have to be handled as raw materials, intermediate goods or finished products from
the point of receipt and storage of raw materials, through production processes
and up to finished goods storage and dispatch points.
 Materials handling as such is not a production process and hence does not
add to the value of the product.
 It also costs money; therefore it should be eliminated or at least reduced as
much as possible.
 However, the important point in favour of materials handling is that it helps
production.
  Depending on the weight, volume and throughput of materials, mechanical
handling of materials may become unavoidable.
Based on the need to be of optimum design and application specific to different
type of industries, materials handling can be as diverse as industries themself. As
a consequence, unfortunately, there is no universally accepted definition of
materials handling.
One of the definition adopted way back by the American Materials Handling
Society is: Materials handling is the art and science involving the moving,
packaging and storing of substances in any form. Some of the other definitions
are:
 Materials handling is the movement and storage of materials at the
lowest possible cost through the use of proper methods and
equipment.
 Materials handling is the moving of materials or product by any
means, including storage, and all movements except processing
operations and inspection.
 Materials handling is the art and science of conveying, elevating,
positioning, transporting, packaging and storing of materials.
In one of the definitions, all the functions of materials handling have been refered
to which are conveying, elevating, positioning, transporting, packaging and
storing. Storage or warehousing is very much a part of materials handling.
Materials handling uses different equipment and mechanisms called Materials
Handling Equipment. Though in one of the definitions, processing operations and
inspection have been specifically excluded from scope of materials handling
operations, it is worth mentioning that in specific cases processing or inspection of
materials may be accomplished simultaneously with handling activity. One
definition also covers the important objective of materials handling which is lowest
cost solution.
The essential requirements of a good materials handling system may be
summarized as:
i. Efficient and safe movement of materials to the desired place.
 ii. Timely movement of the materials when needed.
iii. Supply of materials at the desired rate.
iv. Storing of materials utilising minimum space.
v. Lowest cost solution to the materials handling activities.
Functional scope of materials handling within an industry covers the following:
i. Bulk materials as well as unit materials handing. Bulk handling
is particularly relevant in the processing, mining and
construction industries. Unit materials handling covers
handling of formed materials in the initial, intermediate and
final stages of manufacture.
ii. Industrial packaging of in-process materials, semi finished or
finished goods, primarily from the point of view of ease and
safety of handling, storage and transportation. However,
consumer packaging is not directly related to materials
handling.
iii. Handling of materials for storage or warehousing from raw
materials to finished product stage.
Often materials handling extends beyond the boundary of the industry in the form
of movement of raw materials from the sources to the plant or in the form of
finished goods from the plant to the points of consumption. These long distance
movements of materials are generally termed as transportation of materials
through various modes of transport like, road, rail, ship or air.
Transportation is generally excluded from the scope of materials handling.
However, at each of the sources and destinations, loading and unloading of
materials is necessary and these are referred to as materials handling of these
locations.
Some production equipment are fitted with facilities for handling of the materials
being processed. Such materials handling equipment are generally considered to
be an integral part of the production equipment.
A few typical examples are:
(i) the feeding mechanism in an automatic machine,
 (ii) coiler and de-coiler in a strip rolling mill or
(iii) paper feeding and transportation arrangement in a multi-station
printing machine.
1.2 OBJECTIVES OF MATERIAL HANDLING
Following are the objectives of material handling:
 Minimise cost of material handling.
 Minimise delays and interruptions by making available the materials at the
point of use at right quantity and at right time.
 Increase the productive capacity of the production facilities by effective
utilisation of capacity and enhancing productivity.
 Safety in material handling through improvement in working condition.
 Maximum utilisation of material handling equipment.
 Prevention of damages to materials.
 Lower investment in process inventory
1.3 PRINCIPLES OF MATERIAL HANDLING
Following are the principles of material handling:
1. Planning principle: All handling activities should be planned.
2. Systems principle: Plan a system integrating as many handling activities as
possible and co-ordinating the full scope of operations (receiving, storage,
production, inspection, packing, warehousing, supply and transportation).
3. Space utilisation principle: Make optimum use of cubic space.
4. Unit load principle: Increase quantity, size, weight of load handled.
5. Gravity principle: Utilise gravity to move a material wherever practicable.
6. Material flow principle: Plan an operation sequence and equipment
arrangement to optimise material flow.
7. Simplification principle: Reduce combine or eliminate unnecessary
movement and/or equipment.
8. Safety principle: Provide for safe handling methods and equipment.
9. Mechanisation principle: Use mechanical or automated material handling
equipment
 10. Standardisation principle: Standardise method, types, size of material
handling equipment.
11. Flexibility principle: Use methods and equipment that can perform a
variety of task and applications
12. Equipment selection principle: Consider all aspect of material, move and
method to be utilised.
13. Dead weight principle: Reduce the ratio of dead weight to pay load in
mobile equipment.
14. Motion principle: Equipment designed to transport material should be kept
in motion.
15. Idle time principle: Reduce idle time/unproductive time of both MH
equipment and man power.
16. Maintenance principle: Plan for preventive maintenance or scheduled
repair of all handling equipment.
17. Obsolescence principle: Replace obsolete handling methods/equipment
when more efficient method/equipment will improve operation.
18. Capacity principle: Use handling equipment to help achieve its full
capacity.
19. Control principle: Use material handling equipment to improve production
control, inventory control and other handling.
20. Performance principle: Determine efficiency of handling performance in
terms of cost per unit handled which is the primary criterion.
1.4 SELECTION OF MATERIAL HANDLING EQUIPMENTS
Selection of Material Handling equipment is an important decision as it affects
both cost and efficiency of handling system. The following factors are to be
taken into account while selecting material handling equipment.
 PROPERTIES OF THE MATERIAL
Whether it is solid, liquid or gas, and in what size, shape and weight it is to
be moved, are important considerations and can already lead to a
preliminary elimination from the range of available equipment under review.
 Similarly, if a material is fragile, corrosive or toxic this will imply that certain
handling methods and containers will be preferable to others.
 LAYOUT AND CHARACTERISTICS OF THE BUILDING
Another restricting factor is the availability of space for handling. Low-level
ceiling may preclude the use of hoists or cranes, and the presence of
supporting columns in awkward places can limit the size of the material-
handling equipment. If the building is multi-storeyed, chutes or ramps for
industrial trucks may be used. Layout itself will indicate the type of
production operation (continuous, intermittent, fixed position or group) and
can indicate some items of equipment that will be more suitable than others.
Floor capacity also helps in selecting the best material handling equipment.
 PRODUCTION FLOW
If the flow is fairly constant between two fixed positions that are not likely to
change, fixed equipment such as conveyors or chutes can be successfully
used. If, on the other hand, the flow is not constant and the direction
changes occasionally from one point to another because several products are
being produced simultaneously, moving equipment such as trucks would be
preferable.
 COST CONSIDERATIONS
This is one of the most important considerations. The above factors can help
to narrow the range of suitable equipment, while costing can help in taking a
final decision. Several cost elements need to be taken into consideration
when comparisons are made between various items of equipment that are all
capable of handling the same load. Initial investment and operating and
maintenance costs are the major cost to be considered. By calculating and
comparing the total cost for each of the items of equipment under
consideration, a more rational decision can be reached on the most
appropriate choice.
  NATURE OF OPERATIONS
Selection of equipment also depends on nature of operations like whether
handling is temporary or permanent, whether the flow is continuous or
intermittent and material flow pattern-vertical or horizontal.
 ENGINEERING FACTORS
Selection of equipment also depends on engineering factors like door and
ceiling dimensions, floor space, floor conditions and structural strength.
 EQUIPMENT RELIABILITY
Reliability of the equipment and supplier reputation and the after sale service
also plays an important role in selecting material handling equipments.
1.5 MATERIAL HANDING EQUIPMENTS
Broadly material handling equipment’s can be classified into two categories,
namely:
(a) Fixed path equipments, and
(b) Variable path equipments.
(a) Fixed path equipments which move in a fixed path. Conveyors, monorail
devices, chutes and pulley drive equipments belong to this category. A slight
variation in this category is provided by the overhead crane, which though
restricted, can move materials in any manner within a restricted area by
virtue of its design. Overhead cranes have a very good range in terms of
hauling tonnage and are used for handling bulky raw materials, stacking and
at times palletizing.
(b)Variable path equipments have no restrictions in the direction of
movement although their size is a factor to be given due consideration
trucks, forklifts mobile cranes and industrial tractors belong to this category.
Forklifts are available in many ranges, they are manoeuvrable and various
attachments are provided to increase their versatility. Material Handing
Equipments may be classified in five major categories.
1. CONVEYORS: Conveyors are useful for moving material between two
fixed workstations, either continuously or intermittently. They are
mainly used for continuous or mass production operations—indeed,
 they are suitable for most operations where the flow is more or less
steady. Conveyors may be of various types, with rollers, wheels or belts
to help move the material along: these may be power-driven or may roll
freely. The decision to provide conveyors must be taken with care, since
they are usually costly to install; moreover, they are less flexible and,
where two or more converge, it is necessary to coordinate the speeds at
which the two conveyors move.
2. INDUSTRIAL TRUCKS: Industrial trucks are more flexible in use than
conveyors since they can move between various points and are not
permanently fixed in one place. They are, therefore, most suitable for
intermittent production and for handling various sizes and shapes of
material. There are many types of truck petrol-driven, electric, hand-
powered, and so on. Their greatest advantage lies in the wide range of
attachments available; these increase the trucks ability to handle
various types and shapes of material.
3. CRANES AND HOISTS: The major advantage of cranes and hoists is
that they can move heavy materials through overhead space. However,
they can usually serve only a limited area. Here again, there are several
types of crane and hoist, and within each type there are various loading
capacities. Cranes and hoists may be used both for intermittent and for
continuous production.
4. CONTAINERS: These are either ‘dead’ containers (e.g. Cartons, barrels,
skids, pallets) which hold the material to be transported but do not
move themselves, or ‘live’ containers (e.g. wagons, wheelbarrows or
computer self-driven containers). Handling equipments of this kind can
both contain and move the material, and is usually operated manually.
5. ROBOTS: Many types of robot exist. They vary in size, and in function
and maneuverability. While many robots are used for handling and
transporting material, others are used to perform operations such as
welding or spray painting. An advantage of robots is that they can
 perform in a hostile environment such as unhealthy conditions or carry
on arduous tasks such as the repetitive movement of heavy materials.
The choice of material-handling equipment among the various possibilities that
exist is not easy. In several cases the same material may be handled by various
types of equipments, and the great diversity of equipment and attachments
available does not make the problem any easier. In several cases, however, the
nature of the material to be handled narrows the choice.
GUIDELINES FOR EFFECTIVE UTILISATION OF MATERIAL
1.6
HANDLING EQUIPMENTS

The following guidelines are invaluable in the design and cost reduction of the
materials handling system:
1. As material handling adds no value but increases the production cycle time,
eliminate handling wherever possible. Ideally there should not be any
handling at all!
2. Sequence the operations in logical manner so that handling is unidirectional
and smooth.
3. Use gravity wherever possible as it results in conservation of power and fuel.
4. Standardise the handling equipments to the extent possible as it means
interchangeable usage, better utilisation of handling equipments, and lesser
spares holding.
5. Install a regular preventive maintenance programme for material handling
equipments so that downtime is minimum.
6. In selection of handling equipments, criteria of versatility and adaptability
must be the governing factor. This will ensure that investments in special
purpose handling equipments are kept at a minimum.
7. Weight of unit load must be maximum so that each ‘handling trip’ is
productive.
8. Work study aspects, such a elimination of unnecessary movements and
combination of processes should be considered while installing a material
handling system.
 9. Non-productive operations in handling, such as slinging, loading, etc.,
should be kept at a minimum through appropriate design of handling
equipment. Magnetic cranes for scrap movement and loading in furnaces
combination of excavators and tippers for ores loading and unloading in
mines are examples in this respect.
10. Location of stores should be as close as possible to the plant which uses the
materials. This avoids handling and minimizing investment in material
handling system.
11. Application of OR techniques such as queueing can be very effective in
optimal utilisation of materials handling equipments.
12. A very important aspect in the design of a material handling system is the
safety aspect. The system designed should be simple and safe to operate.
13. Avoid any wasteful movements-method study can be conducted for this
purpose.
14. Ensure proper coordination through judicious selection of equipments and
training of workmen.
1.7 CHARACTERISTICS AND CLASSIFICATION OF MATERIALS
Method to be adopted and choice of equipment for a materials handling system
primarily depends on the type of material/s to be handled. It is, therefore, very
important to know about different types of materials and their characteristics
which are related to methods and equipment used for their handling.
As innumerable different materials are used and need to be handled in industries,
they are classified based on specific characteristics relevant to their handling.
Basic classification of material is made on the basis of forms, which are
(i) Gases,
(ii) Liquids
(iii) Semi Liquids and
(iv) Solids.
Following characteristics of gases, liquids and semi liquids are relevant to their
handling.
For gases it is primarily pressure, high (25 psi and more) or low (less than 25 psi).
Chemical properties are also important.
For liquids the relevant characteristics are density, viscosity, freezing and boiling
point, corrosiveness, temperature, inflammability etc. Examples of common
industrial liquids are: water, mineral oils, acids, alkalies, chemicals etc. Examples
of common semi-liquids are: slurry, sewage, sludge, mud, pulp, paste etc.
Gases are generally handled in tight and where required, pressure resisting
containers. However, most common method of handling of large volume of gas is
through pipes by the help of compressor, blower etc. This process is known as
pneumatic conveying.
Liquids and semiliquids can be handled in tight or open containers which may be
fitted with facilities like insulation, heating, cooling, agitating etc. as may be
required by the character of the liquid. Large quantity of stable liquids/semiliquids
are generally conveyed through pipes using suitable pumps, which is commonly
known as hydraulic conveying.
Solids form the majority of materials which are handled in industrial situation.
Solids are classified into two main groups: Unit load and Bulk load (materials).
Unit loads are formed solids of various sizes, shapes and weights. Some of these
are counted by number of pieces like machine parts, molding boxes, fabricated
items. Tared goods like containers, bags, packaged items etc. and materials which
are handled en-masses like forest products (logs), structurals, pig iron etc. are
other examples of unit loads. The specific characteristics of unit loads are their
overall dimensions, shape, piece-weight, temperature, inflammability,
strength/fragility etc. Hoisting equipment and trucks are generally used for
handling unit loads. Certain types of conveyors are also used particularly for
cartons/packaged items and metallic long products like angles, rods etc.
Unit loads have been classified by Bureau of Indian Standards' (BIS) specification
number IS 8005:1976(2).
The classifications are based on:
a) Shape of unit loads - (i) basic geometric forms like rectangular, cylindrical,
pyramidal/conical and spherical; (ii) typical or usual forms like pallets,
 plate, containers, bales and sacks; (iii) irregular forms like objects with flat
base dimension smaller than overall size, loads on rollers/wheels and
uneven shapes.
b) Position of C.G. (stability) of load.
c) Mass of unit load in 10 steps from 0-2.5 kg to more than 5000 kg.
d) Volume per unit in 10 steps from 0-10 cm3 to more than 10 m3.
e) Type of material in contact with conveying system like metal, wood,
paper/cardboard, textile, rubber /plastics, glass and other materials.
f) Geometrical shape (flat, concave, convex, irregular/uneven, ribbed etc.)
and physical properties (smooth, slippery, rough, hard, elastic etc) of base
surface of unit load.
g) Specific physical and chemical properties of unit loads like abrasive,
corrosive, dust emitting, damp, greasy/oily, hot, cold, fragile, having sharp
edges, inflammable, explosive, hygroscopic, sticky, toxic, obnoxious,
radioactive etc.
h) Loads sensitive to pressure, shock, vibration, turning/tilting,
acceleration/deceleration, cold, heat, light, radiation, damp etc.
Bulk materials are those which are powdery, granular or lumpy in nature and
are stored in heaps. Example of bulk materials are: minerals (ores, coals etc.),
earthly materials (gravel, sand, clay etc.) processed materials (cement, salt,
chemicals etc.), agricultural products (grain, sugar, flour etc.) and similar other
materials.
Major characteristics of bulk materials, so far as their handling is concerned,
are: lump-size, bulk weight, specific weight, moisture content, flowability
(mobility of its particles), angles of repose, abrasiveness, temperature,
proneness to explosion, stickiness, fuming or dusty, corrosivity, hygroscopic
etc.
REFERENCES AND BIBLIOGRAPHY:
1. Bolz, H. A and Hagemann, G. E (ed.), ‘‘Materials Handling Handbook’’,
Ronald Press.
2. IS 8005:1976, Classification of Unit Loads, Bureau of Indian Standards.
3. Apple, J.A., ‘‘Material Handling System Design’’, John Wiley & Sons
4. Allegri, T.H., ‘‘Materials Handling: Principles and Practice’’, CBS Publishers
Distributors, N. Delhi.
 Section A
1. Define material handling
2. Mention any four objectives of material handling.
3. Mention any four principles of material handling.
4. What do you mean by “Equipment Utilisation Ratio”?
5. Mention some of the fixed path equipments.
6. Mention some of the valuable path equipments.
Section B
1. Explain the objectives of material handling.
2. Explain the principles of material handling.
3. How do you evaluate the material handling system?
4. What are the relationship between plant layout and material handling?
Section C
1. Discuss the factors to be considered while selecting material handling
equipment.
2. Discuss the different material handling equipments.
3. Discuss the guidelines for effective utilisation of material handling
equipments.
4. Material handling in the restaurant for production and services.
5. Utilisation of material handling equipment.