EMM 507: Chp: Material Handling

4.0 MATERIAL HANDLING.

4.1 Introduction.

Materials handling can be defined as the function dealing with the preparation, placing and
positioning of materials to facilitate their movement and storage during different stages of
manufacturing.

Haynes defines, "Material handling embraces basic operations in connection with the movement
of bulk, packaged and individual products in a semi-solid or solid state by means of gravity
manually or power actuated equipment and within the limits of individual producing,
fabricating, processing or service establishment".

Material handling does not add any value to the product but adds to the cost of the product and
hence it will cost the customer more. Hence the handling should be kept to minimum.

It should be noted that poor material handling may result in delays leading to idling of
equipment.

The concept of material handling includes every consideration of the product except the actual
processing operation. In many cases, the handling is also included as an integral part of the
process.

Through scientific material handling considerable reduction in the cost as well as in the
production cycle time can be achieved.

4.2 Objectives of Material Handling.

Following are the objectives of material handling;

1. Minimise the cost of material handling.

2. Minimise delays and interruptions by making available the materials at the pint of use at
right quantity and right time,
3. Increase the productive capacity of the production facilities by effective utilization of
capacity and enhancing productivity.
4. Safety in material handling through improvement in working condition.
5. Maximum utilization of material handling equipment.
6. Prevention of damages to materials
7. Lower investment in process inventory.

4.3 Principles of Material handling.

1. Planning principle: All handling activities should be planned.

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EMM 507: Chp: Material Handling

2. Systems principle: Plan a system integrating as many handling activities as possible and
coordinating the full scope of operations (receiving, storage, production, inspection,
packaging, warehousing, supply and transportation).
3. Space utilization: make optimum use of cubic space.
4. Unit load: Increase quantity, size, weight of load handled.
5. Gravity principle: Utilize gravity to move a material wherever applicable.
6. Material flow principle: Plan an operation sequence and equipment arrangement to
optimize material flow.
7. Simplification principle: Reduce, combine or eliminate unnecessary movement and/
equipment.
8. Safety principle: Provide for safe handling methods and equipment.
9. Mechanization principle: Use mechanized or automated material handling equipment.
10. Standardization principle: Standardize methods, types, size of material handling
equipment.
11. Flexibility principle: Use methods and equipment that can perform a variety of task and
applications.
12. Equipment selection principle: Consider all aspect of material, movement and method
to be utilized.
13. Motion principle: Equipment designed to transport material should be kept in motion.
14. Idle time principle: Reduce idle time or unproductive time for both material handling
equipment and manpower.
15. Maintenance principle: Plan for preventive maintenance or scheduled repair of all
handling equipment.
16. Performance principle: Determine efficiency of handling performance in terms of cost
per unit handled which the primary criterion.
17. Control principle: Use material handling equipment to improve production control,
inventory control and other handling.
18. Capacity principle: Use handling equipment to help achieve its full capacity.
19. Obsolescence principle: Replace obsolete handling methods/equipment when more
efficient method/equipment would improve operation.

4.4 Selection of Material Handling Equipments.

The following factors are to be taken into account while selecting material handling equipment.

1. Properties of the material: Depending on material state whether solid, liquid or gas and
in what shape , size and weight it is to be moved are vital considerations and can already
lead to preliminary selection/elimination of the available equipments. Alternatively, if
material is fragile, corrosive or toxic implies that certain handling methods and containers
would be preferable.

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EMM 507: Chp: Material Handling

2. Layout and characteristics of the building. This determines space availability for
handling. Low level ceiling may limit the use of hoists, cranes and the presence of
supporting columns in awkward places can hinder the size of the material handling
equipment. If the building is multi-storeyed, chutes, ramps for industrial trucks may be
used.
The type of layout will indicate the type of production operation (continuous,
intermittent, fixed position or group) and can indicate some items of the equipment that
will be suitable than others.
Floor capacity also helps in selecting the best material handling equipment.

3. Production flow. If the flow is fairly constant between two fixed positions that are not
likely to change, fixed equipment such as conveyors or chutes can be successfully used.
If on the other hand, the flow is not constant and direction changes occasionally from one
point to another because several products are being produced simultaneously, moving
equipments such as trucks would be preferable.

4. Cost considerations: Several cost elements need to be put into consideration when
comparisons are made between various items of the equipment that are all capable of
handling the same load.
Initial investment, operating and maintenance costs are the major costs to be considered.
By calculating and comparing the total cost for each of the items of the equipment under
consideration, a more rational decision can be reached on the most appropriate choice.
Cost is the most significant consideration.

5. Nature of operations: This involves whether handling is temporary or permanent.,

whether the flow is continuous or intermittent and material flow pattern is vertical or
horizontal.
6. Engineering factors: These include factors like door and floor space, ceiling dimensions,
floor conditions and structural strength.
7. Equipment reliability:

4.5 MATERIAL HANDLING EQUIPMENTS.

Material handling equipments can be classified into two categories namely;

i Fixed path equipments and

ii Variable path equipments.

Fixed path equipments move in a fixed path. They include conveyors, monorail devices, chutes
and pulley drives. A slight variation in this category provided by the overhead crane, which
though restricted can move materials in any manner within a restricted area by virtue of its

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EMM 507: Chp: Material Handling

design. Overhead cranes have a very good range in terms of hauling tonnage and are used for
handling bulky raw materials, stacking and at times palletizing.

Variable path equipments have no restrictions in the direction of movement although their size is
a factor to be given due consideration. Trucks, forklifts, mobile cranes and industrial tractors
belong to this category.

4.5.1 Material handling categories.

1. Conveyors: These are useful for moving material between two fixed work stations either
continuously or intermittently. They are mainly used for continuous or mass production
operations. They are suitable for most operations where the flow is more or less steady.

Conveyors may be of various types; roller, wheel or belt conveyors which may be power driven
or may roll freely and help to move materials along.

They are costly to install hence the decision to provide them ought to be taken with care. Also
they are less flexible hence where two or more converge, it is necessary to coordinate the speeds
at which the two move.

2. Industrial Trucks: Are more flexible in use than conveyors since they can move between
various points and are not permanently fixed in one place. Hence are most suitable for
intermittent production and for handling various sizes and shapes of material. They include;
petrol driven, electric, hand-powered etc.

They have the advantage in the wide range of attachments available which increase their ability
to handle various types and shapes of material.

3. Cranes and Hoists: These have the advantage of moving heavy materials through overhead
space. However, they can usually serve only a limited area. The types include loading capacities.
They can be used for both intermittent and for continuous production.

4. Containers: Handling equipments of this type can both contain and move the material, and
are usually operated manually. They are either 'dead' containers (e.g. cartons, barrels, skids,
pallets) which hold the material to be transported but do not move themselves or 'live' containers
e.g. wheelbarrows, wagons or computer self driven containers.

5. Robots: They exist in many types, vary in size, function and maneuverability. They are used
for handling and transporting materials. Others are used to perform operations such as welding or
spray painting.

They have the advantage of performing in a hostile environment such as unhealthy conditions or
carry an arduous/difficult tasks such as the repetitive movement of heavy materials.

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EMM 507: Chp: Material Handling

It should be noted that in several cases the same material may be handled by various types of
equipments. However, the great diversity of equipment and attachments available does not make
the problem any easier. The nature of material to be handled narrows the choice.

4.6 RELATIONSHIP BETWEEN PLANT LAYOUT AND MATERIAL HANDLING.

A good layout ensures minimum material handling and eliminates re-handling in the following
ways;
i Material movement does not add any value to the product hence material handling should
be kept to minimum though not avoid it. This is possible only through the systematic
plant layout. Thus a good layout minimizes handling.
ii The productive time of workers will go without production if they are required to travel
long distance to get the material tools etc. Thus a good layout ensures minimum travel for
workman thus enhancing the production time and eliminating hunting and traveling time.
iii Space is a vital criterion. Plant layout integrates all the movement of laborers, material
through a well designed layout with material handling system.
iv Good plant layout helps in building efficient material handling system. It helps to keep
material handling shorter, faster and economical. A good layout reduces material
backtracking, unnecessary labour movement ensuring effectiveness in manufacturing.

Thus a good layout ensures minimum material handling always.