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Material Handling
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.
The cost of MH estimates 20-25 of total manufacturing labor cost in the United States [The Material Handling Industry of America (MHIA)]
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
Material Handling
Lifting/Lowering Pushing/Pulling Carrying Weights and Forces Frequency of Activities Load Center of Gravity
Measures
Solid, liquid, or gas
Size
Weight Shape
Condition
Safety risk and risk of Hot, cold, wet, etc. damage Explosive, flammable, toxic; fragile, etc.
Considerations cont.
2. Flow rate
Quantity of material moved
High Low
Conveyors
Short
Long
Move Distance
Considerations cont.
3. Plant Layout
Layout Type
Fixed position Process
Characteristics
Large product size, low production rate Variation in product and processing, low and medium production rates Limited product variety, high production rate
Typical MH Equipment
Cranes, hoists, industrial trucks Hand trucks, forklift trucks, AGVs Conveyors for product flow, trucks to deliver components to stations.
Product
Material Handling
Manual Trolley
Versatile For smaller loads For short distance
Material Handling
Forklift
Manual or mechanized Portable Large distance travel Medium & large loads handling Vertical movement Intermittent duty
Material Handling
Overhead Crane
Carry heavy loads Continuous duty Size shape no bar
Material Handling
Semi-automatic system
Sorting devices Robotics
Automatic system
Human factor eliminated Operator required for to programming and controls Productivity
Unit loads shall be appropriately sized and configured in a way which achieves the material flow and inventory objectives at each stage in the supply chain. A unit load is one that can be stored or moved as a single entity at one time, such as pallet, container or tote, regardless of the number of individual items that make up the load. Principle 6. Space Utilization Principle
Effective and efficient use must be made of all available space. Space in material handling is three dimensional and therefore is counted as cubic space.
Is the material handling equipment more than 10 years old? Do you use a wide variety of makes and models which require a high spare parts inventory? Are equipment breakdowns the result of poor preventive maintenance? Do the lift trucks go too far for servicing?
Is material being damaged during handling? Do shop trucks operate empty more than 20% of the time? Does the plant have an excessive number of re-handling points? Is power equipment used on jobs that could be handled by gravity? Are too many pieces of equipment being used because their scope of activity is continued? Are many handling operations unnecessary? Are single pieces being handled where unit loads could be used? Are floors and ramps dirty and in need of repair?