1.

0 INTRODUCTION TO MATERIALS HANDLING SUMMARY

1.1 DEFINITION AND SCOPE OF MATERIALS HANDLING

Materials handling is the art and science of conveying, elevating, positioning, transporting, packaging
and storing of materials. Since primitive men discovered the use of wheels and levers, they have been moving
materials mechanically. Any human activity involving materials need materials handling. In the field of
engineering and technology, the term materials handling is used with reference to industrial activity. In any
industry, be it big or small, involving manufacturing or construction type work, materials have to be handled as
raw materials, intermediate goods or finished products from the point of receipt and storage of raw materials,
through production processes and up to finished goods storage and dispatch points.

Materials Handling Equipment the use of different equipments and mechanisms.

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.

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

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. Unit materials handling covers handling of
formed materials in the initial, intermediate and final stages of manufacture.
(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. However,
consumer packaging is not directly related to materials handling.
(iii) Handling of materials for storage or warehousing from raw materials to finished product
stage

Transportation is generally excluded from the scope of materials handling. However, at each of the
sources and destinations, loading and unloading of materials is necessary and these are referred to as
materials handling of these locations. These long distance movements of materials are generally termed as
transportation of materials through various modes of transport like, road, rail, ship or air.

1.2 IMPORTANCE OF MATERIALS HANDLING

The foremost importance of materials handling is that it helps productivity and thereby
increases profitability of an industry. Many enterprises go out of business because of inefficient
materials handling practices. In many instances it is seen that competing industries are using
same or similar production equipment, and one who uses improved materials handling system
stays ahead of their competitors.
A well designed materials handling system attempts to achieve the following:
(i) Improve efficiency of a production system by ensuring the right quantity of materials
delivered at the right place at the right time most economically.
(ii) Cut down indirect labor cost.
(iii) Reduce damage of materials during storage and movement.
(iv) Maximize space utilization by proper storage of materials and thereby reduce storage
and handling cost.
(v) Minimize accident during materials handling.
(vi) Reduce overall cost by improving materials handling.
(vii) Improve customer services by supplying materials in a manner convenient for
handlings.
(viii) Increase efficiency and saleability of plant and equipment with integral materials
handling features.

1.3 SYSTEMS CONCEPT

The system concept of materials handling means the different types of materials handling
needed at different parts of an industry and associated suppliers’ and customers’ end are to be
considered in totality. Only this approach will ensure an overall cost effective materials handling
solution for the industry. The important characteristics of a system is that the parts, called
subsystems, are interrelated and guided by an objective for which the system exists. In an
industry, materials handling is a subsystem (or part) of the production system. 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.
The common objective by which the different subsystems are guided is the lowest cost solution
of the materials handling system for that industry.

1.4 CHARACTERISTICS AND CLASSIFICATION OF MATERIALS

Method to be adopted and choice of equipment for a materials handling system primarily
depends on the type of material/s to be handled. It is, therefore, very important to know about
different types of materials and their characteristics which are related to methods and equipment
used for their handling. As innumerable different materials are used and need to be handled in
industries, they are classified
based on specific characteristics relevant to their handling.

Basic classification of material is made on the basis of forms, which are

I . Gases,
 For gases it is primarily pressure, high (25 psi and more) or low (less than 25 psi). Chemical
properties are also important.
 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.
II. Liquids,

 For liquids the relevant characteristics are density, viscosity, freezing and boiling point, corrosiveness
temperature, inflammability etc. Examples of common industrial liquids are: water, mineral oils,
acids, alkalies , chemicals etc.

III. Semi Liquids

 Liquids and semiliquids can be handled in tight or open containers which may be fitted
with facilities like insulation, heating, cooling, agitating etc. as may be required by the
character of the liquid. Large quantity of stable liquids/semiliquids are generally
conveyed through pipes using suitable pumps, which is commonly known as hydraulic
conveying. Examples of common semi-liquids are: slurry, sewage, sludge, mud, pulp,
paste etc.

IV. Solids

 Solids form the majority of materials which are handled in industrial situation. Solids are classified
into two main groups: Unit load and Bulk load (materials).

2.0 Principles of Materials Handling

The word principle means, in the context of materials handling, a prescribed rule or guide to accepted
procedures, established through past experience, which is taken for granted or accepted as authoritative by
practitioners. Certain fundamental principles for analyzing and designing solutions to materials handling
problems have been developed over a period of time based on experience of many materials handling experts.
These can be used as general guide by any fresh materials handling practitioner, for analyzing a materials
handling problem and arriving at a solution to same. Many of the materials handling problems may be initially
treated by these principles before undertaking detailed technical analysis. In certain materials handling
problems, these principles may become the only resort to an acceptable solution where the exact analysis is too
costly or difficult.

It will be seen that each principle applies to a particular aspect of materials handling helps in achieving one or
more objectives of materials handling. A set of twenty principles of materials handling, (prepared by
H.H.Hall(2)) is stated and briefly explained.

I. PLANNING PRINCIPLE
All handling activities should be planned. This is the most basic principle which is in line
with the Materials Handling Equation.
Suggestions for carrying out planning principles are:
• Consider the plant layout before equipment / system design.
• Plan correct location for materials supply and disposal. Plan for scrap removal.
• Assure adequate storage space at the workplace.
• Avoid placing materials directly on the floor. Place product on a pallet, skid etc. at the
beginning
of the process.
• Use same container throughout the materials movement, as far as practicable.
• Observe principles of motions economy.
• Plan productive operations and inspections during material movement, if possible.
• Use judicious amount of manual handling.

II. SYSTEMS PRINCIPLE

Integrate as many handling activities as possible encompassing full scope of operations like
receiving, storage, production, inspection, packaging, warehousing, shipping/transportation.

Suggestions:
• Consider the entire scope of the handling activities, beyond the scope of immediate concern.
• Integrate operations into handling systems like processing, inspection, packaging etc.
• Avoid/ minimize intermediate storage.
• While designing a materials handling system, the practices/requirements of the suppliers,
clients and transporters are to be considered.
• Allow necessary flexibility considering future requirements/emergencies.

III. MATERIAL FLOW PRINCIPLE

Plan operations sequence and equipment arrangement to optimize material flow.

Suggestions:

• Eliminate obstacles from material flow.

• Plan material movement in a direct path (avoid backtracking, zig-zag movements etc.)
• Use product layout whenever possible.
• Keep related work areas close together.
• Combine operations to reduce material movement.
• Minimize movement between floors.
• Move bulky / weighty materials the least distance.
• Process heavy / bulky materials close to receiving.

IV. SIMPLIFICATION PRINCIPLE

Reduce, combine or eliminate unnecessary movement and/or equipment. It increases efficiency

of materials handling.

Suggestions:
• Apply principles of motions economy. Avoid unnecessary handling. Eliminate re-handling as
 much as possible.
• Plan direct moves. Reduce or eliminate long, awkward or complicated moves.
• Deliver materials at correct location first time.
• Use material out of original container.
• Avoid use of variety of equipment types, sizes and makes.
• Plan adequate material handling equipment capacity.
• Do not mechanize unnecessarily.

V. GRAVITY PRINCIPLE

Utilize gravity to move material whenever practicable.

Suggestions:

• Use roller conveyors, slides, chutes between equipment/processes.

• Use ramps between varying work or floor levels.
• Use sloping floor when materials movement by hand truck is mainly in one direction.
• Use spiral chutes to feed machines at different floors.

VI. SPACE UTILIZATION PRINCIPLE

Make optimum use of building volume.

Suggestions:

• Space equipment/processes close together.

• Eliminate or reduce temporary storage of materials.
• Stack materials to use building height.
• Use racks to permit higher stacking.
• Use stacking containers to permit stacking.
• Exercise economic order quantities to reduce inventory.
• Clean storage areas and dispose scrap regularly.
• Use narrow aisle handling equipment to reduce aisle width.

VII. UNIT SIZE PRINCIPLE

Increase quantity, size, weight of loads handled.

Suggestions:
• Examine possibility of unitization of loads.
• Use containers for unitization of loads.
• Procure materials in larger units.
• Design load size to make optimum use of handling equipment capacity.

VIII. SAFETY PRINCIPLE

Handling methods and handling equipment use must be safe.

Suggestions:

• Provide adequate guards & safety devices on materials handling equipment.

• Do not overload materials handling equipment.
• Maintain floor in good condition.
• Provide adequate shop lighting.
• Provide good housekeeping.
• Use mirror at aisle intersections.
• Materials handling equipment operators should be properly trained.
• Stack / unstuck materials safely.
• Keep materials handling equipment in proper condition and do not use defective equipment.
• Use mechanical handling equipment for difficult handling activities and to handle dangerous/
hazardous materials.
• Use proper personal protective gears during handling materials.

IX. MECHANIZATION/AUTOMATION PRINCIPLE

When appropriate, use mechanized or automatic materials handling equipment.

Suggestions:

• Consider mechanized system in the following cases:

(a) Large quantities or volumes of materials, (b) Repetitive movement, (c) Long moves,
(d) Hazardous move/materials, (e) Two man lifting, moving tasks, (f) Excess manual handling,
(g) Replacing large number of persons involved in handling, (h) Heavy materials, (i) Scrap
removal, (j) Feeding/unloading of high speed automated production machines.
• Do not over mechanize.

X. EQUIPMENT SELECTION PRINCIPLE

Before selecting materials handling equipment, consider all aspects of materials handling,
e.g., materials to be handled, moves to be made, methods to be utilized.

Suggestions:
• Select versatile equipment.
• Select standardized equipment.
• Consider unitization of load for handling.
• Select capacity judiciously. Provide additional capacity based on future plan.
• Compare alternatives based on cost of handling.

XI. STANDARDIZATION PRINCIPLE

Materials handling methods and equipment should be standardized to the extent possible.
Suggestions:

• Use standardized containers.

• Purchase standard types and sizes of equipment.
• Use standard sizes of pallets to fit products, bay sizes, equipment and transport trucks.

XII. FLEXIBILITY PRINCIPLE

Use methods and equipment, which can perform different tasks and applications.
Suggestions:
• Buy flexible equipment like Fork Lift Truck, Conveyor etc.
• Use variable speed drives.
• Make use of attachment & accessories.
• Use four ways pallets, skids and containers.
• Utilize mobile in favour of fixed equipment (e.g. trucks in favour of fixed conveyors)

XIII. DEAD-WEIGHT PRINCIPLE

Reduce the dead-weight movement.

Suggestions:
• Movable materials handling equipment should be made of lightweight materials like aluminum,
magnesium etc.
• Use lightweight, pallets, skids, containers etc.
• Consider expendable pallets, containers etc.
• Select lightweight equipment for light load.

XIV. MOTION PRINCIPLE

Stoppage of mobile equipment should be minimum.

Suggestions:
• Reduce loading/unloading time.
• Load/unload while materials handling equipment is in motion, if possible.
• Use mechanized loading/unloading equipment.
• Use self-loading/unloading equipment like lift truck.
• Plan materials movement on both ways movement of materials handling equipment.
• Use equipment where carrying device is attached to motive unit like platform-type trucks,
trailers
etc.
• Use pallets, skids etc. to hasten loading/unloading.
• Use devices like tipplers, bottom discharge containers etc.

XV. IDLE TIME PRINCIPLE

Reduce idle or unproductive time of both materials handling equipment and manpower.
This principle is similar to motion principle, so far as materials handling equipment are
concerned, hence same suggestions are applicable. Additional suggestions for ‘‘manpower’’ are:

• Deliver materials at proper rate so that operators are not idle for materials.
• Use indirect labor for materials handling.
• Install handling equipment to reduce labor.
• Combine jobs i.e. one man handles two or more machines or jobs.

XVI.MAINTENANCE PRINCIPLE
Do schedule maintenance and repair work of all materials handling equipment to minimize
outage.
Suggestions:
• Train operators/maintenance personnel properly.
• Follow maintenance procedures as per manufacturers' recommendations.
• Operators should check conditions daily and report.
• Do repair/maintenance to avoid breakdowns.
• Establish preventive maintenance programme.
• Maintain adequate spares.
• Standardize equipment to reduce spares.
• Avoid over maintenance.
• Avoid over loading of materials handling equipment.

XVII.OBSOLESCENCE PRINCIPLE

Replace obsolete handling methods and equipment by more efficient methods or equipment
to improve operations.
Suggestions:

• Establish a definite replacement policy.

• Rent or lease new equipment to tryout.
• Keep up-to-date as to what is new in the market through books, journals, expositions, factory
visits, conference, manufacturers' representatives etc.
XVIII. CONTROL PRINCIPLE

Use materials handling equipment to improve production & inventory control and order
handling.
Suggestions:

• Move materials in lots, batches, containers of a predetermined quantity and size.

• Use containers with wire mesh for visual checking/counting.
• Synchronize materials handling with production.
• Coordinate materials handling programme with purchasing and production.
• Use mechanized handling.

XIX.CAPACITY PRINCIPLE
Use Materials Handling so that full production capacity can be achieved.
Suggestions:

• Use mechanical handling systems for uniform flow of materials.

• Operate equipment at optimum rate.
• Plan to utilize return run of the materials handling equipment.
• Make full use of building volume.
• Change size, shape of unit load to utilize space, equipment and manpower.
• Use outdoor or rented storage space, when necessary.
• Widen aisle ways to speed materials movement.
XX.PERFORMANCE PRINCIPLE
Select materials handling systems with higher efficiency, measured in terms of expenses
per unit load handled.

Suggestions:
• Identify all possible units, which could be used as a basis for comparison.
• Select common, convenient, standard equipment.
• Use versatile equipment.