Lecture 1 Material Handling Equipment (Introduction to Material handling equipment)

Material Handling Equipment Lecture - 1 out of 5

1. MATERIALS HANDLING EQUIPMENT LECTURE ONE Introduction Basics of Materials Handling Equipment Outlines Definitions of MHE Benefits & Limitation of MHE Classification and Application of Material handling Design considerations in MHE By: Amanuel DIriba . 06-Sep-19 By: Amanuel Diriba 1

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3. 1.1 Material handling definition Material Handling is the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution process including their consumption and disposal. MH is the art and science of moving, storing, protecting, and controlling material. 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 art and science of conveying, elevating, positioning, transporting, packaging and storing of materials. 06-Sep-19 By: Amanuel Diriba 3

4. Cont.. 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 production cost. 06-Sep-19 By: Amanuel Diriba 4

5. Cont.. 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 utilizing minimum space. (v) Lowest cost solution to the materials handling activities. 06-Sep-19 By: Amanuel Diriba 5

6. Importance Of Materials Handling A good material handling system may have the following benefits. Reduce cost by Utilizing space to better advantage Increasing productivity Making a few number of effective movements Reduce waste by Eliminating damage to materials during the handling process Maintaining proper control over the in- and out of stock handling process Improve working conditions by Providing safer working conditions Reducing worker fatigue Improve the efficiency of the plant by Providing a better organization of storage facilities 06-Sep-19 By: Amanuel Diriba 6

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9. Limitations Of Materials Handling Additional capital cost involved in any materials handling system. Once a materials handling system get implemented, flexibility for further changes gets greatly reduced. With an integrated materials handling system installed, failure/stoppage in any portion of it leads to increased downtime of the production system. Materials handling system needs maintenance , hence any addition to materials handling means additional maintenance facilities and costs. 06-Sep-19 By: Amanuel Diriba 9

10. Classification and Application of MHE The material handling technically divided into five distinct functional divisions or spheres of activity are:- Bulk handling It involves the extracting, handling and storage of bulk materials including gases liquids, semi-liquids and solids. These processes apply particularly in the processing, basic heavy industries, and in the mine and construction industries . 06-Sep-19 By: Amanuel Diriba 10

11. Unit handling In manufacturing operations it covers the handling of formed materials in the initial, intermediate and final stages of manufacture. It involves the handling of unit loads ranging from pins to locomotives. 06-Sep-19 By: Amanuel Diriba 11

12. Packaging Covers the design, selection and use of in process containers, and included packing of semi-finished and finished products 06-Sep-19 By: Amanuel Diriba 12

13. Warehousing The area covered by warehousing includes the receiving, storing, shipping of materials in any form, and at any point in the process of manufacture and distribution. 06-Sep-19 By: Amanuel Diriba 13

14. Carrier handling It covers the loading , securing, transporting , unloading and transfer of all kinds of materials in highway trucks railway cars, barges, ships, airlines and at carrier terminals . 06-Sep-19 By: Amanuel Diriba 14

15. Material handling equipment can be classified into five major categories:- Transport Equipment :- Equipment used to move material from one location to another e.g. between workplaces, between a loading dock and a storage area, etc. The major subcategories of transport equipment are conveyors, cranes, and industrial trucks. Material can also be transported manually using no equipment. 06-Sep-19 By: Amanuel Diriba 15

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19. Cranes 06-Sep-19 By: Amanuel Diriba 19

20. Industrial trucks 06-Sep-19 By: Amanuel Diriba 20

21. Positioning Equipment:- Equipment used to handle material at a single location e.g. to feed and/or manipulate materials so that are in the correct position for subsequent handling, machining, transport, or storage. Unlike transport equipment, positioning equipment is usually used for handling at a single workplace. Material can also be positioned manually using no equipment 06-Sep-19 By: Amanuel Diriba 21

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23. Cont .. Unit Load Formation Equipment:- Equipment used to restrict materials so that they maintain their integrity when handled a single load during transport and for storage. If materials are self-restraining (e.g., a single part or interlocking parts), then they can be formed into a unit load with no equipment. 06-Sep-19 By: Amanuel Diriba 23

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25. 4. Storage Equipment Equipment used for holding or buffering materials over a period of time. Some storage equipment may include the transport of materials (e.g., the S/R machines of an AS/RS, or storage carousels). If materials are block stacked directly on the floor, then no storage equipment is required. 06-Sep-19 By: Amanuel Diriba 25

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28. Cont .. Identification and Control Equipment:- Equipment used to collect and communicate the information that is used to coordinate the flow of materials within a facility and between a facility and its suppliers and customers. The identification of materials and associated control can be performed manually with no specialized equipment. 06-Sep-19 By: Amanuel Diriba 28

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30. Cont.. The three groups of materials handling equipment classified by their design features Hoisting equipment: A group of machines with lifting gear intended for moving loads mainly in batches. This type of equipment is intended mainly for unit loads Hoisting machinery , cranes and elevators belong to this group. Conveying equipment: A group of machines, which may have no lifting gear and which move load in a continuous flow. They are intended for bulk and unit loads one at a time 06-Sep-19 By: Amanuel Diriba 30

31. Cont.. Surface and overhead equipment: A group of machines which may not be provided with lifting gear and which usually handle loads in batches. Trackless trucks, narrow-gauge cars belong to this group . Unit loads are formed solids of various sizes, shapes and weights. 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. 06-Sep-19 By: Amanuel Diriba 31

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34. Some Application area of MHE The application of materials handling is very wide. It is worthwhile to list a few of them. Manufacturing industry Building construction industry Heavy construction industry Mining industry Food industry Automotive and transportation industry 06-Sep-19 By: Amanuel Diriba 34

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40. 1.4 Design considerations in Material handling Material characteristics Flow rate Plant layout Unit load principle 06-Sep-19 By: Amanuel Diriba 40

41. Material Characteristics Material characteristics affect type of transport and storage equipment required Category Measures Physical state Size Weight Shape Condition Safety risk and risk of damage 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. 06-Sep-19 By: Amanuel Diriba 41

42. Considerations …cont. 2. Flow rate Manual handling Hand trucks Powered trucks Unit load AGV Conveyors Conveyors AGV train High Low Long Short Move Distance Quantity of material moved 06-Sep-19 By: Amanuel Diriba 42

43. Considerations …cont. 3. Plant Layout Layout Type Characteristics Typical MH Equipment Fixed – position Process Product Large product size, low production rate Variation in product and processing, low and medium production rates Limited product variety, high production rate Cranes, hoists, industrial trucks Hand trucks, forklift trucks, AGVs Conveyors for product flow, trucks to deliver components to stations. 06-Sep-19 By: Amanuel Diriba 43

44. 4. Unit Load Principle T he unit load should be as large as practical for the material handling system that will move and store it. A unit load is the unit to be moved or handled at one time. A unit load includes the container, carrier, or support that will be used to move materials. 06-Sep-19 By: Amanuel Diriba 44

45. Cont.. Factors for determining unit load/ container: Size of carrier Size and weight of items Space for storing loaded/unloaded container Equipment used for moving Cost, supply and maintenance Aisle widths, door sizes, and clear stacking heights Environmental regulations 06-Sep-19 By: Amanuel Diriba 45

46. Cont.. 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 Unit Load Disadvantages Time spent forming and breaking down the unit load Empty containers/pallets may need to be returned to their point of origin. Cost of containers/pallets and other load restraining materials used in the unit load 06-Sep-19 By: Amanuel Diriba 46

47. Cont.. The major advantages of unitization and handling of unit loads are: It permits handling of larger loads at a time and thereby reduces handling and transportation costs. Loading and unloading time of unit load is substantially less than when handled as loose/ individual material. Unitized loads are less susceptible to damage and loss during movement from one place to another. It offers safer handling and transportation compared to those of loose materials 06-Sep-19 By: Amanuel Diriba 47