Introduction

Definition: 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 2025 of total manufacturing labor cost in the United States
[The Material Handling Industry of America (MHIA)]

Material handling is the art and science

Moving Storing Protecting Controlling material

Chapter 5
Material Handling

Material handling provides:

Right amount Right material Right condition Right sequence Right orientation Right place Right time Right cost Right method

Izman@fkm.utm.my/2008

Introduction
Scope of material handling: 3 views on the scopes of material handling identities by Apple:
Conventional limits movement of materials from 1 location to another within the facility Contemporary expands overall movement of materials in a factory or warehouse to be as integrated MH plan Progressive total system view covers from all suppliers, handling within facility up to customers
Izman@fkm.utm.my/2008

Introduction
Material handling adds COST, but not VALUE
as much as 60% of total production cost 20%-30% of direct labor costs 50%-70% of indirect labor costs

Objective: Optimize amount of material handling and use of space Improve material flows Reduce damages/defects due to material handling Promote safety and improve working conditions Reduce unit cost of production
Izman@fkm.utm.my/2008

Whats the best way to handle materials? DONT!! Ultimate goal:

MINIMIZE COSTS OF MATERIAL HANDLING

Material Handling Principles

Principles used as a guide to design material handling system as no mathematical model can provide extensive solution Originally has 20 principles but have been reduced to 10 as follows:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Material Handling Principles

System principle Automation principle Environmental principle Life cycle cost principle

Material handling checklists

Used to find opportunities for improving existing MH system and designing new system as well Table 5.1 shows examples of conditions checklist for improvement activities

Planning principle Standardization principle Work principle Ergonomic principle Unit load principle Space utilization principle
Izman@fkm.utm.my/2008

Izman@fkm.utm.my/2008

How to design MH systems?

Six-step engineering design process applied in the context of MH:
1. 2.

Material handling system equation

Yes WHY ? WHAT WHERE + WHEN HOW + WHO = recommended system

Nadlers approach can be used to develop alternatives in MH system designs:

1.

3.

4. 5. 6.

Define the obj & scope Analyze the requirements for moving, storing, protecting & controlling material Generate alternative designs for meeting MH requirements Evaluate alternative MH system designs Select the preferred design Implement the preferred design

Aim for the theoretical ideal system (0 cost, no hazards, no wasted space etc) 2. Conceptualize the ultimate ideal system (achievable in the future) 3. Design the technologically workable ideal system (based on available tech but high cost prevents install now) 4. Install the recommended system (cost effective, will work without obstacle & successful)

No

MATL

MOVE

METHOD

Used to analyze flow within and between:

B Q etc. A D

Receiving Storage Production Warehousing

P C

Shipping

Ty pe, Qty, Characteristics

Sink, Source Flow; Direction Flow, Volume Ty pe of Move, etc.

Unit Manpower Equipment

Izman@fkm.utm.my/2008

Izman@fkm.utm.my/2008

Material handling questions 5W1H

Need to repeatedly ask WHY it is necessary or not to have MH What?
What are the types of material to be moved?

Material Handling Equipments

Classify into the following categories:
1.

How?
How is the material moved or stored? Any alternative ways?

I.

Container & unitizing equipment

a)

Containers and unitizing equipments

Containers
i. ii.

Pallets Skids & skid boxes Stretchwrap Palletizers

Who?
Who should be handling material? Skill? Who should be trained?
2.

containers Unitizers

b) Unitizers
a) b)

Where?
Where is the material coming from? Delivered from?

Material transport equipment

Which?
Which material handling operations are necessary? Type of material handling equipment is cost effective?

Conveyors Industrial vehicles Monorails, hoists & cranes

II.

Material transport equipment

a)

Conveyors
Chute conveyor Belt conveyor iii. Roller conveyor
i. ii. iv. v.

When?
When is material needed? Should be moved?

3. 4.

Storage & Retrieval equipment Automatic data collection & communication equipment
Izman@fkm.utm.my/2008

Wheel conveyor Slat conveyor

Izman@fkm.utm.my/2008

Material Handling Equipments

v i. v ii. v iii. ix. x. xi.

Unit load
What is unit load? A single item, a number of items or bulk material which is arranged and restrained so that the load can be stored and picked up and move between two locations as a single mass Movement by manual or mechanized Rule of unit load size Time for handling unit load size must be shorter than the unit processing time
Izman@fkm.utm.my/2008

Chain conveyor Tow line conveyor Trolley conveyor Power and free conveyor Cart-on-track conveyor Sorting conveyor

III.

Storage & retrieval equipment Automatic identification and communication equipment

Bar coding character recognition c) Radio frequency tag d) Magnetic stripe e) Machine vision
a) b) Optical

IV.

b)

Industrial vehicles
i. ii. iii.

Walking Riding Automated

c)

Monorails, hoists & cranes

Izman@fkm.utm.my/2008

Unit load returnable containers

Containers with good stacking and nesting features provide significant reduction in material handling costs Nestability means that the shape of containers permits an empty container to be inserted into another empty container

Unit load efficiency of returnable containers

Given the following dimensions of a particular type of plastic reusable containers: Inside dimension: 18x11x11 Outside dimension: 20x12x12 Each nested container: 20x12x12 Trailer inside dimension: 240x120x120 Determine: 1. Container space utilization 2. Storage space efficiency Assume storage opening size 24x16x14 Container nesting ratio Trailer space utilization if all containers are stacked vertically in only one orientation Trailer return ratio Solution 1. CPU = container internal cube size/external cube size
= (18x11x11)/20x12x12 = 76%

2.

SPE = container internal cube size/storage opening

Izman@fkm.utm.my/2008

Izman@fkm.utm.my/2008

Unit load efficiency of returnable containers

= (18x11x11)/24x16x14 = 45% 3. CNR = overall container height/ nested height
= 12/2 = 6, ie. The ratio is 6:1 TSU = (container internal cube size)*(total no of container)/ trailer inside dimensions
= (18x11x11)*1200/(240x120x 120) = 76%

4. Trailer Space Utilization Length: 240/20 = 12 containers Width: 120/12 = 10 containers Vertical: 120/12 = 10 containers Total no of container = 12x10x10 = 1200

5. Trailer return ratio One stack empty container = 1 + (trailer height container height) = 1 + (120 12) = 55 Total no of empty container per trailer = 55x(240/20)x(120/12) = 6600 TRR = empty container/loaded container per trailer
= 6600/200

Izman@fkm.utm.my/2008

Izman@fkm.utm.my/2008