material handling systems

material handling systems

1. •MaterialhandlingisdefinedbytheMaterialHandlingIndustryof
Americaas“themovement,storage,protectionandcontrolof
materialsthroughoutthemanufacturinganddistributionprocess
includingtheirconsumptionanddisposal”.
•Thehandlingofmaterialsmustbeperformedsafely,efficiently,at
lowcost,inatimelymanner,accuratelyandwithoutdamageto
thematerials.
•(therightmaterialsintherightquantitiestotherightlocations)
Introduction to Material Handling

2. Material handling in the production system

3. Material Handling Definitions
MHistheartandscienceofmoving,storing,
protecting,andcontrollingmaterial.
PROVIDE
Right amount
Right material
Right time
Right condition
Right place
Right position
Right sequence
Right cost
Right methods

4. New MHI Material Handling Definition
MaterialHandlingisthemovement,
storage,controlandprotectionof
materials,goodsandproductsthroughout
theprocessofmanufacturing,distribution,
consumptionanddisposal.Thefocusison
themethods,mechanicalequipment,
systemsandrelatedcontrolsusedto
achievethesefunctions.
Operations
Subjects
Business Processes

5. Objectives of Material Handling
Increase the efficiency of material flow
Reduce MH cost
Improve facilities utilization
Safety and working conditions
Manufacturing process
Increase productivity

6. Material Handling Examples
Material Handling is not restricted to the manufacturing or distribution
environment
Construction
Mail Delivery
Hospitals
Mass Transportation

7. Material Handling Systems Design
Define the objectives
& scope
Analyze the
requirements
Generate alternative
designs
Evaluate alternative
designs
Select the preferred
design
Implement the
preferred design

8. Thiscostofmaterialhandlingisasignificantportionoftotalproduction
cost,estimatesaveragingaround20–25%oftotalmanufacturinglabor
costintheunitedstates.
Theproportionmayvaries,dependingonthetypeofproductionand
degreeofautomationinthematerialhandlingfunction.
Somematerialhandlingdevicesare
-palletshuttlesinNCmachiningcenters
-Conveyorsinmanualassemblylines
-transfermechanismsinautomatedtransferlines
-partsfeedingdevicesinautomatedassembly

9. Overview of Material Handling Equipment
Materialhandlingequipmentisavailablecommercially
1.Transportequipment
2.Storagesystems
3.Unitizingequipment
4.Identificationandtrackingsystems

10. Material Transport Equipment
Materialtransportincludesequipmentthatisusedtomovematerials
insideafactory,warehouse,orotherfacility.Thisequipmentcanbedivided
intothefollowingfivecategories
1.Industrialtrucks:
Industrialtrucksdividedintotwotypespoweredandnon-powered.
Non-poweredtrucksareplatformsorcontainerswithwheelsthatare
pushedorpulledbyhumanworkerstomovethematerials.
Poweredindustrialtrucksaresteeredbyhumanworkers.
Theyprovidemechanizedmovementofmaterials.

11. 2.Automatedguidedvehicles(AGVs):AGVsarebattery–powered,
automaticallysteeredvehiclesthatfollowdefinedpathwaysinthefloor.AGVs
areusedtomoveunitloadsbetweenloadandunloadstationsinthefacility.
Routingvariationsarepossible(Differentloadsmovebetweendifferent
stations)
3.Monorailsandotherrailguidedvehicles:Theseareself-propelledvehicles
thatrideonafixedrailsystem.Thevehiclesoperateindependentlyandare
usuallydrivenbyelectricmotorsthatpickuppowerfromanelectrifiedrail.
Routingvariationsarepossible
4.Conveyors:ConveyorsconstitutealargefamilyofmaterialTransport
equipmentthataredesignedtomovematerialsoverfixedpaths,generallyin
largevolumes.Poweredconveyorsroller,beltandtow-lineandnon-powered
byhumanworkers

12. 5.Cranesandhoists:Thesearehandlingdevicesforlifting,lowering,and
transportingmaterials,oftenasveryheavyloads.Hoistsaccomplishverticallifting.
Bothmanuallyoperatedandpoweredtypesareavailable.Cranesprovide
horizontaltravelandgenerallyincludehoists.
a)Fork lift truck, industrial truck b) unit load automated guided vehicle
c) Monorail d) roller conveyor e) jib crane with hoist

13. Storagesystems:Itisgenerallydesirabletoreducethestorageofmaterialsin
manufacturing,itseemsunavoidablethatrawmaterialsandwork-inprocesswill
spendsometimebeingstored,evenifonlytemporarily.Andfinishedproductsare
likelytospendsometimeinawarehouseordistributioncenterbeforebeing
delivered to the final customer.
Storagemethodsandequipmentcanbeclassifiedasfollows
a)Bulkstorage:Itconsistsofsimplystoringmaterialsinanopenfloorarea,
generallyinpalletsorcontainers.Itrequireslittleornostorageequipment
b)racksystems:Thesearestructuralframesdesignedtostackunitloads
vertically,thusincreasingtheverticalstorageefficiencycomparedtobulkstorage
c)Shelvingandbins:Steelshelvingcomesinstandardwidths,depths,andheights
toserveavarietyofstoragerequirements.Shelvescanincludebins,whichare
containersforlooseitems.

14. •d)Drawerstorage:Thisstoragemediumismorecostlythanshelves,butis
moreconvenient.Findingitemsstoredinshelvescanbedifficultiftheshelf
levelistoohighortoolowortoodeep.Itisgenerallyusedfortools,
hardwareandothersmallitems.
•e)Automatedstoragesystems:Automatedandsemiautomatedsystemsare
availabletodepositandwithdrawitemsintoandfromthestorage
compartments.
Therearetwobasictypes:automatedstorageorretrievalsystems:consists
ofrackandshelfsystems2)Carouselsystemsthatrotatestoragebinspasta
stationaryloadorunloadstation.

15. •Examplesofunitloadcontainersformaterialhandling
•a)Woodenpalletb)palletboxandc)totebox

16. The 10 Principles in Material Handling
The10principlesofmaterialhandlingareexplainedbelow.
Implementingtheseprincipleswillresultinsaferoperatingconditions,lowercosts,
andbetterutilizationandperformanceofmaterialhandlingsystems.
Theunitloadprinciplesstandsasoneofthemostimportantandwidelyapplied
principleinmaterialhandling.Inmaterialhandling,aunitloadisSimplythe
massthatistobemovedorotherwisehandledatonetime.
Therearegoodreasonsforusingunitloadsinmaterialhandling
1)Multipleitemscanbehandledsimultaneously
2)Therequirednumberoftripsisreduced
3)Loadingandunloadingtimesarereduced
4)Productdamageisdecreased.Thesereasonsresultinlowercostandhigher
operatingefficiency.

17. Principle1.PLANNINGPRINCIPLE:Allthematerialhandlingshould
betheresultofadeliberateplanwheretheneeds,performance
objectivesandfunctionalspecificationoftheproposedmethodsare
completelydefinedattheoutset.
Principle2.STANDARDIZATIONPRINCIPLE:MaterialhandlingMethods,
equipment,controls,andsoftwareshouldbestandardized.Itmeans
lessvarietyandcustomizationinthemethodsandequipment
employed.
Principle3.WORKPRINCIPLE:Materialhandlingworkshouldbe
minimizedwithoutsacrificingproductivityorthelevelofservice
requiredoftheoperationSimplifyingtheprocessesbyreducing,
combining,shortening,oreliminatingunnecessarystepswillreduce
work.

18. Principle4.ERGONOMICPRINCIPLE:Humancapabilitiesand
limitationsmustberecognizedandrespectedinthedesignofmaterial
handlingtasksandequipmenttoensuresafeandeffectiveoperations.
Principle5.UNITLOADPRINCIPLE:Aunitloadisonethatcanbe
storedormovedasasingleentityatonetime,suchaspallet,container
totesetc..
Lesseffortandworkarerequiredtocollectandmovemanyindividual
itemsasasingleloadthantomovemanyitemsoneatatime.
Principle6.SPACEUTILIZATIONPRINCIPLE:Effectiveandefficient
usemustbemadeofallavailablespaceSpaceinmaterialhandlingis
three–dimensionalandthereforeiscountedasCubicspace.

19. •Principle7.SYSTEMPRINCIPLE:Materialmovementandstorage
activitiesshouldbefullyintegratedtoformaco-ordinate(receiving,
inspection,storage,production,assemblyetc.)
•Principle8.AUTOMATIONPRINCIPLE:Materialhandlingoperations
shouldbemechanizedandorautomatedtoimprovetheoperating
efficiency,increaseresponsiveness,decreasecostetc..
Principle9.ENVIRONMENTALPRINCIPLE:Environmentalimpactand
energyconsumptionshouldbeconsideredascriteria.
Principle10.LIFECYCLECOSTPRINCIPLE:Economicanalysisshould
accountfortheentirelifecycleofallmaterialhandlingequipment.

20. Material Handling equipment Features Applications
Industrial trucks, manual Low cost Moving light loads in a
factory
Industrial trucks, poweredMedium cost Movement of pallet
loads
AGV’S High cost Movement of pallet
loads
Monorails and other rail
guided vehicles
High cost, Flexible
routing
Moving single product
assemblies
Conveyors Powered Variety of
equipments
Moving product along
the assembly line
Cranes and hoists Lift capacity is moreLarge and heavy items
more than 100 tonnes
Applications of five categories of material handling equipment