Material Handling Systems

Definition

• Defined as the art and science of moving, packing

and storing of substances in any form.
– Creation of time and place utility
– Movement and storage of material at the lowest possible
cost through the use of proper methods and equipments.
– Lifting, shifting and placing of materials which effect a
saving in money, time and place
– Art and science of conveying, elevating, positioning,
transporting, packaging and storing of materials
 Objectives
• Main objective is to reduce the number of
handlings as well as the overall cost of
material handling equipment and reducing
the distances through which the materials
are handled.
 Objectives
• Lower unit material handling costs by ensuring efficient
materials handling.
• Reduction in manufacturing cycle time through faster
movement of materials and by reducing the distance
through which the materials are moved. Reduction in
manufacturing cycle time results in reduced work –in –
progress inventory costs.
• Improved working conditions and greater safety in
movement of materials
 Objectives
• Contribute to better quality by avoiding damage to
products by inefficient handling
• Increased storage capacity through better utilisation of
storage areas
• Higher productivity at lower manufacturing cost
 Role of MHS
• Unloading incoming material from vehicles
• Moving unloaded material to assigned
storage areas in warehouses.
• Lifting the material from storage areas
during order picking
• Moving the material for inspection &
packing
• Loading the order onto the outbound
vehicle.
 Principles of MHS
• 1. Orientation Principle
• Study the system relationships thoroughly prior to
preliminary planning in order to identify existing
methods and problems, physical and economic
constraints, and to establish future requirements
and goals
• 2. Planning Principle
Establish a plan to include basic requirements,
desirable options, and the consideration of
contingencies for all material handling and storage
activities.
 Principles of MHS
• 3. Systems Principle
Integrate those handling and storage activities
which are economically viable into a coordinated
system of operation including receiving,
inspection, storage, production, assembly,
packaging, warehousing, shipping and
transportation.
• 4. Unit Load Principle
Handle product in as large a unit load as
practical.
 Principles of MHS
• 5. Space Utilization Principle
Make effective utilization of all cubic space.
6. Standardization Principle
Standardize handling methods and equipment wherever
possible.
7. Ergonomic Principle
Recognize human capabilities and limitations by designing
material handling equipment and procedures for effective
interaction with the people using the system.
8. Energy Principle
Include energy consumption of the material handling systems
and material handling procedures when making comparisons or
preparing economic justifications.
 Principles of MHS
• 9. Ecology Principle
Minimize adverse effects on the environment when selecting
material handling equipment and procedures.
10. Mechanization Principle
Mechanize the handling process where feasible to increase
efficiency and economy in the handling of materials.
11. Flexibility Principle
Use methods and equipment which can perform a variety of
tasks under a variety of operating conditions.
12. Simplification Principle
Simplify handling by eliminating, reducing, or combining
unnecessary movements and/or equipment.
 Principles of MHS
• 13. Gravity Principle
Utilize gravity to move material wherever possible, while respecting
limitations concerning safety, product damage and loss.
14. Safety Principle
Provide safe material handling equipment and methods which
follow existing safety codes and
regulations in addition to accrued experience.
15. Computerization Principle
Consider computerization in material handling and storage
systems, when circumstances warrant, for improved material and
information control.
16. System Flow Principle
Integrate data flow with the physical material flow in handling and
storage.
 Principles of MHS
• 17. Layout Principle
Prepare an operational sequence and equipment layout for all
viable system solutions, then select the alternative system
which best integrates efficiency and effectiveness.
18. Cost Principle
Compare the economic justification of alternate solutions in
equipment and methods on the basis of economic
effectiveness as measured by expense per unit handled.
19. Maintenance Principle
Prepare a plan for preventive maintenance and scheduled
repairs on all material handling equipment.
20. Obsolescence Principle
Prepare a long range and economically sound policy for
replacement of obsolete equipment and methods with special
consideration to after-tax life cycle costs.
 Classification
Material handling systems classified into two
categories :
a) Manual system
b) Mechanized system
 Manual system

• Cabinets
• Stacking boxes
• Special storage racks
• Gravity feed racks
• Outdoor platform & racks
• Open & closed shelves
• Trays
• Drums
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Manual System

• In manual work transport, the units of the product are passed

from station to station by the workers themselves.
• Continuous manpower are difficult to sustain due to fatigue,
and production rates tend to be lower.
 Mechanised systems
A. Forklift Trucks
• Forklift trucks can move loads of master
cartons both horizontally and vertically.
• A pallet or slip sheet forms a platform
upon which master cartons are stacked.
• A forklift truck normally transports a
maximum of two unit loads i.e. two
pallets at a time
 Mechanised systems
Conveyors
• Conveyors are classified according to
power, gravity or roller/belt movement.
• Portable gravity style roller conveyors are
often used for loading and unloading.
• In some cases these are transported on
the over-the-road trailers to assist in
unloading at the destination.
 Mechanised systems

• Conveyors
– Belt conveyors, Chain conveyors, Roller conveyors,
Pneumatic conveyors, bucket conveyors, screw
conveyors, pipeline conveyors, vibratory conveyors,
chute or gravity conveyors.
– Do not require operators, inexpensive to operate
• Cranes, Elevators and Hoists
– Cranes – overhead rails or ground rails or wheels
– Elevators – between floors – vertically
– Hoists - vertically, horizontally – limited area –
electric or chain hoist
• Industrial trucks
 Cranes and Hoists

Moving large, heavy items in factories, warehouses

Manual hand trucks
 Semi automated Handling
 Semi automated system supplements a mechanized
system by automating a specific handling requirements.
 Semi automated warehouse is a mixture of mechanized
and automated handling.
A. Automated-Guided Vehicle Systems
• Performs similar kind of handling function as a
mechanized tow tractor with a trailer.
• The essential difference is that an AGVS does not
require an operator and is automatically routed and
positioned at destination with intervention of the
operator.
 Rail Guided Vehicles

High cost, moving single assemblies, product or pallets over fixed routes.
 Automated Guided Vehicles
(AGV)

High cost, moving pallet loads and work in-progress in factory

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Conveyers
Powered Roller Conveyor

Moving products in large quantities along the line

 Automated Handling
Automatic Storage and Retrieval System
(ASRS)
• High rise handling systems are fully
automated from receiving to shipping.
• The components of this system are
storage racks, storage and retrieval
equipment and control systems.
• The high rise are the vertical storage racks
up to the height of 120 feet.
 Automated Handling
• The storage and retrieval machine travels back
and forth with the primary objective of moving
products in and out of storage.
Functions of storage & retrieval equipment
(1)To reach the desired position rapidly.
(2)To deposit or retract a load of merchandise.
(3)To ensure merchandise flowing from production
is automatically stacked to create a unit load.
(4)To transport the unit load to the high rise
storage area by power conveyor.