IPX-629 Industrial Engineering (Open Elective)

Rakesh K.Sharma 1
Associate Professor
Department of Industrial and Production Engineering
Dr. B.R. Ambedkar National Institute of Technology Jalandhar
Jalandhar

Note: The images used in this ppt are reproduced from various resources on internet for the sole purpose of teaching to B.Tech. students.
At the end of this lecture, the students will be able
to understand
 why the issue of ‘Material Handling’ so important?
 the principles of material handling.
 the interrelationship between plant layout and
material handling.
 the classification of material handling devices.

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 Material handling includes the movement, protection, storage and control of
materials and products throughout manufacturing, warehousing,
distribution, consumption and disposal.
 As a process, material handling incorporates a wide range of manual, semi-
automated and automated equipment and systems that support logistics and
make the supply chain work. Their application helps with:
 Forecasting
 Resource allocation
 Production planning
 Flow and process management
 Inventory management and control
 Customer delivery
 After-sales support and service

 A company’s material handling system and processes are put in place to

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 When designing a material handling system, it is important to refer to best
practices to ensure that all the equipment and processes—including manual,
semi-automated and automated—in a facility work together as a
unified system.
 By analyzing the goals of the material handling process and aligning them to
the 10 Principles of Material Handling, a properly designed system will
improve customer service, reduce inventory, shorten delivery time, and lower
overall handling costs in manufacturing, distribution and transportation.
 The 10 material handling principles include:
(1) Principle of planning (2) Principle of standardization
(3) Principle of work flow (4) Principle of ergonomics
(5) Principle of unit load (6) Principle of space utilization
(7) Principle of system (8) Principle of environment
(9) Principle of automation (10) Principle of life cycle cost 5
 Define the needs, strategic performance objectives and functional
specification of the proposed system and supporting technologies at the
outset of the design.
 The plan should be developed in a team approach, with input from
consultants, suppliers and end users, as well as from management,
engineering, information systems, finance and operations.

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 All material handling methods, equipment, controls and software should be
standardized and able to perform a range of tasks in a variety of operating
conditions.
 These must be standardized within the limits that achieve global performance
objectives without sacrificing flexibility, modularity and production.

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 Material handling work should be minimized without sacrificing productivity
or the required level of operation.
 It should be simplified by reducing, combining, shortening or eliminating
unnecessary movement that will impede productivity. Examples include
using gravity to assist in material movement, and employing straight-line
movement as much as possible.

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 Work and working conditions should be adapted to support the abilities of a
worker, reduce repetitive and strenuous manual labor, and emphasize safety.
 Human capabilities and limitations must be recognized to ensure safe and
effective operations.

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 Because less effort and work is required to move several individual items
together as a single load (as opposed to moving many items one at a time),
unit loads—such as pallets, containers or totes of items—should be used.
 The unit loads must be of the appropriate size and be configured according to
which they achieve a material flow and the inventory objectives at each stage
of the supply chain.

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 Effective and efficient use of available space must be made.
 To maximize efficient use of space within a facility, it is important to keep
work areas organized and free of clutter, to maximize density in storage areas
(without compromising accessibility and flexibility), and to utilize overhead
space.

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 Material movement and storage activities must be fully integrated to form an
operating system that encompasses reception, inspection, storage,
production, assembly, packaging, unification, order selection, shipping,
transportation, and claims handling.

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 Energy use and potential environmental impact should be considered when
designing the system, with reusability and recycling processes implemented
when possible, as well as safe practices established for handling hazardous
materials.

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 To improve operational efficiency, responsiveness, consistency and
predictability, automated material handling technologies should be deployed
when possible and where they make sense to do so.
 If we pay attention to how the industry has changed in the last 20 years, the
number of people involved in each of the stages of the process is less and less
with new technologies, if it is automated, it gains in reliability, efficiency,
safety , time, standardization and transportation, since there is better
coordination.

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 For all equipment specified for the system, an analysis of life cycle costs
should be conducted. Areas of consideration should include capital
investment, installation, setup, programming, training, system testing,
operation, maintenance and repair, reuse value and ultimate disposal.

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The different types of handling equipment can be classified
into four major categories:
Transport equipment,
Positioning equipment,
Unit load formation equipment, and
Storage equipment.
For details refer:
https://en.wikipedia.org/wiki/Material-handling_equipment
https://www.mhi.org/fundamentals/material-handling
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 There is a close relationship between plant layout and material handling. The
material handling technique to be used definitely effects the plant layout and
the factory building. A sound low cost method can be designed and installed
only if material handling is considered an integral part of plant layout.
 A well considered arrangement of production equipment, the proper location
of different departments, a logical sequence of operation within the
department and convenient location of store areas, tool cribs and similar
activity centres is required for a good material handling arrangement. The
efficient and economical material handling system can be designed and
selected for installations only after the floor plan has been adequately
organized.

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 In all types of plant layout, provisions for the receiving and shipping of
materials by various possible means (like trucks or train etc.) should be
made. If it is required to move the materials by hand operated or power
operated trucks, sufficient passage should be provided.
 If the building is multi storied, lift, elevators and conveyors of different types
must be utilized to enable efficient material handling. The location of items in
the store room should provide for minimum handling of materials to the point
of issue, accessibility and efficient space utilization.

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Material Handling in Product Type of Layout:
 The product type of layout require some direct means of transportation
between various operations, Material handling methods and machines like
the layout itself tend to be special purpose in nature for this type of layout
where the nature of the product allows it, gravity chutes can be effectively
utilized.
 Conveyors to fit all different applications of size, shape and weight of part are
commercially available. These conveyors may fit in product type of layout
well. Many processes such as cleaning, painting drying and weighing as in
case of certain liquid materials may take place while the material moves.
 The special purpose nature of product layout design often makes it worth
while to design special handling equipment which is integrated with
processing so completely that the entire line works as a single integrated
machine. 19
Material Handling in Functional Layout:
 The basic requirement of material handling techniques used in functional
layout is flexibility i.e. flexibility of size, weight and shape of load and
flexibility of path. The types of material handling equipment which suit this
requirement are in general, mobile trucks, tractor, trains, fork, lift, trucks
and cranes etc.
 The important characteristic of an efficient material handling equipment is
the time required to pick up or set down load. Therefore, quick pickup system
have developed around skids and pallets. Material can be directly loaded on a
skid or pallet by the worker as his operation on the part is completed.
Continued on next page…..

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Material Handling in Functional Layout:
 In this way without further handling, a skid truck, fork lift truck or pallet
truck can pick up the entire load very quickly and move it to its goal.
Therefore one important consideration in developing the details of layout is to
allow easy access to all operations to be performed by efficient material
handling equipment. Supplementary cranes are often needed at the work
stations to handle heavy jobs to and from the machines. Overhead cranes are
utilized to transport and position large heavy jobs within a fixed area.
 It is common to find the material handling equipment unutilized in functional
type of layout and at the same time complaints are that material can never be
moved when wanted. Therefore much material handling equipment is
required in this type of layout. This has always been a different question in
functional type of layout in view of the demand for transporting capacity is on
random basis.
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Thanks