MATERIAL HANDLING, STORAGE

FACILITIES & LAYOUT

GROUP 6
Material Handling-Definition
Material handling is the art and science of moving, storing,
protecting, and controlling material
 Right amount
 Right material
 Right condition
 Right place
 Right time
 Right position
 Right sequence
 Right cost
 Right method(s)
Need for Improvement

 Time spend in material handling

 Costly handling and no value addition
 Excessive loading and unloading
 Repeated manual handling
 Long distance material movement
 Congestion and damages
 Ideal scenario is ‘No Handling’
How to Improve?

 Eliminating or reducing handling

 Improving the efficiency of handling
 Making the correct choice of material handling
Elimination & Reduction
 Method study approach
Outline
flow process
flow diagrams

 Questioning
When? Where? How? Who? Why?
Improving Efficiency
 Increase no of units handled

 Increase the speed of handling

 Ensure easy transportation

 Use gravity for advantage

 Ensure straight line movement

Types of Materials

Gases
Liquids
Solids
Gases and Liquids
Pipelines
Solids
 Conveyors
 Industrial Trucks
 Cranes
 Hoists
 Containers
 AGVs
FACTORS CONSIDERED WHEN CHOOSING MATERIAL HANDLING
EQUIPMENT

Material properties
Layout and characteristics of the
building
Production flow
Cost consideration
Pipelines
Conveyors

Gravity or powered devices commonly

used for moving uniform loads
continuously from point to point over
fixed paths, where the primary function
is conveying.
Types:
Belt
Roller
Overhead
Belt Conveyors

An endless fabric, rubber, plastic,

leather or metal belt operating over
suitable drive, tail end, and bend
terminals and over bend idlers or
slider bed for handling material,
packages or objects placed directly
upon the belt
Belt conveyor
Belt conveyor
Belt conveyor in airports
Roller Conveyors

A conveyor which supports the load

on a series of rollers, turning on fixed
bearings and mounted between side
rails at fixed intervals determined by
the size of object to be carried, which
is usually moved manually or by
gravity.
Roller conveyor
Roller conveyor
Overhead Conveyors

An endless chain supported by

trolleys from an overhead track.
At a height of 8-9 ft from floor.
It frees the floor and eliminates
interference with other traffic. Tracks
may dip to lower level for more
convenient access to carts
Overhead Conveyors
Industrial Trucks

Hand or powered vehicles used for

the movement of mixed or uniform
loads intermittently over various paths
having suitable running surfaces and
clearances, where the primary
function is maneuvering.
Industrial Trucks
Forklifts
CRANES

DIFFERENT TYPES:

 OVERHEAD CRANES

 GANTRY CRANES

 JIB CRANES

 LOADER CRANES
OVERHEAD CRANES

 Also known as a “suspended crane”.

 Can lift very heavy, bulky, lengthy loads.
 It consists of a bridge constructed from one or
several girders supporting a mobile hoist.
 The floor area remains completely free for other
activities.
OVERHEAD CRANE
 GANTRY CRANES

 Gantry Cranes provide an economical way to lift

materials anywhere in a facility.

 They are supported on legs with wheels, that run on

rails on the ground.

 Used for very heavy loads (over 20 tones)

 Cheaper but slower than overhead cranes.

GANTRY CRANES
 JIB CRANES

 Pillar and wall-mounted jibs are typically needed to

service specific work areas.

 Jib cranes help to cut setting up and idle times and

reduce unnecessary waiting for an overhead crane.
JIB CRANES

 Wall traveling jibs cranes with under hung or top

running hoist trolleys are also available.

 The main characteristic of all designs is the low jib

deadweight and correspondingly large outreach
and high load capacity.
JIB CRANES
 LOADER CRANES

 Hydraulically-powered articulated arm fitted to a trailer,

used to move goods onto or off of the trailer.

 Unlike most cranes the operator must move around to be

able to view his load; hence he has a portable cabled or

radio linked control system.

LOADER CRANE
HOISTS

 Hand Chain Wheel Driven Trolley

 Wire Hoists

 Chain Hoists
HAND CHAIN WHEEL
DRIVEN TROLLEY

High quality chain hoists

are easy to use, the large
spur gears make raising and
lowering the loads easy.
They are compact and
lightweight, which allows
them to be used be used
anywhere.
 WIRE HOIST

Heavy-duty,
frequent lifting
calls for an electric
hoist. An electric
hoist utilizes the
same components
as a manual hoist
but utilizes a motor
for speed and ease
of operation.
ELECTRIC CHAIN HOIST
AGVs (Automated Guided Vehicles)

 To bring work to operator

 Increases productivity and flexibility
of scheduling
 Advantages over conveyors
 Bigger load sizes than conveyors
 Frequency of service is different
 Changing Path
AGVs (Automated Guided Vehicles)

 Parts of AGVs
 Transmitter – Sends out Signals (Optical
or Audio)
 Receiver – Receives Reflected Signal,
Conditions the Signal, Sends it to the
Logical Unit
 Logical Unit – Heart of the AGV, Decodes
the Received Signal and Acts according
to a Pre-Stored Programme.
AGVs (Automated Guided Vehicles)

 Important Considerations
 Sensitive to extreme temperatures and
fumes
 Floor consideration
AGVs (Automated Guided Vehicles)
AGVs (Automated Guided Vehicles)
AGVs (Automated Guided Vehicles)

 Advantages
 Reduce Manpower
 Increase Productivity
 Efficient long-distance movements
 Reduce Product Damage
 Maintain Better Control of Material
Management
 Creates an ergonomic, safe environment
AGVs (Automated Guided Vehicles)

 Disadvantages
 High Initial Cost
 Maintenance Cost
STORAGE
Why storage is needed?
 Floor space savings
 Increased picking speeds
 Health & safety
 Improved stock accuracy
 Stock security
 Flexibility
 large impact on the company's
bottom line
Types of Storage
 Raw Material Storage
 Work-in-process Storage
 Finished goods storage
 Storage for supplies, packing materials,
maintenance, scrap materials and the like
 Storage for special tools- jigs, fixtures,
inactive equipment
 Office Storage- Active and inactive records
Liquid Storage Raw Material Storage
 Silo Raw Material Storage

Silos are
structures for
storing bulk
materials. it
used in
agriculture to
store grain,
coal, cement,
carbon black.
Coil Storage Raw Material Storage
Shelf
Rack Storage
Vertical carousel
an automated computer
controlled vertical carousel
which can operate both as
a central inventory store or
as an on-line materials
handling system, providing
accurate, real-time data
from the shop floor to high
level planning systems
Vertical carousel
The vertical
carousel
concept makes
maximum use of
ceiling heights.
Horizontal carousel
This storage runs
directly on the floor,
eliminating expensive
support structures
and allowing
headroom to be
used effectively
Movable Rack
Racks mounted
on movable
carriages
Arrangement of Cars in
Volkswagen Golf
Stacking
Stacking
Cold Storage
 Types of boxes to store files

•Group records by series and by

disposition date; clearly labeled
within boxes.
•Boxes should not be overfilled.
•Place archival records in a separate
box from non-archival

Each record has:

• Contains unique numbers
identifying contents (accession
number, location, disposition date,
record status).
Fixed Shelf File:
• Requires no assembly.
• Solid steel reinforced construction
throughout for added unit rigidity.

Storage Cabinets
• Very customisable
• For personal use
Open Shelf Filing System

•Ideal for Open Shelf Filing,

Library Book Stacks, Heavy
Duty Industrial Storage,
•Clean appearance with
remarkable strength.

Lateral Filing systems

•Attached to the wall, saving

valuable floor space
• Allows easier, more efficient
access to your most used
files.
Stocking & Retrieving Files
PLANT LAYOUT
PLANT LAYOUT

 A proper arrangement of machinery, equipment and

materials.

 Initially developed at the start of any office or firm.

 Saves a lot of space and helps in free flow of

operations.
Plant Layout

 Recosideration
 Introduction of new plant
 Redesigning existing facilities
 Inefficient operation
 Product change
 Accidents or safety hazards
 Excessive transfer times and buffers
Major types of layout

 Product layout
 Process layout
 Fixed product layout
 Group layout
Product layout
Also known as line layout or mass production.
The arrangement of machinery and equipment at one
place for production of particular product.
e.g. Bottling plant, car assembly etc.
Advantages Disadvantages
 A high rate of output  Intensive division of labor
usually creates dull,
 Low unit cost due to high repetitive jobs that
provide little opportunity
volume
for advancement & may
lead to stress and morale
 Low material handling down
cost/unit as the units
follow the same sequence
 The system is inflexible to
of operations
changes in volume of o/p
or changes in product or
 High utilization of labor process design
and equipment.
 Preventive maintenance
and quick repairs are
expensive
Process layout
 Layouts that are designed to process items or provide
services that involve the variety of processing
requirements. It features departments or other
functional group in which similar kind of activities are
performed.

e.g. machine shop, textile spinning etc.

Advantages Disadvantages
 System can handle  In process inventory
variety of processing cost is high
requirements
 Material handling is
slow and inefficient
 General purpose
equipments are less  Equipment utilization
costly than the rates are low
specialized equipment
and is easier and less
costly to maintain

 It is possible to use
individual incentive plan
Fixed product layout

Layout in which the product or project remains

stationary and workers materials and equipments
are moved as required
e.g. shipbuilding, aircraft construction etc
Advantages Disadvantages
 Personal and equipment
 Material movement is movement is increased
reduced
 May result in duplicate
equipment
 Provide job enrichment
 Require greater skill for
opportunities
personnel

 Promotes pride and  Require general

quality because an supervision
individual can complete
the whole job  May result in increased
space and greater work in
progress
Group layout

Layout in which workstations are grouped into a cell

that can process items that have similar processing
requirements
e.g. Product with similar design (shape, size, function)
cs
Advantages Disadvantages
 General supervision
 Smoother flow lines and required
shorter travel distances
are expected than for  If flow is not balanced in
process layouts each cell, buffers and work
in progress storage are
 Team atmosphere and job required in the cell to
enlargement benefits eliminate the need for
added material handling to
often results
and from the cell
 Has some of the
 Has some of the benefits disadvantages of the
of the product layouts & product & process layouts;
process layouts; it is a it is the compromise
compromise between the between the two
two  Decreases the opportunity
to use special purpose
tools
 Production volume and product variety
determines type of layout

production product combination process layout

volume layout layout

product variety
THANK
YOU