UNIT LOAD HANDLING

CHAPTER 2
 1. Product Characteristics
• Physical Characteristics
– Density of bulk materials
– Ability to withstand exposure to elements
– Respiration
• Chemical Characteristics
– Incompatible products
– Products requiring chemicals
• Characteristics must be made known to consumers
• Hazardous Cargo: Explosives, Compressed gases,
Flammable liquids, Oxidizers, Poisons, Radioactive materials,
Corrosive materials
• Environmental Protection
– Reduce packing materials used
– Use packaging materials that are more
environmentally friendly with recycled content
– Use reusable containers
– Retain or support services that collect used
packaging and recycle it.
• Packaging Scrap Disposal
– Pallet shredder
• Metric System usage
 2. Packaging
• Building-blocks concept
– Smallest unit is consumer package
– Each unit is stocked within the next larger one to
protect the product
• Promotional functions of boxes
• Protective functions of packaging
– Enclose materials
– Restrain materials from undesired movement
– Separate contents to prevent undesired contact
– Cushion contents from outside vibrations and shocks
– Support the weight of identical containers stacked
above
 – Position the contents to provide maximum protection
– Provide for uniform weight distribution
– Provide exterior surface for labeling
– Be tamperproof
– Be safe for consumers or others
• Package testing
– Vibrations
– Dropping
– Horizontal impacts
– Compression
– Overexposure to extreme temperatures or moisture
– Rough handling
• A package system requires 3 types of information to
design
– Severity of the distribution environment
– Fragility of the product
– Performance characteristics of various cushion materials
Labeling
Batch numbers
Weight
Specific contents
Instructions for use
Information to allow
passage through
customs
Compliance labeling
One- or two-
dimensional bar
codes
Smart labels or RFID
labels Shipping labels
• A Handheld Laser Scanner Scanning Labels on a Pallet Load of Product Sitting in a
Warehouse Rack
 3. Unit Loads in Materials Handling

• Basic unit is a pallet or skid

– Lumber is expensive, so firms want pallets
returned
– Provides cushioning effect in transport
– Quality of pallets varies widely
– Should be less than 50 pounds—difficult with
plastic
– Metal also used in closed loop systems
• Unit load – amount of material that can be moved
as a single mass between two locations
• A unit load is one or more boxes secured to a
pallet or skid so that boxes can be handled by
mechanical means
• Primary advantage of using unit loads is the
capability of handling more items at a time and
reducing the number of trips, handling cost, loading
and unloading times, and product damage.
• Unit load and JIT
Advantages of unit loads:
• It permits handling of larger loads at a time and
thereby reduces handling and transportation costs.
• Loading and unloading time of unit load is
substantially less than when handled as
loose/individual material.
• Unitized loads are less susceptible to damage and
loss during movement from one place to another.
• It offers safer handling and transportation
compared to those of loose materials.
• Unitized load, even made of irregular shaped items,
generally become stable and well shaped. This offers a
number of advantages like stable storage, uniform
stacking to greater heights and increased storage space
utilization.
• For unitized load, individual item labeling may be
avoided.
• The process of unitization often protects loads from
foreign elements.
• Unitization generally provides a basis for
standardization of handling system and equipment
• within the plant as well as at the receiving and shipping
points for transportation
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.
• These unitization medium increase the weight of the final
load to be handled.
• Unitization essentially means deployment of equipment,
which necessitates capital investment.
• There is possibility of damage due to mishandling of large
amount of load.
• Movement of unitized materials may get hampered due to
absence of transfer equipment
 Unit Load Principle (unitizing)

In general, the unit load should be as large as practical

for the material handling system that will move and
store it
– A unit load is the mass that is to be moved or otherwise
handled at one time
• Reasons for using unit loads in material handling:
– Multiple items handled simultaneously
– Required number of trips is reduced
– Loading/unloading times are reduced
– Product damage is decreased
 4. Unit load design
7 steps to design a unit load:
- Unit load concept applicable?
- Select the unit load type
- Identify most remote source of load
- Determine farthest practicable destination for load
- Establish unit load size
- Determine unit load configuration
- Determine how to build unit load
Unit load design involves determining
1. Type, size, weight, and configuration of the load
2. Equipment and method used to handle the load
3. Methods of forming (or building) and breaking
down the load.
Determination of the load size
• Size (volume and weight) of the unit load has
major impact on the specification and operation
of the material handling
• The Optimal Unit Load is the quantity where the
system idle time, WIP and transportation cost are
minimized.
“picked up and moved between two locations as a single mass”
• Example:
1.A single item picked up and moved manually between two
locations
2.Two tote pans with identical components picked up moved by
a dolly from one machine to another
3.One pallet load of nonuniform-size cartons with different
products picked up and moved by a lift truck from the
packaging area to the shipping dock
4.One full load of products delivered by a trucktrailer from a
warehouse to a customer store If the trailer is half full, it is
still one unit load.
Larger unit load:
+ fewer moves
- bigger and heavier equipment
- wider aisles
- higher floor load capacities
- increased work-in-process inventory

Smaller unit load:

+ reduced work-in-process inventory
+ simple material handling methods (i.e., push carts)
+ reduced completion time (How??)
- more moves
- increased material handling time

•“Achieving single unit production requires the materail handling time

to be shorter than the unit processing time.”
 5. Load unitization processes and
handling methods
As unitized load is generally of fairly large weight and
volume, the method of handling them, i.e. how to hold, lift
and carry them is an important issue. The basic methods of
handling a unit load are:
• Putting a lifting device under the load like pallet, skid, tray,
rack etc., and then handling this device along with the load
• Inserting a lifting element into the body of the unit load.
This method is particularly suitable for lifting circular
shaped loads, with a hole in it, like coils, wheels, pipes etc.
The lifting element may be a ram type attachment of a
forklift truck, or may be simply a rod or log inserted
through the hole of the object
• Squeezing the load between two adjustable surfaces.
This is equivalent to carrying an object by squeezing
it between two fingers, between fingers and palm or
between palms of two hands by a man. This action
is simulated by carton-clamp or grabbing attachment
of a lift truck or self-closing tong of a lifting
equipment.
• Suspending the load. This can be done by hooking
the object, looping slings around the load, gripping
the load with a clamp, using a magnet for magnetic
load, using vacuum cups for handling large flat
fragile/delicate object made from glass, plastics etc.
Moving of the unit load:
a) Lifting under the mass
b) Inserting the lifting element into the body of the unit
load
c) Squeezing the load between two lifting surfaces
d) Suspending the load
Based on the process of unitizing and methods employed
for handling, unitized loads are generally grouped into
following five basic types:
• Unit load on a platform: When the load is arranged on
a platform which can be lifted and carried as unit load.
Generally two types of platform are used in industry -
pallet and skid.
• Unit load in a container: When small sized articles are
put inside a box like container, which can be carried
easily by trucks, cranes etc. This is a type of unitized
load which is very popularly practiced in manufacturing
industries. Different sizes and designs of containers are
used like box, bin, crate, carton, sack / balloon etc.
• Unit load on a rack: Specially designed racks are used to hold
different types of parts in desired orientation or relationship to
each other. The racks may be provided with inserts, pegs, or
holes to orient parts or to form dividers between layers for easy
handling, counting, inspection etc. Long products like pipes,
bars etc. are essentially stored in racks. Racks may be provided
with wheels for movement in planes or may be provided with
hooks for lifting.
• Unit load on a sheet: Unitization is possible on a sheet
material and the shape of the load depends on the
character and way the sheet material is used. Flat sheets
like cardboard, chipboard or plywood may be used for
unitization of load on it. Specially formed molded sheets
are used for unitization of bulk materials. In these formed
sheets, provisions are kept for fork entry of lift trucks. A
flexible sheet may be used as sling particularly for odd
shaped unit loads, bulk materials or materials packed in
bags.
• Self contained unit load (not requiring major auxiliary
aids): Different kinds of self - contained unitized loads
are practiced in industry and in everyday use. There are:
(a) Bundle: Long pieces of unequal shapes tied together by
a rope, wire, elastic band etc. for ease of handling.
(b) Bale: Materials like scrap paper, sheet metal trimmings
etc. are compressed in a bailing press to make the loose
materials into a single compact load of reduced size.
(c) Fastened unit load: Loose items fixed in position by
materials like wrapper, tape, glue etc. Shrink-wrapping and
Stretch-wrapping are two very popular processes which are
used more for packaging than unitization
(d) Interlocked unit load: Load which consists of individual
pieces so shaped by design that they can be arranged in a
fashion to make the assembly interlocked and self restrained.
For example cast aluminum pigs interlocked to build a stack.
(e) Unrestrained Load: Items stacked on a lifting device
without any restraining member, such that it can be stored as
an unit, but requires extra care for lifting or moving. Stack of
bricks or cartons on a pallet are examples of unrestrained load
 Unit Load Containers

• (a) Wooden pallet, (b) pallet box, (c) tote box

Common methods of unitizing a unit load
• Containers
• Platforms
* Skids
* Pallets
• Sheets
* Cardboard
* Plywood
* Polyethylene slip-sheets
• Racks
• Strapping
• Wrapping
* Stretch wrapping
* Shrink wrapping
• Pallet: It is essentially a platform used for assembling, storing
and handling of materials as a unit load. Essential feature of a
pallet is that the forks of a lift truck can be inserted at the bottom
side of the platform, while the pallet is resting on floor and thus
can raise the pallet with load and move it to desired place.
Pallets, when not in use, can be stacked one above the other.
• Skid: It is essentially a platform provided with legs so that a
platform truck may get inside it and raise it from ground. Skids
are thus single-faced and non-stackable.
• Two-way and four-way
• Non-wooden pallets
 Pallet loading problem
• The
relationship
between the
container and
the pallet
• The objectives:
◦to maximize
the use of space
◦to maximize
load stability
• Different types of tongs are used in
conjunction with crane for lifting and moving
many types of unit loads
 6. Selecting unit load size for
in-process handling
• Unit loads should not be larger than the production
batch size of parts in process—if the unit load size is
larger, then a delay would occur if the load is forced to
wait until the next batch of the part is scheduled to start
production (which might be days or weeks) before it
can be transported.
• Large production batches (used to increase the
utilization of bottleneck operations) can be split into
smaller transfer batches for handling purposes, where
each transfer batches contains one or more unit loads,
and small unit loads can be combined into a larger
transfer batch to allow more efficient transport
• When parts are transferred between adjacent
operations, the unit load may be a single part
• When operations are not adjacent, short distance
moves ⇒ smaller unit load sizes, and long distance
moves ⇒ larger unit load sizes.
• The practical size of a unit load (cf. the Unit Load
Principle) may be limited by the equipment and
aisle space available and the need for safe material
handling (in accord with the Safety Principle).
 Selecting unit load size for distribution

• Containers/pallets are usually available only in

standard sizes and configurations.
• Truck trailers, rail boxcars, and airplane cargo bays are
limited in width, length, and height.
• The existing warehouse layout and storage rack
configuration may limit the number of feasible
container/pallet sizes for a load.
• Customer package/carton sizes and retail store shelf
restrictions can limit the number of feasible
container/pallet sizes for a load.
 7. Efficiency of containers
• Containers with good stacking and nesting features can
provide significant reduction in material handling costs
• Stack-ability: A full container can be stacked on top of
another full container in the same spatial orientation.
• Nest-ability: Shape of the containers permits an empty
container to be inserted into another empty container of
the same type.
Container Space Utilization:
* Usable space (interior) of the container divided by exterior
envelope.
Example:
inside dimensions 18” x 11” x 11” (w x d x h)
outside dimensions 20” x 12” x 12”
Container Space Utilization= (18x11x11)/(20x12x12) = 76%
Container Nesting Ratio:
*Exterior height divided by the nested height.
Example:
outside dimensions 20” x 12” x 12”
Each nested container 20” x 12” x 2”
Container nesting ratio = 12/2 = 6:1
 Manual Palletizing
• Operators arrange items into the
desired pattern used to form the unit
load
• Since the ergonomics of loading and
unloading are important (e.g.,
vertically, the prime working zone is
between the knees and the chest;
horizontally, reaches of more than 24
in. with a load should be avoided),
lift and turn tables are often used
• Semi-mechanized palletizes use
operators to arrange items into the
desired pattern for each layer of the
unit load and a powered device is
used to transfer layers onto a pallet
and then lower the load for the next
layer
 Robotic Pick and Place Palletizers
• Fully automated device to build
unit loads
• Used when flexibility is required
(e.g., the "Distributor’s Pallet
Loading Problem")
• Greatest limitation is capacity,
typically 6 cycles per minute;
capacity is determined by the
number of items handled with each
pick operation
• Operators arrange items into the
desired pattern for each layer of
the unit load and a powered device
is used to transfer layers onto a
pallet and then lower the load for
the next layer
Conventional Stripper Plate Palletizers
• Fully automated device to build unit loads
• Used when high throughput of identical loads is required (e.g., the
"Manufacturer’s Pallet Loading Problem")
• Capacity is typically greater (30–180 items per minute) than pick
and place because an entire layer is placed on the load at one time;
not as flexible as pick and place
• Preformed layer of items (cases) are indexed onto the stripper plate
(or apron); when properly positioned over the pallet, the apron is
pulled out from underneath the layer to deposit the layer onto the
pallet
• "In-line" pattern formation (top picture)—flexible patterns are not
possible; ideal for high speed operation (up to 180 items per
minute); takes up more room (larger machine) than right angle
• "Right angle" pattern formation (bottom picture)—very flexible
patterns are possible; can handle a wide variety of case sizes and
types; limited capacity (up to 80 items per minute); compact design
 8. Major Equipment Categories

• Transport Equipment. Equipment 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 equipment are conveyors, cranes,
and industrial trucks. Material can also be transported
manually using no equipment.
• Positioning Equipment. Equipment used to handle material at
a single location (e.g., to feed and/or manipulate materials so
that are in the correct position for subsequent handling,
machining, transport, or storage). Unlike transport equipment,
positioning equipment is usually used for handling at a single
workplace. Material can also be positioned manually using no
equipment.
• Unit Load Formation Equipment. Equipment 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.
• Storage Equipment. Equipment used for holding or buffering
materials over a period of time. Some storage equipment may
include the transport of materials (e.g., the S/R machines of
an AS/RS, or storage carousels). If materials are block
stacked directly on the floor, then no storage equipment is
required.
• Identification and Control Equipment. Equipment 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
The following general equipment characteristics can be used to
describe the functional differences between conveyors, cranes,
and industrial trucks
• Path: - Fixed—move between two specific points
- Variable—move between a large variety of points
• Area: - Restricted—move restricted to a limited area
- Unrestricted—unlimited area of movement
• Move frequency: - Low—low number of moves per period,
or intermittent moves
- High—high number of moves per period
• Adjacent move: - Yes—move is between adjacent activities
- No—move is between activities that are not adjacent
number of moves per period
Transport Equipment Characteristics