[PLANT LAYOUT &MATERIAL HANDLING IV YEAR II SEM]

PLANT LAYOUT & MATERIAL HANDLING

UNIT III

INTRODUCTION TO MATERIAL HANDLING SYSTEM

Haynes defines “Material handling covers the basic operations in connection

with the movement of bulk, packaged and individual products in a semi-solid or
solid state by means of gravity manually or power-actuated equipment and within
the limits of individual producing, fabricating, processing or service establishment”.
Material handling does not add any value to the product but adds to the cost of the
product and hence it will cost the customer more. So the handling should be kept at
minimum. Material handling in Indian industries accounts for nearly 40% of the cost
of production. Out of the total time spent for manufacturing a product, 20% of the
time is utilized for actual processing on them while the remaining 80% of the time
is spent in moving from one place to another, waiting for the processing.

Materials handling can be also defined as ‘the function dealing with the preparation,
placing and positioning of materials to facilitate their movement or storage. Material
handling is the art and science involving the movement, handling and storage of
materials during different stages of manufacturing. Thus the function includes
every consideration of the product except the actual processing operation. Expressed
in simple language, 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

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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. Depending on the weight, volume and
throughput of materials, mechanical handling of materials may become unavoidable.
In many cases, mechanical handling reduces the cost of manual handling of
materials, where such material handling is highly desirable. All these facts indicate
that the type and extent of use of materials handling should be carefully designed to
suit the application and which becomes cost effective. Based on the need to be of
optimum design and application specific to different type of industries, materials
handling can be as diverse as industries them self. As a consequence, unfortunately,
there is no universally accepted definition of materials handling. One of the
definitions 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.

Material 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.

There are other definitions also, but above few jointly bring out the salient
features of materials handling. It is referred to as an art and science because to most

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of the materials handling problem no unique solution exists and more than one
solution may be prescribed. Lot of subjective considerations of the materials
handling engineer go into it. At the same time many scientific factors are also
considered to arrive at the solution. In one of the definitions, all the functions of
materials handling have been referred to which are conveying, elevating, positioning,
transporting, packaging and storing. 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.

Objectives of Material Handling

1. Minimize cost of material handling.

2. Minimize delays and interruptions by making available the materials atthe
point of use at right quantity and at right time.
3. Increase the productive capacity of the production facilities byeffective
utilization of capacity and enhancing productivity.
4. Safety in material handling through improvement in working condition.
5. Maximum utilization of material handling equipment.
6. Prevention of damages to materials.
7. Lower investment in process inventory.

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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 coordinating the full scope of operations (receiving, storage,
production, inspection, packing, warehousing, supply and transportation).
3. Space utilization principle: Make optimum use of cubic space.
4. Unit load principle: Increase quantity, size, weight of load handled.
5. Gravity principle: Utilize gravity to move a material wherever practicable.
6. Material flow principle: Plan an operation sequence and equipment arrangement
to optimize 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. Mechanization principle: Use mechanical or automated material handling
Equipment.
10. Standardization principle: Standardize 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 utilized.
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.

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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.

Material Handing Equipments

Broadly material handling equipment’s can be classified into two categories,

namely:
a) Fixed path equipments,
b) Variable path equipments.

Fixed path equipments: which move in a fixed path. Conveyors, monorail devices,
chutes and pulley drive equipments belong to this category. A slight variation in this
category is provided by the overhead crane, which though restricted, can move
materials in any manner within a restricted area by virtue of its design. Overhead
cranes have a very good range in terms of hauling tonnage and are used for
handling bulky raw materials, stacking and at times palletizing.

Variable path equipments: Which 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. Forklifts are

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available in many ranges, they are maneuverable and various attachments are
provided to increase their versatility.

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 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 varioussizes 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

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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 liver 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.
The choice of material-handling equipment among the various possibilities
that exist is not easy. In several cases the same material may be handled by various
types of equipments, and the great diversity of equipment and attachments available
does not make the problem any easier. In several cases, however, the nature of the
material to be handled narrows the choice.

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 [PLANT LAYOUT &MATERIAL HANDLING IV YEAR II SEM]

Some of the materials handling equipment are shown in Below

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Relationship between Plant Layout and Material Handling

The production efficiency of a manufacturing unit depends on how well various

machines, flow paths, storage facilities, and employee amenities are located in the
plant. A systematically designed plant can ensure the smooth and rapid movement
of material, from the raw material stage to the end product stage Plant layout
encompasses new layout as well as improvement in the existing layout.

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In modern manufacturing facilities, efficient layout is complemented by

world class material handling equipment to drive the overall efficiency. Some of the
issues that warrant careful layout planning and utilizing material handling
equipments are improper material flow paths resulting in production idle time,
production bottlenecks due to improper facility layout and planning, increased
material handling costs due to increased number of "touches" across different
operations, inability to scale up operations due to poorly designed infrastructure and
material flow patterns, and reduced employee morale due to non availability of
adequate amenities across the facility.
There is a close relationship between plant layout and material handling. A
good layout ensures minimum material handling and eliminates re handling in the
following ways:
1. Material movement does not add any value to the product so, the material
handling should be kept at minimum though not avoid it. This is possible only
through the systematic plant layout. Thus a good layout minimizes handling.
2. The productive time of workers will go without production if they are required
to travel long distance to get the material tools, etc. Thus a good layout ensures
minimum travel for workman thus enhancing the production time and eliminating
the hunting time and travelling time.
3. Space is an important criterion. Plant layout integrates all the movements of men,
material through a well designed layout with material handling system.
4. Good plant layout helps in building efficient material handling system. It helps to
keep material handling shorter, faster and economical.
A good layout reduces the material backtracking, unnecessary workmen
movement ensuring effectiveness in manufacturing. Thus a good layout always
ensures minimum material handling

The essential requirements of a good materials handling system may be

summarized as:

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(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 utilizing minimum space.

(v) Lowest cost solution to the materials handling activities.

Overview of Material Handling

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.”

1 It can be used to create “time and place utility” thro ugh 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.

2 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, 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

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Principles of Material Handling

Although there are no definite “rules” that can be followed when designing an
effective MHS, the following “Ten Principles of Material Handling,”3 as compiled
by the College-Industry Council on Material Handling Education (CIC-MHE) in
cooperation with the Material Handling Institute (MHI), represent the distillation of
many years of accumulated experience and knowledge of many practitioners and
students of material handling:

1. Planning Principle. All MH should be the result of a deliberate plan where the
needs, performance objectives, and functional specification of the proposed methods
are completely defined at the outset.

2. Standardization Principle. MH methods, equipment, controls and software

should be standardized within the limits of achieving overall performance objectives
and without sacrificing needed flexibility, modularity, and throughput.

3. Work Principle. MH work (defined as material flow multiplied by the distance

moved) should be minimized without sacrificing productivity or the level of service
required of the operation.

4. Ergonomic Principle. Human capabilities and limitations must be recognized

and respected in the design of MH tasks and equipment to ensure safe and effective
operations.

5. Unit Load Principle. Unit loads shall be appropriately sized and configured in a
way that achieves the material flow and inventory objectives at each stage in the
supply chain.

6. Space Utilization Principle. Effective and efficient use must be made of all
available (cubic) space.

7. System Principle. Material movement and storage activities should be fully

integrated to form a coordinated, operational system which spans receiving,

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inspection, storage, production, assembly, packaging, unitizing, order selection,

shipping, and transportation, and the handling of returns.

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, and to eliminate repetitive or potentially unsafe manual labour.

9. Environmental Principle. Environmental impact and energy consumption

should be considered as criteria when designing or selecting alternative
equipment and MHS.

10. Life Cycle Cost Principle. A thorough economic analysis should account for
the entire life cycle of all MHE and resulting systems.

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