2. Material Handling
Material handling is the function of moving the right material to the right place in the right time, in the right amount, in sequence, and in the right condition to minimize production cost.
The cost of MH estimates of total manufacturing labor cost in the United States [The Material Handling Industry of America (MHIA)]

3. Goals of Material Handling
The primary goal is to reduce unit costs of production
Maintain or improve product quality, reduce damage of materials
Promote safety and improve working conditions
Promote productivity
material should flow in a straight line
use gravity! It is free power
move more material at one time
mechanize material handling
automate material handling

4. Goals of Material Handling
Promote increased use of facilities
Reduce tare weight (dead weight)
Control inventory

5. Overview of Material Handling Equipment
Material handling equipment includes:
Transport Equipment: industrial trucks, Automated Guided vehicles (AGVs), monorails, conveyors, cranes and hoists.
Storage Systems: bulk storage, rack systems, shelving and bins, drawer storage, automated storage systems.
Unitizing Equipment: palletizers
Identification and Tracking systems

6. Considerations in Material Handling System Design
1. Material Characteristics
Category
Measures
Physical state
Size
Weight
Shape
Condition
Safety risk and risk of damage
Solid, liquid, or gas
Volume; length, width, height
Weight per piece, weight per unit volume
Long and flat, round, square, etc.
Hot, cold, wet, etc.
Explosive, flammable, toxic; fragile, etc.

7. Considerations …cont. 2. Flow rate Quantity of material moved High Low
Conveyors
Conveyors
AGV train
High
Manual handling
Hand trucks
Powered trucks
Unit load AGV
Low
Short
Long
Move Distance

8. Considerations …cont. 3. Plant Layout Layout Type Characteristics
Typical MH Equipment
Fixed – position
Process
Product
Large product size, low production rate
Variation in product and processing, low and medium production rates
Limited product variety, high production rate
Cranes, hoists, industrial trucks
Hand trucks, forklift trucks, AGVs
Conveyors for product flow, trucks to deliver components to stations.

9. Material Handling Equipment
Between fixed points over a fixed path
Belt conveyor
Roller conveyor
Chute conveyor
Slat conveyor
Screw conveyor
Chain conveyor
Overhead monorail conveyor
Trolley conveyor
Wheel conveyor
Tow conveyor
Bucket conveyor
Cart-on-track conveyor
Pneumatic tube conveyor

10. Material Handling Equipment
Over limited areas
Hoists
Overhead cranes
Hydraulic scissors lift
Over large areas
Handcart/truck
Tier platform truck
Hand lift truck / pallet jack
Power-driven hand truck
Power-driven platform truck
Forklift truck
Narrow aisle truck
Tractor-trailer truck
Material lift
Drum truck
Drum lifter
Dolly
Automated guided vehicle system

11. Belt conveyor

12. Belt conveyor

13. Roller conveyor

14. Chute conveyor

15. Chute conveyor

16. Slat conveyor

17. Screw conveyor

18. Screw conveyor

19. Chain conveyor

20. Chain conveyor

21. Overhead monorail conveyor

22. Overhead monorail conveyor

23. Trolley conveyor

24. Wheel conveyor

25. Wheel conveyor

26. Tow conveyor

27. Tow conveyor

28. Bucket conveyor

29. Bucket conveyor

30. Cart-on-track conveyor

31. Pneumatic tube conveyor

32. Pneumatic tube conveyor

33. Hoists

34. Overhead cranes

35. Hydraulic scissors lift

36. Handcart/truck

37. Tier platform truck

38. Hand lift truck / pallet jack

39. Power-driven hand truck

40. Power-driven platform truck

41. Forklift truck

42. Narrow aisle truck

43. Tractor-trailer truck

44. Material lift

45. Drum truck

46. Drum lifter

47. Drum lifter

48. Dolly

49. Pallet

50. Box

51. Tote Pan

52. Skid

53. 20 Principles of Material Handling
1. The Planning Principle
Large-scale material handling projects usually require a team approach.
Material handling planning considers every move, every storage need, and any delay in order to minimize production costs.
The plan should reflect the strategic objectives of the organization as well as the more immediate needs.

54. 2. The systems principle: MH and storage activities should be fully integrated to form a coordinated, operational system that spans receiving, inspection, storage, production, assembly, …, shipping, and the handling of returns.
Information flow and physical material flow should be integrated and treated as concurrent activities.
Methods should be provided for easily identifying materials and products, for determining their location and status within facilities and within the supply chain.

55. 3. Simplification principle
simplify handling by reducing, eliminating, or combining unnecessary movement and/or equipment.
Four questions to ask to simplify any job:
Can this job be eliminated?
If we can’t eliminate, can we combine movements to reduce cost? (unit load concept)
If we can’t eliminate or combine, can we rearrange the operations to reduce the travel distance?
If we can’t do any of the above, can we simplify?

56. 5. Space utilization principle
4. Gravity principle
Utilize gravity to move material whenever practical.
5. Space utilization principle
The better we use our building cube, the less space we need to buy or rent.
Racks, mezzanines, and overhead conveyors are a few examples that promote this goal.

57. 6. Unit load principle
Unit loads should be appropriately sized and configured at each stage of the supply chain.
The most common unit load is the pallet
cardboard pallets
plastic pallets
wooden pallets
steel skids pp

58. 8. Automation principle
MH operations should be mechanized and/or automated where feasible to improve operational efficiency, increase responsiveness, improve consistency and predictability, decrease operating costs.
ASRS is a perfect example.

59. 10. Equipment selection principle
Why? What? Where? When? How? Who?
If we answer these questions about each move, the solution will become evident.
Look at pp
11. The standardization principle
standardize handling methods as well as types and sizes of handling equipment
too many sizes and brands of equipment results in higher operational cost.
A fewer sizes of carton will simplify the storage.

60. 13.

61. 12. The dead weight principle
Try to reduce the ratio of equipment weight to product weight. Don’t buy equipment that is bigger than necessary.
Reduce tare weight and save money.
13. The maintenance principle
Plan for preventive maintenance and scheduled repairs of all handling equipment.
Pallets and storage facilities need repair too.
14. The capacity principle
use handling equipment to help achieve desired production capacity
i.e. material handling equipment can help to maximize production equipment utilization.

62. Example Press capacity = 60 min / 0.03 = 2000 pieces/hr
A punch press can cycle every 0.03 minute, but our time standard for manually loading and unloading this press is only 300 pieces per hour.
Press capacity = 60 min / 0.03 = 2000 pieces/hr
Utilization = 300 / 2000 = 15%
Should we buy a new press?
If we can purchase a coil-feeding material handling system, we could approach 100% press utilization.

63. Material Handling Equipment

64. Material Handling Equipment