MATERIAL HANDLING

MATERIAL HANDLING
MATERIAL HANDLING MAY BE DEFINED AS THE ART AND SCIENCE OF MOVEMENT, HANDLING AND STORAGE OF MATERIALS DURING DIFFERENT STAGES OF MANUFACTURING CONSIDERED AS MATERIAL FLOW INTO , THROUGH AND AWAY FROM THE PLANT
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MATERIAL HANDLING IS THE TECHNIQUE OF GETTING RIGHT GOODS SAFELY TO THE RIGHT PLACE, AT THE RIGHT TIME AND AT THE RIGHT COST

SYMPTOMS OF POOR MATERIAL HANDLING

Long queue of vehicles at the receiving store. Excessive loading time at despatch point. Transporters complaints of excess loading and unloading time. Congestion at receipt and despatch areas we may have to jump over the material heheheh Over crowded floors with blank overhead space. These indicators in insolation do not mean bad material handling, but then, all of them present together mean bad material handling. Cont. 4

 Frequent

cases of material mix up and assembly being supplied wrong parts. Excessive loading & unloading time at the time of machine setup/testing. Piling of wip at different locations material waits for its turn. Damages during handling causing rework/rejection cont.

 Interrrupted

workload due to improper mh next op doesnt work due to unfinished prior op. Large number of contract labour for mh Ever rising mh costs Too many/too few gangways Gangways blocked ( too frequent cases) Badly damaged floors Cont.

Accidents while handling materials Poor housekeeping Difficulty in locating things when required. Hunting for trolleys/trays/mh equipment Production people engaged in movement of materials Transit damages leading to customer complaints

OBJECTIVES OF MATERIAL HANDLING

Speed

and economy in movement of materials material shd move smoothly. Minimisation of cost of material handling Prevention of damages to materials Safety in materials handling cont.

 Minimisation Higher Better

of fatigue and drudgery

plant efficiency

house keeping - appearance

Efficient

store keeping finding inventory becomes easy. investment in work-in-process

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Lower

MATERIAL HANDLING PRINCIPLES

1. PLANNING 2.OPERATING 3.EQUIPMENT 4. COSTING 5.GENERAL PRINCIPLES PRINCIPLES PRINCIPLES PRINCIPLES PRINCIPLES a. Plant a. Unit load a. Mechanism a. Equip. a. Safety Layout b. Terminal selection b. Training b. Delegation of b. Gravity time b. Replacement responsibility c. Location c. Dead Wt. c. Handling c. Minimization c. Flow of Cost d. Treatment of Rehandling material d. Standardization d. Space saving e. Maintenance f. Speed e. Identification

g. Versatility

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PLANNING
PRINCIPLES

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A. Plant layout principle

Good plant layout and minimum materials handling are akin to each other related to each other theyre cousin brothers.

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B. DELEGATION OF RESPONSIBILITY PRINCIPLE

EFFICIENCY IN MATERIAL HANDLING RESULTS WHEN IT IS RECOGNISED AS AN IMPORTANT FUNCTION AND IS GIVEN WEIGHTAGE EQUAL TO THAT OF OTHER COST CENTRES
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Principles of Material Handling Planning Principles Operating principles Equipment principles Costing Principles General Principles

Planning Principles
a) Plant Layout Principle Good Plant layout minimizes material handling

b) Delegation of Responsibility Principle Giving equal weight-age to material handling Separate Department Separate Workers Not lifting the materials beyond waist height Mechanical Handling of heavy materials.

Planning Principles..cont c) Minimization of Re-handling Principle direct movements of materials Materials to be kept at working height Use of Platforms, Pallets Not mixing the materials Elimination of similar movements Reduction of picking and putting

Planning Principles..cont d) Space Saving Principle Not using floor space Use of fork lift trucks Preventing congestion use of monorail devices

Operating Principles a) Unit Load Handling Principle Bulk handling Careful handling of fragile materials b) Gravity Principle Self rolling & sliding of materials

Operating Principles.cont c) Flow of Material Principle Linear movement of Material Avoidance of Re-handling

Equipment Principles
a) Mechanization Principle Heavy materials should be lifted and moved mechanically Mechanization can help reduce expenditure incurred by a firm on labor charges Mechanize only the necessary part of material handling operations. For e.g. conveyors in process industries

Equipment Principles.cont
b) Terminal Time Principle Waiting time at terminal points should be reduced Palletisation and unit load concepts should be used c) Dead Weight Principle Dead weight of the equipment should be reduced to minimum Weight of trays, trolleys should be least possible

Equipment Principles.cont
d) Standardization Principle Permits interchangeability of equipment between departments Reduces repair cost Reduces investment in spares inventory

Equipment Principles.cont
e) Maintenance Principle Repairs and replacements must be anticipated Preventive maintenance programme should be implemented for all key material handling equipment

f) Speed Principle Pallets should be made square in shape Two-way traffic rule must be followed Gangways should be kept clear Sufficient number of boxes, pallets should be kept at work place

Equipment Principles.cont
g) Versatility Principle Equipment with variety of uses should be preferred Special equipment with limited range will only be economical if total time is justified and no further changes in the plant are foreseen Such a difficulty does not arise for larger plants

Costing Principles
a) Equipment Selection Principle Factors to be considered while selection: Material to be handled Plant buildings Layout Speed requirements Material flow pattern Method of production

Costing Principlescont
Factors to be considered while selection (cont.): Distance over which material is to be moved Safety requirement Installation & operating cost Maintenance of material handling equipment Skill requirements Flexibility of material handling equipment Human factor

Costing Principles.cont
b) Replacement Principle Equipments should not be retained beyond their economic period Retaining for too long can increase repairs cost and cause production hold ups due to eventual breakdowns c) Handling cost appraisal principle Material handling cost should be analyzed periodically to highlight areas of improvement

General Principles
a) Safety Principle Hot materials should be handled & moved mechanically Gangways should be kept well lighted Aisles should be wide Workmen should wear protective clothing Safety regulations should be strictly adhered to

General Principles.cont
b) Training Principle Each employee should be given basic training in material handling techniques Workmen after performing the operation on a job should keep it in a position that is ready to move on c) Identification Principle Materials must be labeled properly failing which it may be required to re-open the pallets and boxes

General Principles.cont
d) Location Principle All equipments should be placed at the right place and at the right time

e) Material Treatment Principle Scrap and end pieces are as important as production materials Material handling costs are not related to the cost of material but to their bulk and physical and chemical characteristics

D. LOCATION PRINCIPLE
ALL HANDLING MATERIALS SHOULD BE PLACED AT THE RIGHT PLACE AND AT THE TIME TO AVOID HUNTING AND DELAYS IN MATERIALS HANDLING.
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MATERIAL TREATMENT PRINCIPLE

ALL TYPES OF MATERIALS SHOULD BE TREATED AS IMPORTANT SINCE MATERIAL HANDLING COSTS ARE NOT RELATED TO COST OF MATERIALS
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MATERIAL HANDLING EQUIPMENTS

1.

2.
3. 4. 5. 6. 7. 8.

CRANES AND HOISTS CONVEYORS SLIDES AND CHUTES LIFTS RAILS ROPEWAYS AND CABLEWAYS PIPE LINES TRUCKS, TRACTORS AND TRAILORS
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Selection of Equipment
a)

Material to be handled Size & Shape Quantity & Weight Material Characteristics Susceptibility to damage

Selection of Equipment.cont b) Plant building Temporary or permanent Width of doors/aisles Height of the ceiling Levels of floors Load bearing capacity of the floors Presence of columns and pillars

Selection of Equipment.cont c) Layout Product layout or process layout d) Speed requirements Minimum/ maximum and average speed to meet desired rate of production e) Material Flow Pattern Vertical Flow Pattern Horizontal Flow Pattern

Selection of Equipment.cont f) Method of Production Mass & Flow Production Batch Production g) Distance over which materials is to be moved Fixed Distance Long Distance Work Station

Selection of Equipment.cont h) Safety requirements i) Installation & Operating costs Initial investment Operating costs Maintenance costs finance available for investment

Selection of Equipment.cont j) Maintenance Amount of maintenance Statutory Requirements Special Precautions k) Skills Requirement l) Flexibility regularity of material handling distance m) Acceptability & safety of operators

CRANES & HOISTS

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CRANES & HOISTS

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LIFTS

HYDRAULIC LIFTING PLATFORM

LIFTS
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LIFTS

HYDRAULIC LIFTING PLATFORM

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CONVEYORS

GRAVITY ROLLER SPUR CONVEYOR

HORIZONTAL BELT CONVEYOR

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Conveyors It is a fixed type of material handling system used for moving materials either continuously or intermittently between two fixed points. creates relatively a fixed route occupy space continuously reduce handling

PALLET TRUCKS

TILT PALLET TRUCKS

ELECTRIC PALLET TRUCK

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PALLET TRUCKS

ALL TERRAIN PALLET TRUCKS

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STACKERS

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TROLLEYS

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TROLLEYS

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TRUCKS

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TROLLEYS

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TRUCK

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TRUCK

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TRUCK & TROLLEY

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TROLLEYS

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TROLLEYS

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TROLLEYS

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TROLLEYS

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TROLLEYS

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PALLETS

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PALLETS

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PALLETS

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PALLETS

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LIFT TRUCK

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CONVEYORS

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CONVEYORS

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CONVEYORS

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CONVEYORS

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CONVEYORS

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CRANES

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CRANES

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FORK LIFT TRUCK

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TRACTOR & TRAILOR

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TRACTOR & TRAILOR

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Hoists Used for loading and unloading of heavy or long objects. Types of Hoists: Chain Hoists Pneumatic Hoists Electric Hoists

Ropeways Used for overhead transport of materials over greater distances

MATERIAL HANDLING RATIOS

RATIOS CAN BE USED TO MEASURE EFFECTIVENESS OF MATERIAL HANDLING

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1.

MATERIAL HANDLING COST PER UNIT (OR WEIGHT) :

= MATERIAL HANDLING COST PER PERIOD WT. OF RAW MATERIAL PROCESSED (QTY. PRODUCED PER PERIOD)

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2. HANDLING TIME TO TOTAL TIME : = TIME SPENT IN HANDLING

TOTAL TIME SPENT IN PRODUCTION

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3. MATERIAL HANDLING LABOUR RATIO (MHL):

PERSONNEL ASSIGNED TO MATERIALS HANDLING______

TOTAL OPERATING WORK FORCE

THIS RATIO MEASURES THE EXTENT OF EFFORTS NEEDED FOR MOVING MATERIALS
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4. MOVEMENT OPERATION RATIO :

= TOTAL NUMBEROF MOVEMENTS TOTAL NUMBER OF PRODUCTIVE OPERATIONS

THIS RATIO INDICATES WHETHER TOO MANY MOTIONS ARE EMPLOYED DUE TO POOR ROUTING
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5.HANDLING TIME SPENT BY DIRECT LABOUR : = TIME SPENT BY DIRECT LABOUR IN MH TOTAL DIRECT LABOUR TIME

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6. MATERIAL HANDLING COST INDEX :

= TOTAL MATERIAL HANDLING COSTS TOTAL VALUE OF MATERIALS RECEIVED AND ISSUED

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7. MATERIAL HANDLING LOSS INDEX :

= TOTAL VALUE OF LOSSES DUE TO MH TOTAL VALUE OF MATERIALS RECEIVED AND ISSUED

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8. MANUFACTURING CYCLE EFFICIENCY :

=SETUP TIME + OPERATION TIME ELAPSED TIME FOR THE JOB

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9. SPACE UTILISATION RATIO : = SPACE OCCUPIED SPACE AVAILABLE

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10. EQUIPMENT UTILISATION RATIO : = NO. OF MH EQUIPMENT IN USE TOTAL NO. OF MH EQUIPMENT

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