MATERIAL

HANDLING
WEEK 1

What is material handling????

al Handling is the movement, storage, control and

ion of materials, goods and products throughout t
s of manufacturing, distribution, consumption and
l. The focus is on the methods, mechanical equipm
s and related controls used to achieve these functi
terial handling industry manufactures and distrib
uipment and services required to implement mater
ng systems. Material handling systems range from
ack and shelving projects, to complex conveyor be
ated Storage and Retrieval Systems (AS/RS).
al handling can also consist of sorting and picking
as automatic guided vehicles.

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

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

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 Costs
handled.
1) Reduced
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

objectives
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

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

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

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

GOALS OF MATERIAL HANDLING

Promote

increased use
of facilities

Reduce

tare weight
(dead weight)

Control

inventory

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

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

Scope of Material handling:

Manufacturing

Processing

Construction

Mining

Power

Machine Tools

Truck building

Rail road car builders

Barge and Ship building

Aircraft

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.

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

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.

2. Flow rate

Quantity of
material
moved
High

Conveyor
s
Manual

Low handling
Hand trucks

Short

Conveyor
s
AGV train
Powered
trucks
Unit load
AGVLong

Move Distance

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.

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

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

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 cant eliminate, can we
combine movements to reduce cost?
(unit load concept)
If we cant eliminate or combine, can
we rearrange the operations to

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.

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

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.

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

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.

THE DEAD WEIGHT

PRINCIPLE
Try to reduce the ratio of
equipment weight to product
weight. Dont buy equipment that
is bigger than necessary.
Reduce tare weight and save
money.

THE CAPACITY
PRINCIPLE
use handling equipment to help
achieve desired production

TYPES OF MATERIAL HANDLING EQUIPMENT

Conventional Material Handling Equipment

1. Storage Equipment

2. Bulk Material Handling

3. Industrial Trucks

Conventional Material Handling Equipment

1. Robotic Delivery System

2. Computer Controlled Conveyor System

3. Automated Guided Vehicles

MATERIAL HANDLING EQUIPMENT

Industrial

trucks include hand

trucks such as two-wheeled, fourwheeled, 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.

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, miniload, person-on-board,

Types of Material Handling

Equipment
Basically there are three types of
materials handling equipments.
1.

Static

Platforms

Pallets

Still ages

2. Fixed Types

Flat Conveyors

Roller Conveyors

Wheel Conveyors

Trolley
Conveyors

Bridge Crane

Electricity Hoist

Jib Crain

Chain Hoist

Gantry Crane

3. Vehicles

Pallets Trucks

Fork lift trucks

Industrial Vehicles

Pros and Cons of Using Material Handling Equipment

PROS:

CONS:

Lessen manual labor.

Require

Less shipping errors.

Minimal damage on
goods and materials.

Less shipping and

production costs.

Lessen employees
compensation claims
therefore allows you to
save more in the long
run.

fast data tracking and

processing.
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.
Require

you to set aside funds

for maintenance and repair.

Factors Affecting the selection of

Material Handling Equipment

Adaptability

Flexibility

Load capacity

Power

Speed

Space requirements

Supervision required

Ease of maintenance

Environment

Cost

THANK YOU