Course of MT- 362 Material Handling Lecture # 3. Principles of Material Handling Planning principle...

Course of MT- 362Material Handling

Lecture # 3

Principles of Material Handling

• Planning principle• Standardization principle

• Work principle• Ergonomic principle• Unit load principle• Space utilization• System principle

• Automation principle• Environmental principle• Life cycle cost principle


• Planning principle- All material handling should be the result of adeliberate plan where the needs, performanceobjectives and functional specification of theproposed methods are completely defined atthe outset.

Planning principle


• Standardization principle- Material handling methods, equipment,

controls and software should be standardizedwithin the limits of achieving overallperformance objectives and without sacrificingneeded flexibility , modularity and throughput(i.e., the quantity of raw materials processedwithin a given time)

Standardization principle


• Work principle- Material handling work should be minimizedwithout sacrificing productivity or the level ofservice required of the operation

- The work principle for MH should be such thatit should simplify the handling processes (e.g.,by reducing, combining, shortening oreliminating unnecessary moves)

• E.g., the shortest distance between two points is astraight line (not a curved path!)

Work principle


• Ergonomic principle- Ergonomics is the science that seeks to adaptwork or working conditions to suit the abilitiesof the worker

- Human capabilities and limitations must berecognized and respected in the design ofmaterial handling tasks and equipment toensure safe and effective operations

Ergonomic principle


• Unit load principle- A unit load is one that can be stored or movedas a single entity at one time, such as a pallet,container or tote (bag), regardless of thenumber of individual items that make up theload

- Unit loads shall be appropriately sized andconfigured in a way which achieves the

material flow and inventory objectives at eachstage in the supply chain

Unit load principle


• Space utilization principle- Space in material handling is three dimensional andtherefore is counted as cubic space

- Effective and efficient use must be made of allavailable space• In work areas, messy and unorganized spaces and blockedpassageways should be eliminated

• In storage areas, the objective of maximizing storage densitymust be balanced against accessibility and selectivity

• When transporting loads within a facility the use of overheadspace should be considered as an option

Space utilization principle


• System principle- A system is a collection of interacting and/orinterdependent entities that form a unified whole

- The MH should be such that material movement andstorage activities are fully integrated to form acoordinated and operational system

• This system should consist of receiving,inspection, storage, production, assembly,

packaging, unitizing, order selection, shipping,transportation and the handling of returns activities


• System principle- Systems integration should include the entire supplychain including reverse (return i.e., two way) logistics

- It should include suppliers, manufacturers, distributorsand customers- Inventory levels should be minimized at all stages ofproduction and distribution

• however process requirements and customerservice should be considered


• System principle- Information flow and physical material flow should beintegrated and treated as concurrent (simultaneous)activities

- Methods should be provided for easily identifyingmaterials and products, for determining their locationand status within facilities and within the supply chainand for controlling their movement

- Customer requirements and expectations regardingquantity, quality, and on-time delivery should be metwithout any distinction

System principle


• Automation principle- Automation is a technology concerned withthe application of electro-mechanical devices,electronics and computer-based systems tooperate and control production and serviceactivities. It suggests the linking of multiplemechanical operations to create a systemthat can be controlled by programmedinstructions


• Automation principle- Material handling operations should be mechanizedand/or automated where feasible to improveoperational efficiency, increase responsiveness,improve consistency and predictability, decreaseoperating costs and to eliminate repetitive orpotentially unsafe manual labor

- Pre-existing processes and methods should besimplified and/or re-engineered before any efforts atinstalling mechanized or automated systems


• Automation principle- Computerized material handling systems should beconsidered where appropriate for effective integrationof material flow and information management

- All items expected to be handled automatically musthave features that accommodate mechanized andautomated handling

- Treat all interface issues as critical to successfulautomation, including equipment to equipment,

equipment to load, equipment to operator, and controlcommunications

Automation principle


• Environmental principle- Environmental consciousness stems from adesire not to waste natural resources and topredict and eliminate the possible negativeeffects of our daily actions on the environment

- Environmental impact and energyconsumption should be considered as criteriawhen designing or selecting alternativeequipment and material handling systems


• Environmental principle- Containers, pallets and other products used to formand protect unit loads should be designed forreusability when possible and/or biodegradability asappropriate

- Systems design should accommodate the handling ofspent dunnage (wooden boxes), empty containersand other by-products of material handling

- Materials specified as hazardous have special needswith regard to spill protection, combustibility and otherrisks

Environmental principle


• Life cycle cost principle- Life cycle costs include all cash flows that willoccur between the time the first dollar is spentto plan or procure a new piece of equipment,or to put in place a new method, until thatmethod and/or equipment is totally replaced

- A thorough economic analysis should accountfor the entire life cycle of all material handlingequipment and resulting systems


• Life cycle cost principle- Life cycle costs include capital investment,installation, setup and equipment programming,

training, system testing and acceptance, operating(labor, utilities, etc.), maintenance and repair, reusevalue, and ultimate disposal- A plan for preventive and predictive maintenanceshould be prepared for the equipment, and theestimated cost of maintenance and spare partsshould be included in the economic analysis


• Life cycle cost principle- A long-range plan for replacement of the equipmentwhen it becomes obsolete should be prepared

- Although measurable cost is a primary factor, it iscertainly not the only factor in selecting among

alternatives. Other factors of a strategic nature to theorganization and which form the basis for competitionin the market place should be considered andquantified whenever possible

Life cycle cost principle

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