* Material handling is defined by the Material Handling Industry of America as “ the movement, storage, protection and control of materials throughout the manufacturing and distribution process including their consumption and disposal”. * The handling of materials must be performed safely, efficiently, at low cost, in a timely manner, accurately and without damage to the materials. «(the right materials in the right quantities to the right locations)Manufacturing support systems Quality control systems Production system Manufacturing systems Automation and control technologies Material handling in the production systemMaterial Handling Definitions Right amount MH is the art and science of moving, storing, Right material a Right time ~___-—+ Right condition PROVIDE i protecting, and controlling material. Right place Right position Right sequence Right cost Right methodsNew MHI Material Handling Definition Operations Material Handling is the movement® e storage, control and protection of materials, goods and products througtrouot-——————- Subjects the process of manufacturing, distribution, consumption and disposal. The fosusis-on———— Business Processes the methods, mechanical equipment, systems and related controls used to achieve these functions.Objectives of Material Handling > Increase the efficiency of material flow Reduce MH cost > Improve facilities utilization > Safety and working conditions > Manufacturing process > Increase productivityMaterial Handling Examples Material Handling is not restricted to the manufacturing or distribution environment Mass Transportation Mail Delivery ConstructionMaterial Handling Systems Design rah pam mA ™ =»This cost of material handling is a significant portion of total production cost, estimates averaging around 20 — 25 % of total manufacturing labor cost in the united states. »The proportion may varies , depending on the type of production and degree of automation in the material handling function. Some material handling devices are - pallet shuttles in NC machining centers - Conveyors in manual assembly lines - transfer mechanisms in automated transfer lines - parts feeding devices in automated assemblyOverview of Material Handling Equipment = Material handling equipment is available commercially 1. Transport equipment 2. Storage systems 3. Unitizing equipment 4. Identification and tracking systemsMaterial Transport Equipment = Material transport includes equipment that is used to move materials inside a factory, ware house, or other facility. This equipment can be divided into the following five categories 1. Industrial trucks: Industrial trucks divided into two types powered and non-powered. ** Non-powered trucks are platforms or containers with wheels that are pushed or pulled by human workers to move the materials. “ Powered industrial trucks are steered by human workers. * They provide mechanized movement of materials.2. Automated guided vehicles (AGVs): AGVs are battery —powered, automatically steered vehicles that follow defined pathways in the floor. AGVs are used to move unit loads between load and unload stations in the facility. Routing variations are possible (Different loads move between different stations) 3. Monorails and other rail guided vehicles: These are self-propelled vehicles that ride on a fixed rail system . The vehicles operate independently and are usually driven by electric motors that pick up power from an electrified rail. Routing variations are possible 4. Conveyors: Conveyors constitute a large family of material Transport equipment that are designed to move materials over fixed paths, generally in large volumes. Powered conveyors roller, belt and tow-line and non-powered by human workers5. Cranes and hoists: These are handling devices for lifting , lowering, and transporting materials, often as very heavy loads. Hoists accomplish vertical lifting. Both manually operated and powered types are available. Cranes provide horizontal travel and generally include hoists. ieee ri a) Fork lift truck, industrial truck b) unit load automated guided vehicle c) Monorail d) roller conveyor e) jib crane with hoistStorage systems: It is generally desirable to reduce the storage of materials in manufacturing, it seems unavoidable that raw materials and work-in process will spend sometime being stored, even if only temporarily. And finished products are likely to spend sometime in a ware house or distribution center before being delivered to the final customer. Storage methods and equipment can be classified as follows a) Bulk storage: It consists of simply storing materials in an open floor area, generally in pallets or containers. It requires little or no storage equipment b) rack systems: These are structural frames designed to stack unit loads vertically, thus increasing the vertical storage efficiency compared to bulk storage c) Shelving and bins: Steel shelving comes in standard widths, depths, and heights to serve a variety of storage requirements. Shelves can include bins, which are containers for loose items.+d) Drawer storage: This storage medium is more costly than shelves, but is more convenient. Finding items stored in shelves can be difficult if the shelf level is too high or too low or too deep. It is generally used for tools, hardware and other small items. + e) Automated storage systems: Automated and semi automated systems are available to deposit and withdraw items into and from the storage compartments. There are two basic types: automated storage or retrieval systems: consists of rack and shelf systems 2) Carousel systems that rotate storage bins past a stationary load or unload station,* Examples of unit load containers for material handling * a) Wooden pallet b) pallet box and c) tote boxThe 10 Principles in Material Handling The 10 principles of material handling are explained below. Implementing these principles will result in safer operating conditions, lower costs, and better utilization and performance of material handling systems. The unit load principles stands as one of the most important and widely applied principle in material handling. In material handling, a unit load is Simply the mass that is to be moved or otherwise handled at one time. There are good reasons for using unit loads in material handling 1) Multiple items can be handled simultaneously 2) The required number of trips is reduced 3) Loading and unloading times are reduced 4) Product damage is decreased. These reasons result in lower cost and higher operating efficiency.Principle 1. PLANNING PRINCIPLE: All the material handling should be the result of a deliberate plan where the needs, performance objectives and functional specification of the proposed methods are completely defined at the outset. Principle 2. STANDARDIZATION PRINCIPLE: Material handling Methods, equipment, controls, and software should be standardized .It means less variety and customization in the methods and equipment employed. Principle 3. WORK PRINCIPLE: Material handling work should be minimized without sacrificing productivity or the level of service required of the operation Simplifying the processes by reducing, combining, shortening, or eliminating unnecessary steps will reduce work,Principle 4. 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. Principle 5. UNIT LOAD PRINCIPLE: A unit load is one that can be stored or moved as a single entity at one time, such as pallet, container totes etc.. Less effort and work are required to collect and move many individual items as a single load than to move many items one at a time. Principle 6. SPACE UTILIZATION PRINCIPLE: Effective and efficient use must be made of all available space Space in material handling is three —dimensional and therefore is counted as Cubic space.*Principle 7. SYSTEM PRINCIPLE: Material movement and storage activities should be fully integrated to form a co-ordinate ( receiving, inspection, storage, production, assembly etc.) * Principle 8. AUTOMATION PRINCIPLE: Material handling operations should be mechanized and or automated to improve the operating efficiency, increase responsiveness , decrease cost etc.. Principle 9. ENVIRONMENTAL PRINCIPLE: Environmental impact and energy consumption should be considered as criteria. Principle 10. LIFE CYCLE COST PRINCIPLE: Economic analysis should account for the entire life cycle of all material handling equipment.Applications of five categories of material handling equipment Material Handling equipment Features Applications Industrial trucks, manual Low cost Moving light loads ina factory Industrial trucks, powered Medium 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 more Large and heavy items more than 100 tonnes