Material Handling Equipment

Chapter One: Introduction

 Material handling (MH) involves “short-distance movement that
usually takes place within the confines of a building such as a
plant or a warehouse and between a building and a
transportation agency.”
 It can be used to create “time and place utility” through the
handling, storage, and control of material, as distinct from
manufacturing (i.e., fabrication and assembly operations), which
creates “form utility” by changing the shape, form, and makeup
of material.
 It is often said that MH only adds to the cost of a product, it
does not add to the value of a product. Although MH does not
provide a product with form utility, the time and place utility
provided by MH can add real value to a product,
Cont.

i.e., the value of a product can increase after MH has taken place; for
example:
 The value (to the customer) added by the overnight delivery of a package
(e.g., Federal Express) is greater than or equal to the additional cost of the
service as compared to regular mail service—otherwise regular mail would
have been used.

 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.
 1.2 Definition Of Materials Handling

One of the definition adopted way back by the American Materials Handling

Society is: Materials handling is the art and science involving the moving,

packaging and storing of substances in any form. Some of the other

definitions are:

Materials handling is the movement and storage of materials at the lowest

possible cost through the use of proper methods and equipment.
Materials handling is the moving of materials or product by any means,
including storage, and all movements except processing operations and
inspection.
Materials handling is the art and science of conveying, elevating,
positioning, transporting, packaging and storing of materials.
Cont.
• Storage or warehousing is very much a part of materials handling.
Materials handling uses different equipment and mechanisms
called Materials Handling Equipment.
• Though in one of the definitions, processing operations and
inspection have been specifically excluded from scope of
materials handling operations,
• it is worth mentioning that in specific cases processing or
inspection of materials may be accomplished simultaneously with
handling activity.
• One definition also covers the important objective of materials
handling which is lowest cost solution.
 The essential requirements of a good materials handling system
may be summarized as:
(i) Efficient and safe movement of materials to the desired place.
(ii) Timely movement of the materials when needed.
(iii) Supply of materials at the desired rate.
(iv) Storing of materials utilising minimum space.
(v) Lowest cost solution to the materials handling activities.
 Functional scope of materials handling within an industry covers
the following:
(i) Bulk materials as well as unit materials handing. Bulk
handling is particularly relevant in the processing, mining and
construction industries.
(ii) Industrial packaging of in-process materials, semi finished
or finished goods, primarily from the point of view of ease and
safety of handling, storage and transportation.
(iii) Handling of materials for storage or warehousing from raw
materials to finished product stage.
 Purpose of Material handling
Material handling means providing the
right amount
 of the right material
in the right condition
at the right place
in the right position
in the right sequence
in the right time
for the right price
by the right method
 Goals of Material Handling
Goals of material handling:
–Reduce unit costs of production
–Maintain or improve product quality, reduce damages, and provide for
protection of materials
–Promote safety and improve working conditions
–Promote productivity
–Promote increased use of facilities
–Control inventory
In a typical manufacturing facility:
25% of the work-force is used in material handling
55% of the factory floor is reserved for it
87% of the production time!
It may represent 15% to 70% of the total cost generated in the company
 Importance Of Materials Handling

A well designed materials handling system attempts to achieve the

following:
Improve efficiency of a production system by ensuring the right quantity of
materials delivered at the right place at the right time most economically.
Cut down indirect labour cost.
Reduce damage of materials during storage and movement.
Maximise space utilization by proper storage of materials and thereby
reduce storage and handling cost.

Minimise accident during materials handling.

Reduce overall cost by improving materials handling.

Improve customer services by supplying materials in a manner convenient
for handlings.

(Increase efficiency and saleability of plant and equipment with integral
materials handling features.
 The Disadvantage Of Materials Handling
(i) Additional capital cost involved in any materials handling
system.
(ii) Once a materials handling system get implemented,
flexibility for further changes gets greatly reduced.
(iii) With an integrated materials handling system installed,
failure/stoppage in any portion of it
leads to increased downtime of the production system.
(iv) Materials handling system needs maintenance, hence any
addition to materials handling means
additional maintenance facilities and costs.
Systems Concept
term ‘‘system’’ has many meaning depending on the field where applied. A
general definition of the term could be: a complex unity formed of many
often diverse parts subject to a common plan or serving a common
purpose.
Materials handling itself can also be considered to be a system whose
subsystems are
(i) design or method to be adopted,
(ii) types of materials handling equipment to be used,
(iii) different operations like packing /unpacking,
movement and storage involved,
(iv) maintenance required for the equipment employed, (v) mode of transportation
by the raw materials suppliers, distributors / customers, waste / scrap collectors
etc.
Material handling system equation
 Characteristics And Classification Of Materials
Basic classification of material is made on the basis of forms, which are
1. Gases: Gases are generally handled in tight and where required, pressure
resisting containers. However, most common method of handling of large
volume of gas is through pipes by the help of compressor, blower etc. This
process is known as pneumatic conveying.
2. Liquids, and semi Liquids: Liquids and semil iquids can be handled in
tight or open containers which may be fitted with facilities like insulation,
heating, cooling, agitating etc. Liquids and semili quids can be handled in
tight or open containers which may be fitted with facilities like insulation,
heating, cooling, agitating etc.
 Large quantity of stable liquids/semi liquids are generally conveyed
through pipes using suitable pumps, which is commonly known as hydraulic
conveying.
4. Solids:- are classified into two main groups:
I. Unit load:- are formed solids of various sizes, shapes and weights.
Some of these are counted by number of pieces like machine parts,
molding boxes, fabricated items.
unit load also classified based on:
(a) Shape of unit loads –
(i) basic geometric forms like rectangular, cylindrical,
pyramidal and spherical;
(ii) typical or usual forms like pallets, plate, containers, bales
and sacks;
(iii) irregular forms like objects with flat base dimension smaller
than overall size, loads on rollers/wheels and uneven shapes.
(b) Position of C.G. (stability) of load.
(c) Mass of unit load in 10 steps from 0-2.5 kg to more than 5000
kg.
(d) Volume per unit in 10 steps from 0-10 cm3 to more than10 m3.
(e) Type of material in contact with conveying system like metal,
wood, paper/cardboard, textile, rubber /plastics, glass and other
materials.
(f) Geometrical shape (flat, concave, convex, irregular/uneven,
ribbed etc.) and physical properties (smooth, slippery, rough,
hard, elastic etc) of base surface of unit load.
(g) Specific physical and chemical properties of unit loads like
abrasive, corrosive, dust emitting, damp, greasy/oily, hot, cold,
fragile, having sharp edges, inflammable, explosive,
hygroscopic, sticky, toxic, obnoxious, radioactive etc.
(h) Loads sensitive to pressure, shock, vibration, turning/tilting,
acceleration/deceleration, cold, heat, light, radiation, damp etc.
II. Bulk materials:- are those which are powdery, granular or lumpy in
nature and are stored in heaps. Example of bulk materials are:
 minerals (ores, coals etc.),
 earthly materials (gravel, sand, clay etc.)
 processed materials (cement, salt, chemicals etc.),
 agricultural products (grain, sugar, flour etc.) and similar other
materials.
 Major characteristics of bulk materials, are:
 lump-size (size of particle)
 bulk weight,
 specific weight, moisture content,
 flowability (mobility of its particles),
 angles of repose, abrasiveness, temperature,
 proneness to explosion,
 stickiness,
 fuming or dusty and corrosivity.
List of a Few Typical Bulk Materials with Codes
 Bulk materials are generally handled by
 belt-conveyor,
 screw conveyor,
 pneumatic conveyor,
 bucket elevator,
 grab bucket,
 skip hoist,
 stacker-reclaimer,
 dumper-loader etc.
 It can be handled by cranes / trucks when collected in containers or
bags.
 Small lump (powdered / granular) materials can be handled
pneumatically or hydraulically.
 Bulk materials are generally stored on ground / floor in the open or
under shed, and also in bunkers / silos.
 Plant Layout And Material Handling
A plant layout can be defined as follows:
• Plant layout refers to the arrangement of physical facilities such as
machinery, equipment, furniture etc.
• within the factory building in such a manner so as to have quickest flow of
material at the lowest cost and with the least amount of handling in
processing the product from the receipt of material to the shipment of the
finished product.
• It is also important because it affects the flow of material and processes,
labour efficiency, supervision and control, use of space and expansion
possibilities etc.
 The Main Objectives Of Plant Layout
The objectives of plant layout are:
Streamline the flow of materials through the plant.
Facilitate the manufacturing process.
Maintain high turnover of in-process inventory.

Minimize materials handling and cost.

Effective utilization of men, equipment and space.

Make effective utilization of cubic space.

Flexibility of manufacturing operations and arrangements.

Provide for employee convenience, safety and comfort.

Minimize investment in equipment.

Minimize overall production time.

Maintain flexibility of arrangement and operation.

Facilitate the organizational structure
 FACTORS INFLUENCING LAYOUT
a) Factory building: The nature and size of the building determines the
floor space available for layout.
b) Nature of product: product layout is suitable for uniform products
whereas process layout is more appropriate for custom-made
products.
c) Production process: In assembly line the product layout is better.
d) Type of machinery: General purpose machines are often arranged as
per process layout.
e) Repairs and maintenance: machines should be so arranged that
adequates pace is available between them for movement of
equipment and people required for repairing the machines.
f) Human needs: Adequate arrangement general need.
g) Plant environment: Heat, light, noise and ventilation