01 An Introduction - Material Handling

System Analysis &
Industrial Management Laboratory

Agro-Industrial Technology Dept
Material Handling:
An Introduction
Scope of Work
Alan D. Wibowo,
MT
System Analysis &
Despite its size, material handling remains largely

unknown as an industry because its work is done behind
the scenes of the greater supply chain.
System Analysis &
Material handling is the ONLY industry that touches every product

as it moves through the global supply chain to the consumer.
The world’s most successful companies use material handling
solutions to gain a competitive edge by improving their customer
service efficiency, improving productivity and maximizing growth
and profits.
System Analysis &
How it works
Material handling uses a broad array of equipment,

systems, services and expertise to move products
through the supply chain such as:
automation, information technology, automatic
identification, lifting equipment, storage equipment,
conveying equipment, facilities design and planning,
ergonomic and safety equipment, sustainable and green
solutions.
System Analysis &
From Assembly Line: Industrial Management Laboratory
Forklift trucks, automated guided vehicles, and Agro-Industrial Technology Dept
conveyors are all moving product from one place to

another in today’s industrial plants.
System Analysis &
System Analysis &
System Analysis &
System Analysis &
System Analysis &
To Warehouse:
Storage and retrieval
systems, shelving,
racks, mezzanines,
carousels, bar coding,
radio frequency
identification devices
and data collection are
just some of the
solutions in today’s
dynamic material
handling industry.
System Analysis &
System Analysis &
System Analysis &
From team offices:

Automated computerized control
systems are stocking, identifying,
storing, retrieving, moving and
accounting for all of today’s
products…in the plants, on the
road, in the store…making sure
the right product is available
when needed.
System Analysis &
To Back Docks:
The latest in wrapping
equipment, packaging
and unitizing systems
are all helping today’s
companies protect and
ship their valuable
products and materials,
and it’s all part of
material handling.
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
System Analysis &
System Analysis &
Material Handling Defined

“The movement, storage, protection and control of materials
throughout the manufacturing and distribution process including
their consumption and disposal”
(The Material Handling Industry of America)
Estimated to represent 20-25% of total manufacturing labor

cost in the world
 The proportion varies depending on type of production and
degree of automation
System Analysis &
 Handling of materials must be performed

 Safely
 Efficiently
 At low cost
 In a timely manner
 Accurately (the right materials in the right quantities to the
right locations)
 And without damage to the materials
System Analysis &
Concerned with the acquisition, movement, storage, and distribution of

materials and products as well as the planning and control of these operations
to satisfy customer demand
 Two categories of logistics:

 External logistics - transportation and related activities that occur outside of
a facility (between different geographical locations)
 Five traditional modes of transportation: rail, truck, air, ship, and pipeline
 Internal logistics - material handling and storage within a facility
System Analysis &
System Analysis &
Categories of Material Handling Equipment

1. Material transport equipment - to move materials
inside a factory, warehouse, or other facility
2. Storage - to store materials and provide access to
those materials when required
3. Unitizing equipment - refers to
1. containers to hold materials, and
2. equipment used to load and package the

containers
4. Identification and tracking systems - to identify and
keep track of the materials being moved and stored
System Analysis &
Design Considerations
in Material Handling
• Material characteristics
• Flow rate, routing, and scheduling
• Plant layout
• Unit load principle
System Analysis &
Material Characteristics
Material characteristics affect type of transport and

storage equipment required
• Solid, liquid or gas
• Size
• Weight
• Shape - long, flat, bulky
• Condition - hot, cold, wet, dirty
• Risk of damage - fragile, brittle, sturdy
• Safety risk - explosive, flammable, toxic, corrosive
System Analysis &
Flow Rate, Routing, and

Scheduling
• Flow rate - amount of material moved per unit time
• Examples: pieces/hr, pallet loads/hr, tons/hr
• Whether the material must be moved in individual
units, as batches, or continuously (pipe line)
• Routing - pick-up and drop-off locations, move
distances, routing variations, conditions along the
route (surface, traffic, elevation)
• Scheduling - timing of each delivery
• Prompt delivery when required
• Use of buffer stocks to mitigate against late
deliveries
System Analysis &
Plant Layout
Material handling equipment considerations must be

included in the plant layout design problem
Correlation between layout type and material handling
equipment:
Plant layout type Material handling equipment

Fixed-position Cranes, hoists, industrial trucks
Process Hand trucks, forklift trucks, AGVs
Product Conveyors for product flow
Trucks to deliver parts to stations
System Analysis &
Unit Load Principle (unitizing)
In general, the unit load should be as large as practical

for the material handling system that will move and
store it
• A unit load is the mass that is to be moved or
otherwise handled at one time
Reasons for using unit loads in material handling:

• Multiple items handled simultaneously
• Required number of trips is reduced
• Loading/unloading times are reduced
• Product damage is decreased
System Analysis &
Unit Load Principle (unitizing)
(a) Wooden pallet, (b) pallet box, (c) tote box

System Analysis &
Material Transport Equipment
Five categories:
1. Industrial trucks
2. Automated guided vehicles
3. Monorails and other rail guided vehicles
4. Conveyors
5. Cranes and hoists
System Analysis &
Industrial Trucks
(a) Two-wheel hand truck, (b) four-wheel dolly, (c) hand-

operated low-lift pallet truck
System Analysis &
Industrial Trucks
Walkie Truck
• Wheeled forks insert into pallet

openings
• No provision for riding; truck is
steered by worker using control
handle at front of vehicle
System Analysis &
Industrial Trucks
Fork Lift
• Widely used in factories and

warehouses because pallet loads
are so common
• Capacities from 450 kg (1000 lb)
up to 4500 kg (10,000 lb)
• Power sources include on-board
batteries and internal
combustion motors
System Analysis &
Industrial Trucks
Towing Tractor
• Designed to pull one or more

trailing carts in factories and
warehouses, as well as for
airport baggage handling
• Powered by on-board batteries or
IC engines
System Analysis &
Automated Guided Vehicles
An Automated Guided Vehicle System

(AGVS) is a material handling system
that uses independently operated, self-
propelled vehicles guided along defined
pathways in the facility floor
Types of AGV:
• Driverless trains
• Pallet trucks
• Unit load AGVs
System Analysis &
Overhead Monorail
System Analysis &
Conveyor System
Large family of material transport equipment

designed to move materials over fixed paths,
usually in large quantities or volumes
1. Non‑powered
Materials moved by human workers or by gravity
2. Powered
Power mechanism for transporting materials is
contained in the fixed path, using chains, belts,
rollers or other mechanical devices
System Analysis &
Hoist
Hoist with mechanical

advantage of four:
(a) sketch of the hoist
(b) diagram to illustrate
mechanical advantage
(a) (b)
System Analysis &
Bridge Crane
System Analysis &
For further information please contact:
Alan D. Wibowo
Phone. +62 811 9544 624
WA +62 81 351 708907
Email: alan.dwi@unlam.ac.id

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System Analysis &

Industrial Management Laboratory

Despite its size, material handling remains largely

Material handling is the ONLY industry that touches every product

Material handling uses a broad array of equipment,

conveyors are all moving product from one place to

From team offices:

Material Handling Defined

Estimated to represent 20-25% of total manufacturing labor

 Handling of materials must be performed

Concerned with the acquisition, movement, storage, and distribution of

 Two categories of logistics:

Categories of Material Handling Equipment

1. containers to hold materials, and

2. equipment used to load and package the

Material characteristics affect type of transport and

Flow Rate, Routing, and

Material handling equipment considerations must be

Plant layout type Material handling equipment

Unit Load Principle (unitizing)

In general, the unit load should be as large as practical

Reasons for using unit loads in material handling:

Unit Load Principle (unitizing)

(a) Wooden pallet, (b) pallet box, (c) tote box

Material Transport Equipment

(a) Two-wheel hand truck, (b) four-wheel dolly, (c) hand-

• Wheeled forks insert into pallet

• Widely used in factories and

• Designed to pull one or more

Automated Guided Vehicles

An Automated Guided Vehicle System

Large family of material transport equipment

Hoist with mechanical

For further information please contact:

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