Chapter         9

Material Handling Systems

9.1 Introduction
Material handling is defined as the movement, storage, control and protection of materials and
products throughout the production process, distribution, consumption and disposal. It is loading
and unloading of different types of materials to and from the transporting vehicles/material
handling devices. Material handling systems are applied in both manufacturing and distribution
systems. It is a non-value-adding activity, but involves costs (Bolz and Stocker 1951). The three
basic functions of material handling systems are picking up the load, transporting the load
and setting the load down (Apple 2000; Raymond 1985). The production effectiveness can be
increased by having the right quantity of material at the right places at the right time (Amstead
et al. 1979; James 1977; Vijayaram 2006).
One of the major objectives of work study and plant layout is to minimize material handling
time and cost. Material handling does not add any value to the product. It only helps in value
addition at different workstations in the plant. Poor material handling can increase the cost of
production. Therefore, material handling should be as minimum as possible. Material handling
is considered as an integral part of the total manufacturing system.

9.2 Relationship between Material

Handling and Plant Layout
Plant layout is pre-production planning. Material handling and manufacturing process
equipments are established as per requirement of plant layout. The material handling systems are
to be integrated with the following material handling functions:
1. Transportation to the production facility
2. Receiving, storage and retrieval
3. Transportation to the work-centres/workstations
4. Transportation between operations and staging
5. Packaging and shipping
 Material Handling Systems  173

9.3 Functions of Material Handling Systems

The functions of material handling are as follows:
1. To plan the plant layout, building and production centre as per the suitability of a
particular type of material handling equipments.
2. To minimize the movement of materials and material transportation time.
3. To optimize the speed of material handling equipments and devices.
4. To eliminate or minimize the backtracking.
5. To prevent the accident and facilitate the safe movement of materials.
6. To minimize the damage of materials during movement, loading and unloading.
7. To minimize the material handling costs.
8. To provide training to the persons operating the material handling equipments for their
efficient handling and safe working.

9.4 Objectives of Material Handling Systems

The objectives of materials handling are:
1. To increase the space utilization by keeping the materials in racks, one above the other.
The material handling generally affects space requirements. Storing various types of
materials like raw materials, parts, sub-assemblies, assemblies and finished parts is
facilitated by material handling devices and methods, stored at proper space.
2. To improve the operating efficiency by reducing material handling. Increasing load per
movement using the proper material handling devices improves productivity and saves
cost of materials handling.
3. To ensure on-time delivery of the materials at different work centres/facilities. Materials,
parts and finished products must be moved from the place of storage to their destination
speedily and efficiently.
4. To reduce the production cost by increased capacity, improving working conditions,
improving customer services, increased equipment and space utilization and reducing
cost of materials handling.

9.5 Principles of Material Handling Systems

Material handling is a technique, the efficiency of which is governed by the following principles:
1. The materials should be moved minimally as much as possible. The selection of
production machinery and the type of the plant layout should be such that the long
movement of material may be eliminated as far as possible.
2. The time of each move should be minimized. This can be attained through the shortest
routes and use of mechanized or automated material handling equipment in place of
manual labour.
3. The distance of each move should be minimized. This can be accomplished through the
use of the shortest routes and elimination of backtracking.
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4. The principle of unit load should be applied. According to this principle, the materials
should be moved in lots rather than on an individual basis. The optimum number of
pieces should be moved in one unit. The principal of unit load avails the economies
in the form of reduced loading, labour cost, packing cost, elimination of damage and
pilferage, savings in time and the effective utilization of material handling equipment.
5. The gravity feed should be used wherever possible as it is the cheapest source of motive
power.
6. Re-handling and backtracking of the materials should be avoided. This can be attained
through effective layout and efficient routing and scheduling.
7. The appropriate material handling equipment should be selected so that the safety,
efficiency and flexibility can be maintained.
8. The design of the container, pallets, drums, etc. should entail economy in handling and
reduce the material damages during the transit.
9. The material handling service must not interfere with the production flow.
10. The safety of the people must be taken care of and it should be the first preference.
11. The provision of the stand-by facilities should be made so that the sudden breakdown
may not shut down the operations.
12. There should be periodical maintenance of material handling devices.
13. The material handling services should be evaluated periodically and necessary changes
should be incorporated wherever it is possible.
14. The adverse effects on the environment should be minimized when selecting material
handling equipment and procedures.
15. Simplify handling by eliminating, reducing or combining unnecessary movements
and/or equipment.

9.6 Types of Material Handling Equipments

Material handling equipments can be classified into the following five major categories
(Michael 2012):
1. Transport equipments: These are the equipments used to move material from one
location to another (e.g. between workplaces, between a loading dock and a storage
area, etc.). The major subcategories of transport equipments are conveyors, cranes and
industrial trucks.
2. Positioning equipments: These equipments are used to handle material at a single
location so that the material is in the correct position for subsequent handling,
machining, transport or storage. Unlike transport equipments, positioning equipment is
usually used for handling at a single workplace.
3. Unit load formation equipments: These equipments are used to restrict materials so
that they maintain their integrity when handled a single load during transport and for
storage. If materials are self-restraining (e.g. a single part or interlocking parts), then
they can be formed into a unit load with no equipment.
 Material Handling Systems  175

4. Storage equipments: These equipments are used for holding or buffering materials
over a period of time. Some storage equipments may include the transport of materials
(e.g. the storage/retrieval machines of an automated storage/retrieval system).
5. Identification and control equipments: These equipments are used to collect and
communicate the information that is used to coordinate the flow of materials within
a facility and between a facility and its suppliers and customers. The identification
of materials and associated control can be performed manually with no specialized
equipment.

9.6.1 Transport Equipments

A. Conveyors
Chute conveyor (Figure 9.1)
Chute conveyor is used to accumulate the materials in bulk in the shipping area. It is used to link
two handling devices and convey items between floors. But it is difficult to position the materials
accurately using this device.
Wheel conveyor (Figure 9.2)
Wheel conveyor consists of a series of skate wheels mounted on a shaft or axle, where the spacing
of the wheels is dependent on the load being transported. Slope for gravity movement depends on
load weight. It is used for light-duty applications and different versions of the device are available.

Figure 9-1: Chute conveyor Figure 9-2: Wheel conveyor

Roller conveyor (Figure 9.3)

Roller conveyor is used to handle rigid materials. This may be powered or gravity fed. The roller
used may be tapered to give proper orientation to the materials.
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Flat belt conveyor (Figure 9.4)

Flat belt conveyor is used for transporting light- and medium-weight materials between
operations, departments, levels and buildings, when an incline or decline is required. It provides
considerable control over the orientation and placement of the load. Some operations are difficult
to perform on the belt such as smooth accumulation, merging and sorting. The belt is roller- or
slider bed-supported; the slider bed is used for small and irregularly shaped items.

Figure 9-3: Roller conveyor Figure 9-4: Flat belt conveyor

Bucket conveyor (Figure 9.5)

Bucket conveyor is used to move bulk materials in a vertical or
an inclined path. Buckets are attached to a cable, chain or belt
as shown in Figure 9.5. Buckets are automatically unloaded at
the end of the conveyor run.
Screw conveyor (Figure 9.6)
Screw conveyor consists of a tube through which a shaft-
mounted helix revolves to push loose material forward in a
horizontal or an inclined direction. It is most commonly applied
in the processing industry and chemical processing.

Figure 9-5: Bucket conveyor

Figure 9-6: Screw conveyor

 Material Handling Systems  177

Pneumatic conveyor (Figure 9.7)

Pneumatic conveyor can be used for both bulk and unit movement of materials. In this conveyor,
air pressure is used to convey materials through a system of vertical and horizontal tubes. The
major advantages are that the material is completely enclosed and it is easy to implement turns
and vertical moves. It moves a mixture of air and solid and pushes material from one entry
point to several discharge points. Pull systems move material from several entry points to one
discharge point. Push–pull systems are combinations with multiple entry and discharge points.
Vertical lift conveyor (Figure 9.8)
Vertical lift conveyor is used for low-frequency intermittent vertical transfers. The carrier is used
to raise or lower a load to different floors. The device can be manually or automatically loaded
and/or controlled and can interface with horizontal conveyors.

Rotary airlock

Figure 9-7: Pneumatic conveyor Figure 9-8: Vertical lift conveyor

Trolley conveyor (Figure 9.9)

This device uses a series of trolleys supported from or within an overhead track. Trolleys are equally
spaced in a closed loop path and are suspended from a chain. Carriers are used to carry multiple
units of a product. It is commonly used in processing, assembly, packaging and storage operations.

Figure 9-9: Trolley conveyor

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B. Cranes
Cranes are used to move loads over different paths within a restricted area where the use of a
conveyor cannot be justified due to intermittent flow of materials. They provide more flexibility
in movement than conveyors, but less flexible in movement than industrial trucks. Most cranes
utilize hoists for vertical movement, although manipulators can be used if the precise positioning
of the load is required.
Jib crane (Figure 9.10)
Jib crane operates like an arm in a work area, where it can function as a manipulator for
positioning the jobs. A hoist is attached to the arm for lifting load. The arm can rotate 360° and
the hoist can move along the arm.
Bridge crane (Figure 9.11)
Bridge mounted on tracks that are located on opposite walls of the facility and it enables three-
dimensional handling.

Pivot

Figure 9-10: Jib crane Figure 9-11: Bridge crane

Gantry crane (Figure 9.12)

Gantry crane can be single leg, double leg or mobile types. This is similar to a bridge crane
except that it is floor supported at one or both ends instead of overhead supported and is used
to span a smaller portion of the work area as compared to a bridge crane. The supports can be
fixed in position or they can travel on runways. It can be used outdoors when floor is supported
at both ends.
Stacker crane (Figure 9.13)
Similar to a bridge crane except that instead of a hoist, it uses a mast with forks or a platform to
handle unit loads. It is equipped with fork trucks on a rail. It is used for storing and retrieving unit
loads in storage racks, especially in high-rise applications in which the racks are more than 15 m
height. It can be controlled by remote or by an operator in a cab on the mast.
 Material Handling Systems  179

Figure 9-12: Gantry crane Figure 9-13: Stacker crane

C. Industrial Trucks
Industrial trucks are used to move materials over horizontal paths with no restrictions on the area
covered. They can provide vertical movement if the truck has lifting capabilities. They are used
when there is an intermittent flow volume such that the use of a conveyor cannot be justified.
They provide more flexibility in movement than conveyors and cranes.
Some important characteristics of trucks are enumerated as follows:
1. The trucks may or may not have forks for handling pallets, or truck may have a flat
surface on which loads are placed.
2. The truck may have manual or powered vertical and/or horizontal movement capabilities.
3. For non-automated trucks, the operator can ride in the truck or the operator is required
to walk with the truck during travel.
4. The truck can be used to lift loads for stacking purposes.
5. The lift truck may be designed to have a small turning radius.
6. The truck may be automated so that it can transport loads without involving an operator.
Hand trucks (Figure 9.14)
Hand truck is used to move the lighter load. Two-wheeled trucks are used to tilt the load and to
move from one place to another place. Dolly is three- or multiple-wheeled hand truck with a flat
platform in which, the load is used for pushing since it has no handle. Floor hand truck is four- or
multiple-wheeled hand truck with handles for pushing or hitches for pulling.

(a) Two-wheeled hand truck    (b) Dolly     (c) Floor hand truck

Figure 9-14: Hand trucks

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Pallet jacks (Figure 9.15)

In this jack, front wheels are mounted inside the end of the forks and extend to the floor as the
pallet is only lifted enough to clear the floor for subsequent travel. Reversible pallets cannot be
used, double-faced non-reversible pallets cannot have deck boards where the front wheels extend
to the floor, and enables only two-way entry into a four-way notched-stringer pallet because the
forks cannot be inserted into the notches.

(a) Manual pallet jack (b) Powered pallet jack

Figure 9-15: Pallet jacks

Walkie stacker (Figure 9.16)

Walkie stack is used for manual lifting and/or travel (and straddle load support). This device may
be powered by an engine.
Counterbalanced lift truck (Figure 9.17)
This is also referred to as fork lift truck. The weight of the vehicle behind the front wheels of the
truck counterbalances weight of the load and front wheels act as a fulcrum or pivot point. The
rated capacity used to lift the load is more than 13 ft height. It is very useful in the plant because
of their flexibility: indoor/outdoor operation over a variety of different surfaces; variety of load
capacities available; and a variety of attachments available.

Figure 9-16: Walkie stacker Figure 9-17: The counterbalanced lift truck
 Material Handling Systems  181

Automatic guided vehicle (Figure 9.18)

Automatic Guided Vehicles (AGVs) do not require any operator. They are good for high labour
cost, hazardous, or environmentally sensitive, low-to-medium volume, medium-to-long distance
random material flow operations (transport between work cells in a flexible manufacturing
system environment). Two means of guidance used for AGV systems are: fixed path (wire, tape,
paint for guidance) and free-ranging (software guided), but absolute position estimates (from
lasers) are needed to correct dead-reckoning error.

Figure 9-18: Automatic guided vehicle (AGV)

9.6.2 Positioning Equipments

Positioning equipments are used to give proper orientation or position of the material or job. This
equipment has following advantages:
1. It raises the productivity of each worker when the frequency of handling is high.
2. It improves the product quality and limits damage to materials and equipment when the
item handled is heavy or awkward to hold and damage is likely through human error or
inattention, and
3. It reduces fatigue and injuries when the environment is hazardous or inaccessible.
Lift/Tilt/Turn table (Figure 9.19)
Lift table is used when positioning involves the lifting, tilting or turning off a load.
Dock leveller (Figure 9.20)
This is used at loading docks to compensate for height differences between a truck bed and the
dock.
Rotary index table (Figure 9.21)
Rotary indexing table is used for the synchronous transfer of small parts from station to station
in a single work-centre. The circular table rotates in discrete intermittent steps to move parts
between stations located along its perimeter. Since each part moves between stations at the same
182  Industrial Engineering and Management

Figure 9-19: Lift/Tilt/Turn table Figure 9-20: Dock leveller

time, it is difficult to put buffers between stations. It is different from conveyors used as in-
line indexing machines, where linear transfers can take place between multiple work-centres
separated by long distances, since a rotary index table is restricted to circular transfers with a
single compact work-centre.

Figure 9-21: Rotary index table

Parts feeder (Figure 9.22)

Part feeders are used for feeding and orienting small identical parts, particularly in automatic
assembly operations. Motion of parts in a random pile is channelled so that each part
automatically assumes a specified orientation, where the symmetries of a part define its possible
orientations. Motion can be imparted through vibration, gravity, centrifugal force, tumbling or
air pressure. Vibratory bowl feeder is the most versatile type of parts feeder in which the parts
are dumped into a bowl and then vibrated and moved uphill along a track towards an outlet,
where rejected parts fall off the track and are recycled. Parts feeders can be used to provide
inspection capabilities with respect to the shape and weight of parts (e.g. the coin feeder of a
vending machine).
 Material Handling Systems  183

Figure 9-22: Parts feeder Figure 9-23: Manipulator

Manipulator (Figure 9.23)

The manipulator is used for vertical and horizontal translation and rotation of loads. It can be
powered manually, electrically or pneumatically. Manipulator’s end-effector can be equipped
with mechanical grippers, vacuum grippers, electromechanical grippers, or other tooling.
Manipulators fill the gap between hoists and industrial robots and they can be used for a wider
range of positioning tasks than hoists and are more flexible than industrial robots due to their use
of manual control.
Industrial robot (Figure 9.24)

Z
Y
X

Figure 9-24: Industrial robot

Industrial robot is used in positioning to provide variable programmed motions of loads.

Intelligent industrial robots utilize sensory information for complex control actions, as opposed
to simple repetitive ‘pick-and-place’ motions. Industrial robots are also used for parts fabrication,
inspection and assembly tasks. It consists of a chain of several rigid links connected in series by
revolute or prismatic joints with one end of the chain attached to a supporting base and the
other end free and equipped with an end-effector. Robot’s end-effector may be equipped with
184  Industrial Engineering and Management

mechanical grippers, vacuum grippers, electromechanical grippers, welding heads, paint spray
heads or any other tools. Although similar in construction, an industrial robot is distinguished
from a manipulator by the use of programmed control logic as opposite to manual control.

9.6.3 Unit Load Formation Equipments

Unit load formation equipments are various types of packaging of the materials those can
provide the safe movement or handling of the materials. These can be boxes, bags, cartons,
pallets, skids, slip sheets, containers, etc. There are some advantages and disadvantages of unit
loads as discussed below:
Advantages of Unit Loads
• More items can be handled at the same time, thereby reducing the number of trips required
and, potentially, reducing handling costs, loading and unloading times, and product damage.
• Enables the use of standardized material handling equipments.
Disadvantages of Unit Loads
• Time spent forming and breaking down the unit load.
• Cost of containers/pallets and other load restraining materials used in the unit load
• Empty containers/pallets may need to be returned to their point of origin.

9.6.4 Storage Equipments

The most common reason for storing a product allows the other elements of production to operate
more efficiently on a per unit basis because the fixed costs associated with utilizing the element
can be spread over more products, e.g. storing up to a truckload of product in a facility reduces
the per-unit costs of shipping; and buffering or storage of WIP enables batch production which
reduces the per-unit set-up costs.
Other potential reasons for storage include time bridging that allows the product to be
available when it is needed; processing for some products, storage can be considered as a
processing operation because the product undergoes a required change during storage; and
securing, for example, nuclear waste storage. The storage equipments used in an industry are
racks, frames, shelves, bins, drawers, AS/RS, etc.
Automatic Storage/Retrieval Systems
It consists of an integrated computer-controlled system that combines the storage medium,
transport mechanism, and controls with various levels of automation for fast and accurate
random storage of products and materials. Storage/retrieval (S/R) machine in an automatic
storage/retrieval system (AS/RS) operates in narrow aisles, serving rack slots on both sides of
the aisle; it can travel in horizontal and vertical directions at the same time.

9.6.5 Identification and Communication Equipments

Identification and control equipment is used to collect and communicate the information that is
used to coordinate the flow of materials within a facility and between a facility and its suppliers
 Material Handling Systems  185

and customers. The major types of identification and communication equipment are bar codes,
radio-frequency tag, magnetic strips, machine vision, electronic data interchange, etc.
Selection of Material Handling Equipments
Selection of the material handling devices is based on the following factors:
1. Size, shape, weight and volume of the materials.
2. Types of materials to be moved.
3. Layout of the plant, production centre and other facilities.
4. Types of buildings, width of roads, corridors, pavements, floor levels, doors, height ceiling,
size of rooms and storing places, single-storey buildings and multi-storey buildings.
5. Methods, direction and movement of materials.
6. Types of machines and equipments used for production.
7. Production processes and methods of manufacturing.
8. Material handling cost.
9. Cost of material handling equipments.
10. Material handling efficiency and automation needed.
11. Life of equipment.
12. Safety of equipments.
13. Maintenance of material handling equipments.
14. Ease of operation.

 Summary
In this chapter, we have discussed about objectives, functions and principles of material handling
equipments. Different types of handling equipments are introduced. Finally, the bases for
equipment selection have been explained. The main purpose of the chapter was to familiarize the
readers with material handling equipments frequently used in industries.

Multiple-Choice Questions
1.Material handling is defined as
(a) the activities of material management
(b) the function of purchasing of the materials for manufacturing
(c) the movement, storage, control and protection of materials and products throughout the production
process
(d) quality testing of the materials
2. Which of the following is not a function of material handling systems?
(a) to minimize the movement of materials and material transportation time.
(b) to optimize the speed of material handling equipments and devices.
(c) to eliminate or minimize the material handling cost.
(d) to minimize the material costs.
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3. Which of the following is not an objective of material handling systems?

(a) to increase the space utilization by keeping the materials in racks, one above the other
(b) to improve the quality of the product to be manufactured
(c) to improve the operating efficiency by reducing material handling
(d) to ensure on-time delivery of the materials at different work centres/facilities
4. Materials handling covers the following processes except
(a) Storing the product (b) Handling the materials
(c) Moving an assembly (d) Surface finishing
5. Material handling process can be justify with the process characteristics
(a) high repeatability (b) high volume
(c) line flows (d) all the above
6. When encountering bottlenecks in a process, the AGV generally responds in the following manners
(a) Fixes the problems causing the bottlenecks
(b) Reroutes the materials to alternative workstations
(c) Halts the process and sounds the alarm
(d) All the above
7. Material handling in automobile company is done by
(a) Overhead crane (b) Trolley
(c) Belt conveyor (d) All the above
8. Which of the following material handling equipment has counter balance type weight?
(a) Gravity conveyor (b) Forklift
(c) Overhead crane (d) Robot
9. A device used for lifting or lowering an object suspended from a hook at the end of retractable chains
is called
(a) Jib crane (b) Hoist
(c) Portable elevator (d) Chain conveyor
10. Which of the following devices is used in part orientation in an automated assembly line?
(a) Part feeder (b) Manipulator
(c) Dock leveller (d) Rotary indexing table
11. In a chemical industry, frequently used conveyor is
(a) belt conveyor (b) roller conveyor
(c) screw conveyor (d) all the above
12. Which of the following is a positioning equipment?
(a) belt conveyor (b) trolley conveyor
(c) trucks (d) industrial robot
13. Industrial truck is frequently used in
(a) Warehouses (b) Manufacturing work of shop floor
(c) Both (a) and (b) (d) None of these
 Material Handling Systems  187

14. Automatic guided vehicle can be controlled by

(a) a software (b) sensors using wire, tape, paints
(c) lasers (d) all the above
15. Which of the following devices is used for vertical and horizontal translation and rotation of loads?
(a) Manipulator (b) AGV
(c) Lift table (d) Rotary index table

Answers
1. (c) 2. (d) 3. (b) 4. (d) 5. (d) 6. (b) 7. (a) 8. (b) 9. (b)
10. (a) 11. (c) 12. (d) 13. (c) 14. (d) 15. (a)

Review Questions
1. Define the term ‘material handling systems’ and highlight the relationship between material handling
and plant layout.
2. Explain the functions of material handling systems.
3. Explain the objectives of material handling systems.
4. Discuss the principles of material handling systems.
5. What are the various types of material handling equipments used in a manufacturing industries?
Explain in brief.
6. Diferntiate the use of positioning equipments and the use of transport equipments.
7. Write short notes on automated guided vehicle (AGV).
8. Write short notes on automated storage (AS) and automated retrieval (AV).

 References and Further Readings

1. Amstead, B. H., Ostwald, P. F. and Begeman, M. L. (1979), Manufacturing Process, 7th edn, pp. 33–35
(New York: John Wiley and Sons).
2. Apple, J. M. (1972), Material Handling System Design (New York: Ronald).
3. Apple, J. M. (2000), ‘Lesson Guide Outline on Material Handling Education’, in R. L. Shell and
E. L. Hall (eds), Handbook of Industrial Automation (New York: Marcel Dekker Inc.), pp. 99–109.
4. Bolz, H. and Stocker, H. E. (1951), Basics of Material Handling, 2nd edn, pp. 22–33 (Englewood
Cliffs, N.J.: Prentice Hall Inc.).
5. Frazelle, E. (2002), World-Class Warehousing and Material Handling (New York: McGraw-Hill).
6. James, M. A. (1977), Plant Layout and Material Handling, 3rd edn, pp. 75–99 (New York: John Wiley
and Sons).
7. Kulwiec, R. A., (ed.) (1985), Materials Handling Handbook, 2nd ed., (New York: Wiley).
188  Industrial Engineering and Management

8. Michael, G. Kay (2012), Material Handling Equipment (Fitts Department of Industrial and System
Engineering: North Carolina State University).
9. Mulcahy, D. E. (1994), Warehouse Distribution & Operations Handbook (New York: McGraw-Hill).
10. Mulcahy, D. E. (1999), Materials Handling Handbook (New York: McGraw-Hill).
11. Raymond, A. K. (1985), Material Handling Handbook, pp. 87–97 (New York: Wiley).
12. Vijayaram, T. R. (2006), Materials handling technology and significance of expert systems to select
appropriate handling equipments in engineering industries: A review. Journal of Scientific and
Industrial Research, 65(8): 619–624.