#04:

Material Handling &

Storage System

Dewanti Anggrahini
Manufacturing System Laboratory
Department of Industrial Engineering
Institut Teknologi Sepuluh Nopember

© 2019
Outline

Overview of Design of Material Handling Major Equipment Storage

Material Handling Material Handling Principles Categories System
System System
What is Material Handling?

• Material handling is the movement, protection, storage and control of materials and products
throughout manufacturing, warehousing, distribution, consumption and disposal. (MHI)

• Material handling involves short-distance movement within the confines of a building or betwe
en a building and a transportation vehicle. (Coyle, 1992)

• Material Handling can be defined as "efficient short-distance movement of goods that usually
takes place within the confines of a building such as a plant or a warehouse or between a buil
ding and a transportation agency. (Kay, 2012)

Material Handling is the function of moving the right materials to the right place in
the right time, in the right amount, in sequence, and in the right condition to minim
ize production cost.
 Is the material handling important?

• The value (to the customer) added by the overnight delivery of a package is greater than or
equal to the additional cost of the service as compared to regular mail service. (Logistics Indus-
try)

• The value added by having parts stored next to a bottleneck machine is the savings associated
with the increase in machine utilization minus the cost of storing the parts at the machine

Material Handling vs Logistics ?

Logistics

• Logistics is the procurement, maintenance, distribution, and replacement of personnel and

material. (Websters Dictionary)
• Logistics is defined as a business planning framework for the management of material,
service, information and capital flows. It includes the increasingly complex information,
communication and control systems required in today's business environment. (Logistix
Partners Oy Helsinki, 1996)
• Logistics is the planning, execution, and control of the movement / placement of goods and
/ or people, and the related supporting activities, all within a system designed to achieve
specific objectives. (Transfreight)
Logistics (2)

 Inbound logistics is the transportation, storage, and delivery activities of items coming into a
plant or business.
 The selection of inbound logistic partners is based on the concern of relationship between
companies and their suppliers.
Logistics (3)

• Outbond logistics is the transportation, storage, and delivery activities of items going out of a
plant or business.
• In the perspective of supply chain partners, the selection of outbound logistic partners deals
with the way of companies in getting products to their customers.
Design of Material Handling System
Design of Material Handling System (2)
Design of Material Handling System (3)

• Material Handling as a cost to be minimized.

• Material Handling System design depends on the degree to which the other aspect
s of production process are able to be charged.

Production
process design

New
Facilities

Material
Handling System
Principles of Material Handling

 Planning principle
 Standardization principle
 Work principle
 Ergonomic principle
 Unit load principle
 Space utilization principle
 System principle
 Automation principle
 Environment principle
 Life cycle cost principle

(Material Handing Institute)

(Kay, 2012)
 Planning Principle

Key points:
 The plan should be developed in consultation between the planner and the one who will use.
 Requires a team approach involving suppliers, consultants, and end user.
 The plan should reflect the strategic objectives of the organization.
 The plan should document existing methods and problems, physical and economic constraints
and future goals.
 The plan should promote concurrent engineering of product, process design, process layout,
and material handling method.

(Material Handing Institute)

(Kay, 2012)
Standardization Principle

Key points:
 The planner should select methods and equipment that can perform a variety tasks under a
variety of operating condition.
 Standardization applies to sizes of containers and other load forming components as well
as operating procedures and equpiment.
 Standardization, flexibility and modularity must not be incompatible.

(Material Handing Institute)

(Kay, 2012)
Work Principle

Key points:
 Simplifying processes.
 Consider each pickup and setdown, or placing material in and out of storage, distinct moves
and components of the distinct moved.
 Process methods, operation sequences and process/layouts should be prepared.
 Gravity should be used to move materials or to assist in their movement.
 The shortest distance between two points is a straight line.

(Material Handing Institute)

(Kay, 2012)
Ergonomic Principle

Key points:
 Equipment should be selected that eliminates repetitive and strenuous manual labor and
which effectively interacts with users.
 Embraces both physical and mental workload.
 Material handling workplace nad equipments employed to assist in that work must be safe
designed.

(Material Handing Institute)

(Kay, 2012)
Unit Load Principle

Key points:
 Less effort and work is required.
 Load size and composition may change as material and product moves through stages of
manufacturing.
 Large unit loads are common both pre and post manufacturing.
 During manufacturing, smaller unit loads, including as few as one item, yield less in-process
inventory and shorter item throughput times.
 Smaller unit loads are consistent with manufacturing strategies.
 Unit loads composed of a mix of different items are consistent with just-in-time strategy.

(Material Handing Institute)

(Kay, 2012)
Unit Load Principle (2)

(Kay, 2012)
Unit Load Principle (3)

(Kay, 2012)
Space Utilization Principle

Key points:
 In work areas, cluttered and unorganized spaces and blocked aisles should be eliminated.
 In storage areas, the objective of maximizing storage density must be balanced.
 When transporting loads within a facility the use of overhead space should be considered a
s an option.

(Material Handing Institute)

(Kay, 2012)
System Principle

Key points:
 Systems integration should encompass the entire supply chain.
 Inventory levels should be minimized at all stages of production and distribution.
 Information flow and physical material flow shuld be integrated and treated as concurrent
activities.
 Methods should be provided for easily identifying materials and products.
 Customer requirements and regarding quantity, quality, and on-time delivery should be met
without exception.

(Material Handing Institute)

(Kay, 2012)
Automation Principle

Key points:
 Pre-existing processes and methods should be simplified and re-engineered before any
efforts.
 Computerized material handling systems should be considered where appropriate for affect
ive integration of material flow.
 Treat all interface issues as critical to successful automation.
 All items expected to be handled automatically must have features that accomodate
automated handling.

(Material Handing Institute)

(Kay, 2012)
Environmental Principle

Key points:
 Containers, pallets and other products used to form and protect unit loads should be design
ed for reuseability.
 System design should accomodate the handling of spent dunnage, empty containers and
other material handling.
 Material specified as hazardous have special needs with regard to spill protection, combus-
tibility and other risks.

(Material Handing Institute)

(Kay, 2012)
Life Cycle Cost Principle

Key points:
 Life cycle costs include capital investment, installation, setup and equipment programming,
training, system testing and acceptance, operating, maintenance and repair, reuse value,
and ultimate disposal.
 A plan for preventive and predictive maintenance should be prepared.
 A long range plan for the replacement of the equipment.

(Material Handing Institute)

(Kay, 2012)
Major Equipment Categories

• Transport equipment
• Positioning equipment
• Unit load formation equipment
• Storage equipment
• Identification and control equipment

(Material Handing Institute)

(Kay, 2012)
Material Handling Equipment

(Kay, 2012)
Material Handling Equipment (2)

(Kay, 2012)
Conveyors

• Roller
• Skate-wheel
• Belt
• In-floor towline
• Overhead trolley conveyor
• Cart-on-track conveyor
Roller Conveyors
Skate Wheel Conveyors
Belt Conveyors
In-floor Towline Conveyors
Overhead Trolley Conveyors
Cart-on-Track Conveyor
Hoist
Cranes

• Jib Crane
• Bridge Crane
• Gantry Crane
• Stacker Crane
Jib Cranes
Bridge Cranes
Gantry Cranes
Stacker Cranes
Individual Trucks

• Hand truck
• Pallet jack
• Walkie stacker
• Pallet truck
• Platform truck
• Automated guided vehicle
Hand Truck
Pallet Jack
Walkie Stacker
Pallet truck
Automated Guided Vehicle
Vehicle Guidance Using Guide Wire
Vehicle Control

Two important aspects :

Traffic control – minimizing vehicle intersection.
1. Forward sensor (on-board vehicle)
2. Zone control
Vehicle dispatching
1. Control panel (On-board)
2. Main control station (remote call)
3. Centralized computer control
Control Zone
Transport Equipment Characteristics

Path Fixed Fixed Fixed Variable Variable Variable

Area Restricted Restricted Restricted Restricted Restricted Unrestricted

Frequency High Low Low High Low -

Adjacent - Yes No - - -

Equipment Conveyor Conveyor Industrial Industrial Crane Industrial

Category truck / truck truck
crane
Warehouse

Warehouse is a commercial building for storage of goods.

Warehouse are used by manufacturers, importers, exporters, whosalers, transport
business, custom, etc.
Warehouse usually have loading docks to load and unload goods from truck, some-
times they are designed for the loading and unloading of goods directly from
railways, airports or seaports.
Warehouse Storage System

A warehouse storage system is also called a warehouse management system

because it refers to storage equipments that are used to help company easily
manage its warehouse and keep the workers as well as the products and items
inside the warehouse safe.

Warehouse storage system that is common use:

a. Storage cabinets. Storage cabinets are used to store small or big items
depending on the size of the cabinets.
b. Pallet storage systems. This works just like a cabinet when it comes to
storing items and the only difference is that instead of cabinets.
c. Mezzanine storage system. This type of storage system adds more space to
the warehouse to stack items high up.
d. Automated system. This refers to any type of storage equipments in the
warehouse that are can be operated automatically.
Storage System - Benefit

• A more organized warehouse. In fact, the organization of a warehouse is the

main purpose of these systems and so, they are created to provide warehouse
owners and workers the convenience of managing or maintaining a warehouse.
• A safer warehouse for products and workers. It means there is no mess that can
threaten the safety of the workers while working. Plus, with these systems, the
products or goods are also kept safe and protected as they are placed inside
their proper places.
• Time and effort savings. Maintaining a warehouse can be very time-consuming
especially if you are manually keeping track of all the items and manually taking
the items out of other containers and back.
• Space-savings. It saves space since this system allows the stacking of items
high up above instead of cramming them all in one post making the warehouse
crowded.
Storage Equipments (Kay, 2012)

Block stacking Selective pallet rack

(i) Single-deep rack
(ii) Double-deep rack
Drive-in rack Cantilever rack
Drive-through rack Stacking frame
Push-back rack Bin Shelving
Flow-through rack Storage drawers
(a) Carton-flow rack
(b) Pallet-flow rack
Sliding rack Storage carousel
Vertical lift module Automatic storage/retrieval system (AS/RS)
(a) Unit load AS/RS
(b) Miniload AS/RS
(c) Man-on-board AS/RS
(d) Deep-lane AS/RS

A-Frame
Block Stacking

 Block Stacking refers to the product unit stacked towards the top and stored in
a row into a row or block.
 Pallets stacked with a certain height based on criteria such as the condition
of pallets, including product weight, height permitted forklift and warehouse ca
pabilities.
 Pallets are stored in this method can be taken with LIFO (Last In First Out). This
method does not allow for pickup by the ordering date or FIFO method.
Stacking Frame

 Stacks of pallets with frames made from the deck and milestones that can be
installed and moved if necessary.
 A stack of framed allows pallets to be stacked with a certain height and are espe-
cially useful when the pallets must be stored without having stacked.
 Many companies use a stack of framed at a time when they need the shelf while in
times of increased demand.
Double-deep Pallet Rack

 Method of double deep pallet rack is a variant of the single deep rack that puts two
in a single rack space.
 This method reduces the number of corridor needs, but this method is less efficient
than single-deep racking. And it takes a special forklift to be able to take two pallets
at once for can place and remove pallets from the rack.
Drive-in Rack

 Method of drive in rack provides a place of 5 to 10, which is a continuation of double

deep racking.
 Line drive ins provide access for a forklift to place or remove stocks. However, the fork
lift has limited room for manuever, and this requires additional time to place or
retrieve pallets.
Pallet-flow Rack

 Pallet Flow Rack operates by transferring the load from one side to another with
a simple conveyor so that the pallet can be moved using FIFO.
 When a pallet moved, then the next pallet position filled pallet moved.
 This method is suitable for warehouse shelves that have a high product turnover.
Push Back Rack

 Push back rack is the solution of LIFO in which pallet loads are placed in storage
by using the guide rail.
 This method is not appropriate for warehouse use requires the FIFO method.
Cantilever Rack

 Cantilever rack have flexibility in term of storage with the ability to put the product
a long, strange and heavy.
 Iron pieces, pipes, furniture, plywood, sheet metal and Formica are appropriate
goods placed on the mode cantilever rack.
 Cantilever racks usually require the use of a forklift as Side loader, appliance
makers special items (Special Order pickers) and trucks with 4-way achievement.
Storage System Performance

• Storage capacity
– Volumetric space
– Unit load
• Space volume
• Accessbility
• Throughput System
• Utility and availability
Automated Storage System

1. Automated Storage/Retrieval System (AS/RS)

2. Sistem Penyimpanan Carousel

(Kay, 2012)
AS/RS
TIPE AS/RS

Unit load AS/RS

Deep-lane AS/RS
Mini load AS/RS
Man-on-board AS/RS
Automated item retrieval system
Vertical lift storage modules (VLSM)
Carousel Storage System
Carousel Storage System (2)
A-Frame

(Kay, 2012)
A-Frame (2)

(Kay, 2012)
Pallet Storage Comparison

(Kay, 2012)
MHE Selection

(Kay, 2012)