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Material Handling - An Overview

Presented By:

Anupam Kumar

Reader

SMS Varanasi

Email: anupamkr@gmail.com

1© Copyright 2013 Anupam Kumar

Objectives of Material Handling

• Reduce Unit Material

Handling Cost

– Eliminate Unnecessary

Handling

–Handle Material in Batch

Lots

–Minimize Required

Handling Time

– Replace Handling

Equipment as

Appropriate

• Reduce Production

Time

–Minimize Delays of

Machine Operations

–Maintain Uniform,

Appropriate Movement

of Material

–Use Automatic

Processing When

Appropriate

– Coordinate All Material

Handling2© Copyright 2013 Anupam Kumar

Objectives of Material Handling

• Reduce Overhead

–Minimize Non-Productive Labor

–Prevent Damage to Materials

• Conserve Floor Space

– Avoid Excessive Stock Storage

–Move Materials in a Position to Save Space

– Use Equipment Requiring No Floor Space

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Objectives of Material Handling

• Prevent Accidents

– Reduce Physical Load Required

– Insure Handling Equipment is Safe

• Improve Employee Morale

– Provide Proper Relationship Between Employee &

Work

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Principles of Material Handling

There are 10 principles of material handling:

• Planning Principle

• Standardization

Principle

• Work Principle

• Ergonomic Principle

• Unit Load Principle

• Space Utilization

Principle

• System Principle

• Automation Principle

• Environmental Principle

• Life Cycle Cost Principle

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Principles of Material Handling

Planning Principle

• A material handing plan

defines

– the material (what) and

– the moves (when and where);

together they define

– the method (how and who).

Standardization Principle

• Material handling methods,

equipment, controls and

software should be

standardized

• within the limits of

achieving overall

performance objectives and

• without sacrificing needed

flexibility , modularity and

throughput.

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Principles of Material Handling

Work Principle

• Material handling work

should be minimized

– without sacrificing

productivity or

– the level of service required

of the operation.

Ergonomic Principle

• Human capabilities and

limitations must be

recognized and respected in

the design of material

handling tasks and

equipment to ensure safe

and effective operations.

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Principles of Material Handling

Unit Load Principle

• A unit load is one that can be stored or moved as a single entity at one time, such as a pallet, container or tote, regardless of the number of individual items that make up the load.

• Smaller unit loads are consistent with manufacturing strategies that embrace operating objectives such as flexibility, continuous flow and just-in-time delivery.

Space Utilization Principle

• Cluttered and unorganized

spaces and blocked aisles

should be eliminated in

work areas.

• In storage areas, the

objective of maximizing

storage density must be

balanced against

accessibility and selectivity.

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Principles of Material Handling

System Principle

• A system is a collection of interacting and/or interdependent entities that form a unified whole.

• Systems integration should encompass the entire supply chain including reverse logistics.

• It should include suppliers, manufacturers, distributors and customers.

Automation Principle

• Material handling operations

should be mechanized and/or

automated where feasible

– to improve operational

efficiency,

– increase responsiveness,

– improve consistency and

– predictability, decrease

operating costs and

– to eliminate repetitive or

potentially unsafe manual

labor.

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Principles of Material Handling

Environmental Principle

• Environmental impact and

energy consumption should

be considered as criteria

when designing or selecting

alternative equipment and

material handling systems.

Life Cycle Cost Principle

• A thorough economic analysis should account for the entire life cycle of all material handling equipment and resulting systems.

• Life cycle costs include all cash flows that will occur between the time the first rupee is spent to plan or procure a new piece of equipment, or to put in place a new method, until that method and/or equipment is totally replaced.

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• These may broadly be divided into the

following types:

– Fixed Path Equipments

– Semi-Fixed Path Equipments

– Variable Path Equipments

– Accessories

Material Handling Equipments

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Fixed Path Equipments

• Conveyors

– Gravity

– Belt

– Chain

– Pneumatic

– Hydraulic

– Screw

– Vibrating

• Chutes

• Pipelines / Tubes

• Elevators

– Arm

– Reciprocating

– Bucket

• Lifts

– Service Station

– Field Table

– Loading Dock

– Railroad Car

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Conveyors

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Large Conveyors (2 axis)

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Lifts

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Chutes

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Fixed Path Material Handling

• Advantages:

–More economical if large volume of material

moved to same place

– One power supply to drive entire “belt” – more

economical

– Reduction in need for lot identification tags

– Can be used to pace the workers

• Disadvantages

– Less economical if material follows diverse paths

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Semi Fixed Path Material Handling

Types

• Cranes

– Jib

– Bridge

– Gantry

• Tracks

–Monorail

– Industrial Rail

Advantage & Disadvantages:

• Advantage

– Can cover a wider area

• Disadvantage

– Still limited to area covered

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Cranes

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Tracks - Monorail

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Wide Area (Variable Path)

• Powered

– Power Lift Truck

– Fork Lift Truck

– Multiple Trailer

– Yard Truck

– Over the road Truck

• Advantage

– Flexible

• Manual

– Truck (2 Wheel)

– Truck (4 Wheel)

– Lift Truck

– Dolly

• Disadvantage

– Must have portable

power supply with each

piece of equipment21© Copyright 2013 Anupam Kumar

Lift truck

Computer Controlled Truck

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Accessory Items

• Carriers

– Skids

– Pallets

• Containers

– Tote Boxes

– Baskets

– Pans

• Hoist Accessories

– Chains

– Clamps

– Slings

– Chime Hooks

– Spreader Bars

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Accessory Items

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For further details / comments ...

-Contact:

Anupam Kumar

Reader,

School of Management Sciences, Varanasi.

Email: anupamkr@gmail.com

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Bibliography

• Buffa, E.S. and Sarin, R.K., “Modern Production/Operations Management,” Eighth Edition. Singapore: John

Wiley & Sons (Asia). 1994.

• Martinich, J.S., “Production and Operations Management: An Applied Approach”, Singapore: John Wiley &

Sons (Asia), 2003.

• Badi, R.V. and Badi, N.V., “Production and Operations Management”, Second Edition, New Delhi: Vrinda

Publication, 2008.

• Chary, S.N., “Productions and Operations Management,” Third Edition, New Delhi: Tata McGraw Hill, 2004

• Goel, B.S., “Production Operations Management”, Twenty Second Edition, Meerut, U.P.: Pragati Prakashan,

2010.

• Kachru, U. “Production and Operations Management: Text and Cases,” New Delhi: Excel Books, 2007.

• Rama Murthy, P., “Production and Operations Management,” New Delhi: New Age International, 2012.

• Chunawalla, S.A., and Patel, D.R., “Production and Operations Management,” Mumbai: Himalaya

Publishing House, 2006.

• Jauhari, V. and Dutta, K., “Services: Marketing Operations and Management,” New Delhi: Oxford University

Press, 2010.

• Verma, H.V., “Services Marketing: Text and Cases,” New Delhi: Dorling Kindersley, Pearson Education, 2009.

• For Images & Clip arts

– clker.com

– blogs.msdn.com

– mysulitizenwebblog.blogspot.com

26© Copyright 2013 Anupam Kumar