Material Handling

1.1 Introduction
 Materials handling is loading, moving and unloading of materials.
 To do it safely and economically, different types of tackles, gadgets and
equipment are used, when the materials handling is referred to as
mechanical handling 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. However, 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 as such is not a production process and hence does not
add to the value of the product.
 It also costs money; therefore it should be eliminated or at least reduced as
much as possible.
 However, the important point in favour of materials handling is that it helps
production.
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.

1.2 Need of Material Handling System

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.
1.3 Scope of Material Handling System
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.
1.4 OBJECTIVES OF MATERIAL HANDLING
Following are the objectives of material handling:
 Minimise cost of material handling.
 Minimise delays and interruptions by making available the materials at the
point of use at right quantity and at right time.
 Increase the productive capacity of the production facilities by effective
utilisation of capacity and enhancing productivity.
 Safety in material handling through improvement in working condition.
 Maximum utilisation of material handling equipment.
 Prevention of damages to materials.
 Lower investment in process inventory
1.5 PRINCIPLES OF MATERIAL HANDLING
Following are the principles of material handling:
1. Planning principle: All handling activities should be planned.
2. Systems principle: Plan a system integrating as many handling activities as
possible and co-ordinating the full scope of operations (receiving, storage,
production, inspection, packing, warehousing, supply and transportation).
3. Space utilisation principle: Make optimum use of cubic space.
4. Unit load principle: Increase quantity, size, weight of load handled.
5. Gravity principle: Utilise gravity to move a material wherever practicable.
6. Material flow principle: Plan an operation sequence and equipment
arrangement to optimise material flow.
7. Simplification principle: Reduce combine or eliminate unnecessary
movement and/or equipment.
8. Safety principle: Provide for safe handling methods and equipment.
9. Mechanisation principle: Use mechanical or automated material handling
equipment
 10. Standardisation principle: Standardise method, types, size of material
handling equipment.
11. Flexibility principle: Use methods and equipment that can perform a
variety of task and applications
12. Equipment selection principle: Consider all aspect of material, move and
method to be utilised.
13. Dead weight principle: Reduce the ratio of dead weight to pay load in
mobile equipment.
14. Motion principle: Equipment designed to transport material should be kept
in motion.
15. Idle time principle: Reduce idle time/unproductive time of both MH
equipment and man power.
16. Maintenance principle: Plan for preventive maintenance or scheduled
repair of all handling equipment.
17. Obsolescence principle: Replace obsolete handling methods/equipment
when more efficient method/equipment will improve operation.
18. Capacity principle: Use handling equipment to help achieve its full
capacity.
19. Control principle: Use material handling equipment to improve production
control, inventory control and other handling.
20. Performance principle: Determine efficiency of handling performance in
terms of cost per unit handled which is the primary criterion.
1.6 SELECTION OF MATERIAL HANDLING EQUIPMENTS
Selection of Material Handling equipment is an important decision as it affects
both cost and efficiency of handling system. The following factors are to be
taken into account while selecting material handling equipment.
1. PROPERTIES OF THE MATERIAL
2. LAYOUT AND CHARACTERISTICS OF THE BUILDING
3. PRODUCTION FLOW
4. COST CONSIDERATIONS
5. NATURE OF OPERATIONS
6. ENGINEERING FACTORS
7. EQUIPMENT RELIABILITY
1.7 MATERIAL HANDING EQUIPMENTS
Broadly material handling equipment’s can be classified into two categories,
namely:
(a) Fixed path equipments, and
(b) Variable path equipments.
(a) Fixed path equipments which move in a fixed path. Conveyors, monorail
devices, chutes and pulley drive equipments belong to this category.
(b)Variable path equipments have no restrictions in the direction of
movement although their size is a factor to be given due consideration
trucks, forklifts mobile cranes and industrial tractors belong to this category.

Material Handing Equipments may be classified in five major categories.

1. CONVEYORS: Conveyors are useful for moving material between two
fixed workstations, either continuously or intermittently. They are
mainly used for continuous or mass production operations—indeed,

they are suitable for most operations where the flow is more or less
steady. Conveyors may be of various types, with rollers, wheels or belts
to help move the material along: these may be power-driven or may roll
freely.

The decision to provide conveyors must be taken with care, since they are
usually costly to install; moreover, they are less flexible and, where two or
more converge, it is necessary to coordinate the speeds at which the two
conveyors move.
2. INDUSTRIAL TRUCKS: Industrial trucks are more flexible in use than
conveyors since they can move between various points and are not
permanently fixed in one place. They are, therefore, most suitable for
intermittent production and for handling various sizes and shapes of
material. There are many types of truck petrol-driven, electric, hand-
powered, and so on. Their greatest advantage lies in the wide range of
attachments available; these increase the trucks ability to handle
various types and shapes of material.
3. CRANES AND HOISTS: The major advantage of cranes and hoists is
that they can move heavy materials through overhead space. However,
they can usually serve only a limited area. Here again, there are several
types of crane and hoist, and within each type there are various loading
capacities. Cranes and hoists may be used both for intermittent and for
continuous production.
4. CONTAINERS: These are either ‘dead’ containers (e.g. Cartons, barrels,
skids, pallets) which hold the material to be transported but do not
move themselves, or ‘live’ containers (e.g. wagons, wheelbarrows or
computer self-driven containers). Handling equipments of this kind can
both contain and move the material, and is usually operated manually.

5. ROBOTS: Many types of robot exist. They vary in size, and in function
and maneuverability. While many robots are used for handling and
transporting material, others are used to perform operations such as
welding or spray painting. An advantage of robots is that they can
perform in a hostile environment such as unhealthy conditions or carry
on arduous tasks such as the repetitive movement of heavy materials.
 GUIDELINES FOR EFFECTIVE UTILISATION OF MATERIAL
1.8
HANDLING EQUIPMENTS

The following guidelines are invaluable in the design and cost reduction of the
materials handling system:
1. As material handling adds no value but increases the production cycle time,
eliminate handling wherever possible. Ideally there should not be any
handling at all!
2. Sequence the operations in logical manner so that handling is unidirectional
and smooth.
3. Use gravity wherever possible as it results in conservation of power and fuel.
4. Standardise the handling equipments to the extent possible as it means
interchangeable usage, better utilisation of handling equipments, and lesser
spares holding.
5. Install a regular preventive maintenance programme for material handling
equipments so that downtime is minimum.
6. In selection of handling equipments, criteria of versatility and adaptability
must be the governing factor. This will ensure that investments in special
purpose handling equipments are kept at a minimum.
7. Weight of unit load must be maximum so that each ‘handling trip’ is
productive.
8. Work study aspects, such a elimination of unnecessary movements and
combination of processes should be considered while installing a material
handling system.
9. Location of stores should be as close as possible to the plant which uses the
materials. This avoids handling and minimizing investment in material
handling system.
10. A very important aspect in the design of a material handling system is the
safety aspect. The system designed should be simple and safe to operate.
11. Avoid any wasteful movements-method study can be conducted for this
purpose.
12. Ensure proper coordination through judicious selection of equipments and
training of workmen.