TERM PAPER: -MANUFACTURING SCIENCE

TOPIC: - MATERIAL HANDLING TECHNIQUES

SUBMITTED TO: - SUBMITTED BY:

Mr.Kamlesh Kumar Mishra NEERAJ KUMAR SHARMA

CLASS: 1st YEAR (ME) SECTION: K4009

ROLL NO.: B48 REGD NO.-11010909
 ACKNOWLEDGEMENT

We are extremely grateful and remain indebted to our

guide Mr.Kamlesh Kumar Mishra for being a source of
inspiration and for his constant support in the Design,
Implementation and Evaluation of the term paper. We are
thankful to them for their constant constructive criticism and
invaluable suggestions, which benefited us a lot while developing
the term paper on “MATERIAL HANDLING TECHNIQUES”. He
has been a constant source of inspiration and motivation for hard
work. He has been very co-operative throughout this project work.

We also express our

gratitude to Mr.Kamlesh Kumar Mishra for providing us the
infrastructure to carry out the Term paper. This term paper of
“MATERIAL HANDLING TECHNIQUES” gives us the complete
information about it. In the last, we gratefully acknowledge and
express our gratitude to all friends who supported us in preparing
this term paper.
 TABLE OF CONTENTS

1. INTRODUCTION

2. BULK MATERIAL HANDLING

3. IMPORTANCE OF MATERIAL HANDLING

4. SCOPE OF MATERIAL HANDLING

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.

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 themselves. As a consequence,
unfortunately, there is no universally accepted definition of materials handling. One of the
definition 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.

• 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.

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 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.

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 utilizing minimum space.

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

Functioning of materials handling within an industry covers the following: (i) Bulk materials as
well as unit materials handling. 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. Often materials handling extends beyond the boundary of the industry in the form of
movement of raw materials from the sources to the plant or in the form of finished goods from
the plant to the points of consumption. These long distance movements of materials are generally
termed as transportation of materials through various modes of transport like, road, rail, ship or
air. 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.

Some production equipments are fitted with facilities for handling of the materials being
processed. Such materials handling equipment are generally considered to be an integral part of
the production equipment.
A few typical examples are:
(i) the feeding mechanism in an automatic machine,

(ii) coiler and de-coiler in a strip rolling mill or

(iii) paper feeding and transportation arrangement in a multi-station printing machine.

Essentially these are special material handling devices, but when integrated with specific
production machines, they become specialized parts of those machines. Such special devices and
their functions are generally not considered to be within the scope of materials handling.

Material handling is also defined by the Materials Handling Institute as the movement, storage,
control, and protection of materials and products throughout the process of their manufacture,
distribution, consumption, and disposal. The five commonly recognized aspects of material
handling are Parts, materials, and finished products that must be moved from one location to
another should be moved in an efficient manner and at minimum cost, Materials must be where
they are needed at the moment they are needed.Materials must be in the proper location and
positioned for use.The rate of demand varies between the steps of processing operations.
Materials must be continually delivered to, or removed from, operations in the correct weights,
volumes, or number of items required.Storage space, and its efficient utilization, is a key factor
in the overall cost of an operation or process. The science and engineering of material handling is
generally classified into two cate- gories, depending on the form of the material handled.Bulk
solids handling involves the movement and storage of solids that are flowable, such as fine, free-
flowing materials (e.g., wheat flour or sand), pelletized materials (e.g., soybeans or soap flakes),
or lumpy materials (e.g., coal or wood bark).
Manual handling of loads ,manual material handling manutention (in Australia involves the use
of the human body to lift, lower, fill, empty, or carry loads.The load can be animate (a person or
animal) or inanimate (an object). Most manufacturing or distribution systems require some
manual handling tasks. Though decreasing lately, the rate of workers in the EU-25 that report
carrying or moving heavy loads, is still high (34.5 %), reaching 38.0 % in the EU-10When
performed incorrectly or excessively, these tasks may expose workers to physical risk factors,
fatigue, and injury .A variety of MMH techniques and tools exist to alleviate these potential
problems.
Occupational injuries resulting from material handling are among the most frequent and severe
injuries causing lost time from work. The back is the most injured part of the body here at the
University of Florida. Employees have been instructed and whole departments have been trained
on how to prevent back injuries. The number the painful and costly injuries still occur.

BULK MATERIAL HANDLING

The selection of the proper equipment for conveying the handling of bulk solids involves four
main areas:
(1) conveying,
(2) storage
(3) pack- aging, and
(4) transportation.
Bulk solids depends on a number of interrelated factors. First, alternative types of conveyors
must be evaluated and the correct model and size must be chosen. Because standardized
equipment designs and complete engineering data are available for many types of conveyors,
their performance can be accurately predicted when they are used with materials having well-
known conveying characteristics. Some of the primary factors involved in conveyor equipment
selection are as follows:

1.Capacity requirement.

The rate at which material must be transported (e.g., tons per hour). For instance, belt conveyors
can be manufactured in relatively large sizes, operate at high speeds, and deliver large weights
and volumes of material economically. On the other hand, screw conveyors can become very
cumbersome in large sizes, and cannot be operated at
high speeds without severe abrasion problems.

2.Length of travel.

The distance material must be moved from origin to destination. For instance, belt conveyors
can span miles, whereas pneumatic and vibrating conveyors are limited to hundreds of feet.

4.The vertical distance material must be transported.

Vertical bucket elevators are commonly applied in those cases in which the angle of inclination
exceeds 30.

4.Material characteristics.

The chemical and physical properties of the bulk solids to be transported, particularly
flowability.

5.Processing requirements.

The treatment material incurs during transport, such as heating, mixing, and drying.

6.Life expectancy.

The period of performance before equipment must be replaced; typically, the economic life of
the equipment.

7.Comparative costs.

The installed first cost and annual operating costs of competing conveyor systems must be
evaluated in order to select the most cost-effective configuration.
IMPORTANCE OF MATERIAL 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 labour cost.

(iii) Reduce damage of materials during storage and movement.

(iv) Maximise space utilization by proper storage of materials and thereby

reduce storage and handling cost.

(v) Minimise 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 sale ability of plant and equipment with integral
materials handling features.

Apart from these, for certain industries, like process industries, heavy manufacturing industries,
construction industries, mining industries, ship building or aircraft industries etc., the materials are
so large and heavy that these industries just cannot run without appropriate materials handling
system. All the above points clearly show the importance of materials handling in an industry or a
material transportation system. However, the negative aspects of materials handling should also
not be over looked. These are:

(i) Additional capital cost involved in any materials handling system.

(ii) Once a materials handling system get implemented, flexibility for further
changes gets greatly reduced.
(iii) With an integrated materials handling system installed, failure/stoppage in
any portion of it leads to increased downtime of the production system.

(iv) Materials handling system needs maintenance, hence any addition to

materials handling means additional maintenance facilities and costs.

Material handling in addition to handling of materials in an industry is also significant in terms

of costs in overall operations because it is something that is quite common to all manufacturers.
But when once its nature is exposed it may be difficult to overlook it as a major potential of
effecting cost reduction. Materials handling problems assume importance due to a number of
factors.
1. Various studies made in different industries indicate that the cost of handling alone accounts
for about 20-25% of total manufacturing costs. What the cost in any particular industry may be is
largely the result of the methods and equipment used.
2. It is usually found that each part is handled 50-60 times while it passes through the chain of
manufacture. Expressed in tons, it is found that on an average 59 tons of material are handled for
every ton of finished product.
3. Increased safety — Material handling account for 21% of the permanent disabilities and over
25% of the temporary disabilities.
4. Reduce damage claims — Modern handling methods have paid off in the reduction of damage
in parts and materials.
5. Ease drudgery for men — Most of the jobs done by man handling are mere drudgery for men
in the first place. Some of the mechanized handling jobs being done today would be a sheer
physical impossibility for manual labor within the present economic frame work.
6. The field of materials handling remains still to be fully to be fully explored. Material handling
techniques are not only industry’s biggest opportunity — they are industry’s biggest necessity.
Competition is beginning to force this new technology upon industry.

In addition, materials handling refers to the total management of all materials and
processes involved in the entire manufacturing procedure. This includes sourcing, delivery,
movement, protection and storage of product. Significant savings in time, labour and
materials result from effective materials handling achieved through a series of well
coordinated and inter-related procedures. In a manufacturing application materials
handling may involve delivering raw materials – polymers or resins for an injection molder
, for example – or pieces required to complete assembly of a simple product such as
software merchandise requiring a CD, manuals, certificates, sleeves and packaging. In
either case, having a comprehensive and coordinated control system is essential,

This overall management system is achieved through plant-wide integration encompassing

every step in the manufacturing process, where the flow of information is essential for
monitoring, coordinating and tracking each process —from the arrival of raw materials
onto the plant floor through to dispatch of final product awaiting shipment.
SCOPE OF MATERIAL HANDLING

Materials handling is spread over to many different industries and fields of engineering are as:
1 Manufacturing
Manufacturing is the largest single field for applications of material handling where a wide range
of materials handling equipments are used.
Materials handling problems involve surveys, plant and equipment layouts, routing, packaging
and storage of materials.

2 Processing
Processing requires handling of bulk materials (like gases, liquids, semi-liquids and bulk solids).
Special handling problems affect the plant design.
3 Construction
Construction needs proper receiving, sorting, storing and moving materials. In heavy
construction projects, there is now a choice of special methods and equipments of materials
handling. It influences the civil engineers in project planning.
4 Mining
In both underground mines and open pit operations, there is now a variety of equipment for
extraction, handling and transportation of coal and ore. Cost of extracting the materials has been
reduced to the minimum.
5 Power
Materials handling equipment for handling fuel and ash are needed.
6 Machine Tools
The design of many processing machines is influenced by the need for integrating various
material handling features or attachments to modern machine mechanisms.
7 Truck building
The automotive engineer develops trucks and trailer as efficient materials handling vehicles,
designed for speedy loading and unloading, ensure cargo is secured properly, and safe
transportation of a variety of materials.
8 Rail road car builders
The above are involved in improved rail road cars, development of terminal equipment,
improvement in materials handling procedure for loading and securing freight and transferring or
unloading it at terminals.
9 Barge and Ship building
New handling devices and improved kinds of marine carriers are manufactured in this industry.
10 Aircraft
Better cargo and storage methods for air transport where materials handling is concerned.
REFERENCES

1. WWW.EBOOKS.COM

2. BOOKS OF MATERIAL HANDLINGS