Unit 6 material handling

INDUSTRIAL ENGINEERING AND MANAGEMENT
Dr. K.G.DURGA PRASAD
(III B.E – II SEMESTER COURSE)
PROFESSOR OF MECHANICAL ENGINEERING

2
UNIT - VI
MATERIALS HANDLING
FLUID MECHANICSINDUSTRIAL ENGINEEERING AND MANAGEMENT

3
Topics to be covered in this Unit:
 PRINCIPLES OF MATERIAL HANDLING
 UNIT LOAD, , PALLETIZATION , CONTAINERIZATION
 SELECTION OF MATERIAL HANDLING EQUIPMENT
 APPLICATIONS OF BELT CONVEYORS, CRANES, FORKLIFT
TRUCKS IN INDUSTRY
MATERIALS HANDLING

INTRODUCTION TO MATERIALS HANDLING
 In early days man was physically handling material
 Over a period of years he started applying mechanical principles
4
Lever Wheel
Pulley

Material handling
- Does not add value to a product
- Adds significant element of cost
- MH costs 20-35% of the cost of the product
 Earlier believed that MH cost is inevitable and can not be avoided.
 Now-a-days a need for reduction in materials handling cost
 Material handling cost includes
- cost of handling
- cost of transportation
- cost of packing
- cost of space
 Not only cost , majority of production time is also consumed in handling materials
before, during and after manufacturing a product.
5
Introduction to Materials Handling

• Material handling problem must be studied at the time of planning
of various machines and tools to be required and before the
erection of factory building
• Material handling is a prime consideration in designing new plants.
• Even for existing plants for its modification MH is considerable
significant factor as the availability of modern MH devices.
• The modern MH devices
- increase output
- improve quality
- quick delivery
- reduces production cost
6

Material handling
 Science and art both involving the moving, packing and storing of
substance in any form, and includes the preparation, placing and
positioning the material to facilitate their movement or storage.
• Material handling occurs whenever a material is moved
• Material handling also occurs during preparation for shipment
Objectives of Material handling system
• Reduced costs
• Increased capacity
• Improved working conditions
• Improved customer service
• Improved productivity
7

(A) Principles related to planning
(B) Principles related to equipment
(C) Principles related to operation
8
PRINCIPLES OF MATERIAL HANDLING

1. Planning principle
All material handling activities should be planned
Implementation activities:
(i) Material should be placed on pallet or any other support and not on the
floor directly.
(ii) One container should be used throughout
and avoid frequent changes.
(iii) Provide sufficient storage space at the work place
(iv) Each operator must be instructed/trained to follow correct method
(v) Plan for scrap removal means
(vi) Efforts be made to combine operations like inspection during productive
operation
(vii) Minimize movement of men and material
9

2. Systems principle
Handling activities be integrated and coordinated.
(i) Consider all the handling activities while giving a
detailed consideration to an activity.
(ii) Material flow between work areas be planned
(iii) Integrated activities into the handling system
10

3. Simplification principle
Reduce , combine or eliminate un necessary movements and/or
equipment
(i) Motion economy principles be applied
(ii) Reduce or eliminate long and complicated movements
(iii) Deliver the material at correct spot in first instance
(iv) Eliminate re-handling
(vi) Reduce variety of equipment
11

4. Material flow principle
Flow pattern must be determined by operation sequence and
pattern of equipment arrangement
12
(i) Avoid overcrowding
(ii) Eliminate obstacles in the flow
(iii) Move in a direct path and avoid back tracking
(iv) Move greatest weight and/or bulk for least distance
(v) Minimize movements between floors and buildings
(vi) Plan proper locations of sub assemblies
(vii) Plan related work areas close together
(viii) Avoid traffic jams and take necessary precautions for cross traffic

13
5. Gravity principle
Utilize gravity wherever possible
Use slides, chutes , hoppers etc. wherever possible

6. Unit size principle
Increase size , quantity , weight of the load handled. Since larger
the load , lesser will be the cost per unit handled
14
(i) Handle unit loads
(ii) Use containers
(iii) Containers should be standardized
(iv) Use standardized pallets
(v) Optimize unit loads

7. Space utilization principle
Optimum utilization of building space. As space means money
15
(i) Equipment or work area may be kept in reasonably close position
(ii) Inventory at temporary stores must not be kept too much
(iii) Utilize height of building and use rack to permit higher stocking
(iv) Use concept of economic order quantities and economic lot sizes
(v) Dispose obsolete or scrap items in intime
(vi) Use handling equipment requiring minimum aisles
(vii) Use mobile or overhead equipment
(viii) Use collapsible containers to save space required by empty ones

8. Safety principle
Safety handling methods and equipment for better working
conditions and to avoid unsafe conditions
16
(i) Provide adequate guards and other safety devices
(ii) Handling equipment be kept in good operating conditions
(iii) Highlight handling hazards , moving vehicles or danger areas
(iv) Keep floor clean
(v) provide good housekeeping
(vi) Do not overload handling equipment or devices

17
(B) Principles related to Equipment
1. Mechanization principle
For increasing efficiency, use mechanical handling equipments
but to the desired extent only
(i) Mechanization is useful for large quantities , long, frequent , high effort or
hazardous moves
(ii) Replace excess manual handling or when large number of persons are
engaged on handling jobs.
(iii) Moving heavy containers
(v) Design containers suitable for mechanical handling
(vi) Use mechanized communication when required

2. Flexibility principle
Equipments should be capable of handling variety of tasks
(i) Buy versatile and flexible equipment
(ii) Buy adjustable racks
(ii) Utilize accessories and attachments
18

3. Equipment selection principle
Equipments should be capable of handling variety of tasks
(i) Select versatile equipment
(ii) Cost per unit to be handled should be compared
(iii) Consider standardization aspects
(iv) Equipment should be economical on long term basis
19

4. Standardization principle
standardize equipment as well as methods
(i) Standardize the equipment , containers and pallets
(ii) Standardize methods
(iii) Train employees on standardized equipment and methods
20

5. Light weight principle
Reduce weight of equipment
(i) Equipment should have less dead weight to pay load ratio
(ii) Use light weight pallets, skids and containers
21

6. Motion principle
The handling equipment should be kept in motion i.e., minimum
period for loading, un loading or other idleness.
(i) Reduce loading / un loading time
(ii) Use mechanical means or other means for quick loading and
un loading
(iii) Use tractor trailers , so that tractor can be used for other
work while the trailer is being loaded/unloaded
(iv) Minimize down time
22

7. Idle time principle
Reduce idle and un productive time
(i) To avoid idle manpower, deliver material at a desired rate
(ii) Do not use productive labour for handling
(iii) In order to utilize manpower fully, more than one machine can
also be allotted to one man
(iv) Equipment should be fully utilized
23

8. Obsolescence principle
Obsolete methods and equipment be replaced by efficient
methods and equipment
(i) Obsolete equipment be identified and replaced by new
equipment
(ii) Beware of new technological developments and remain in
contact touch through books, journals, attending conferences
etc.
24

9. Maintenance principle
Preventive maintenance practices be adopted for handling
equipment
(i) Preventive maintenance be carried out to avoid breakdowns
(ii) Carryout schedule maintenance and daily inspections and
take remedial measures
(iii) Setup regular maintenance schedule
(iv) Train operators for proper operation and maintenance
(v) Maintain adequate spare suppliers
25

10. Control principle
Control production and inventory through materials handling
equipment
(i) Provide direct mechanical paths for materials movement
(ii) Materials be moved in lots , batches , containers of a
predetermine quantity or size
(iii) Material handling system should have built in features of
controlling production , inventory and accounting
(iv) Material be moved as per schedule
26

1. Capacity principle
Production capacity should be fully achieved
(i) Ensure uniform desired rate of flow
(ii) Equipment be operated at optimum rate
(iii) Plan to utilize forward as well as return runs of the equipment
(iv) Vehicles, conveyors, containers etc should be loaded to full
capacity
(v) Utilize overhead space
(vi) Aisles should be obstacle free and wide enough for speedy
movement
(vii) Store items not affected by weather
27
(C) Principles related to Operation

2. Performance principle
Performance of handling be measured in terms of cost per unit
handled , safe working condition, safe working conditions,
increase in production rate or reduced manpower for handling
This is the effect of all preceding activities
28
(C) Principles related to Operation

Principle of unit load : This principle states that “ it is quicker
and economical to move a lot of items at a time rather to move
each one of them individually”.
 The larger the load handled, the lower the cost per unit handled
 Unit load principle implies that materials should be handled in
most efficient , maximum size unit , mechanical means to
reduce the number of moves needed for a given amount of
material
 A number of items or bulk material, so arranged or restrained
that the mass can be picked up and moved as a single object
too large for manual handling and which upon being released
will retain its initial arrangement for subsequent movement
29
CONCEPT OF UNIT LOAD

Characteristics of unit load :
 There should be minimum number of handlings
 Manual handling should be eliminated
 Materials are assembled into a unit load for economy of
handling and storage
 Redesign packages , containers etc. for better assembly into
unit loads and retain them to prevent product damage
 Unit load should be as large as possible within the constraints
of building, equipment etc.
30

Advantages of unit load concept :
 Possible to handle large loads
 Reduce handling cost of one unit
 Reduce packaging costs
 Maximum space utilization
 Faster movement of materials
 Reduces loading and unloading time
 Reduces pilferage / damage during transit or storage
 safer handling ; Reduces cost of transportation
31

 Material and its characteristics
 Quantity to be handled and
duration
 Starting point and destination
 Loading and unloading techniques
 Objective of space utilization
 Environment, storage requirements
 Limitation of aisles, doors loading
and unloading time
 Reduces pilferage / damage during
transit or storage
 safer handling ; Reduces cost of
transportation
32
DESIGNING THE UNIT LOAD SYSTEM (ULS)
Factors considered for designing ULS

33
 Palletization
Palletization is the process of using pallets to store unit loads
and stock them neatly thereby reducing storage space
requirement.
CONCEPT OF PALLETIZATION

34
 Pallets
Pallet is a horizontal portable platform device used as a base for
handling materials in unit load.
Pallets may be flat pallets, box pallets and post pallets
CONCEPT OF PALLETIZATION

35
 Containerization
Containerization uses the principle of unit load.
In this system , big metal containers have number of small
products filled in them. These containers are placed on the
truck or in the trailers which are pulled by trucks or tractors.
Afterwards, the containers can be loaded on railway trailers
and can be taken to place from where with the help of
cranes, they can be shipped.
CONCEPT OF CONTAINERIZATION

36
Factors to be considered while selecting material handling equipment
1. Nature of material to be handled
2. Plant / buildings
3. Plant layout
4. Speed requirement
5. Material flow type
6. Types of production
7. Distance to be travelled
8. Safety
9. Cost
10. Human factor
11. Equipment reliability
SELECTION OF MATERIAL HANDLING EQUIPMENT

37
1. Conveying equipment
2. Hoisting equipment
3. Transport equipment
4. Bulk handling equipment
5. Ware-housing equipment
TYPES OF MATERIAL HANDLING EQUIPMENT

38
Conveying equipment is a group of machines which moves loads
in a continuous flow
CONVEYING EQUIPMENT
(A)Traction type Conveyors
1. Belt Conveyors
2. Roller Conveyors
3. Chain Conveyors
4. Bucket elevators
5. Cage elevators
(B) Tractionless type Conveyors
1. Gravity type Conveyors
2. Chutes
3. Screw/spiral Conveyors
4. Pneumatic conveyors
5. Vibrating and Oscillating
conveyors

39
Flat Belt Conveyor Magnetic Belt Conveyor Troughed Belt Conveyor
Vibrating Belt Conveyor
Belt Conveyors
Traction type Conveyors

40
Gravity Roller Conveyor
Roller Conveyors
Powered Roller Conveyor

41
Chain Conveyors

42
Bucket Elevators

43
Cage Elevators

44
Gravity type conveyors
Traction less type Conveyors

45
Chutes

46
Screw conveyors

47
Pneumatic conveyors

48
Vibrating and Oscillating conveyors

Unit 6 material handling

More Related Content

What's hot (20)

Similar to Unit 6 material handling (20)

Recently uploaded (20)

Unit 6 material handling