Material Handling | Supply Chain Management

This presentation gives a detailed outlook on the Material Handling during the logistics in the Supply Chain Management Process.

1. 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 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)]

2. 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 conditions Promote productivity 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

3. Goals of Material Handling Promote increased use of facilities Reduce tare weight (dead weight) Control inventory

4. Overview of Material Handling Equipment 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 systems. Unitizing Equipment : palletizers Identification and Tracking systems

5. Considerations in Material Handling System Design 1. Material Characteristics 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.

6. 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

7. 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.

8. Material Handling Equipment Between fixed points over a fixed path Belt conveyor Roller conveyor Chute conveyor Slat conveyor Screw conveyor Chain conveyor Overhead monorail conveyor Trolley conveyor Wheel conveyor Tow conveyor Bucket conveyor Cart-on-track conveyor Pneumatic tube conveyor

9. Material Handling Equipment Over limited areas Hoists Overhead cranes Hydraulic scissors lift Over large areas Handcart/truck Tier platform truck Hand lift truck / pallet jack Power-driven hand truck Power-driven platform truck Forklift truck Narrow aisle truck Tractor-trailer truck Material lift Drum truck Drum lifter Dolly Automated guided vehicle system

10. Belt conveyor

11. Belt conveyor

12. Roller conveyor

13. Chute conveyor

14. Chute conveyor

15. Slat conveyor

16. Screw conveyor

17. Screw conveyor

18. Chain conveyor

19. Chain conveyor

20. Overhead monorail conveyor

21. Overhead monorail conveyor

22. Trolley conveyor

23. Wheel conveyor

24. Wheel conveyor

25. Tow conveyor

26. Tow conveyor

27. Bucket conveyor

28. Bucket conveyor

29. Cart-on-track conveyor

30. Pneumatic tube conveyor

31. Pneumatic tube conveyor

32. Hoists

33. Overhead cranes

34. Hydraulic scissors lift

35. Handcart/truck

36. Tier platform truck

37. Hand lift truck / pallet jack

38. Power-driven hand truck

39. Power-driven platform truck

40. Forklift truck

41. Narrow aisle truck

42. Tractor-trailer truck

43. Material lift

44. Drum lifter

45. Drum lifter

46. Dolly

47. Pallet

48. Tote Pan

49. 14 Principles of Material Handling 1. 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 organization as well as the more immediate needs.

50. 2. 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 status within facilities and within the supply chain.

51. 3. 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 can’t eliminate, can we combine movements to reduce cost? (unit load concept) If we can’t eliminate or combine, can we rearrange the operations to reduce the travel distance? If we can’t do any of the above, can we simplify?

52. 4. Gravity principle Utilize gravity to move material whenever practical. 5. Space utilization principle The better we use our building cube, the less space we need to buy or rent. Racks, mezzanines, and overhead conveyors are a few examples that promote this goal.

53. 6. 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 wooden pallets steel skids

54. 8. 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. ASRS is a perfect example.

55. 10. Equipment selection principle Why? What? Where? When? How? Who? If we answer these questions about each move, the solution will become evident. 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 simplify the storage.

56. 12. The dead weight principle Try to reduce the ratio of equipment weight to product weight. Don’t buy equipment that is bigger than necessary. Reduce tare weight and save money. 13. The maintenance principle Plan for preventive maintenance and scheduled repairs of all handling equipment. Pallets and storage facilities need repair too. 14. The capacity principle use handling equipment to help achieve desired production capacity i.e. material handling equipment can help to maximize production equipment utilization.