ASSIGNMENT MATERIAL HANDLING
HIMANSHU SONI 11113030 IPE
MATERIAL HANDLING-
Material Handling is the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal. The focus is on the methods, mechanical equipment, systems and related controls used to achieve these functions. The material handling industry manufactures and distributes the equipment and services required to implement material handling systems. Material handling systems range from simple pallet rack and shelving projects, to complex conveyor belt and Automated Storage and Retrieval Systems (AS/RS). Material handling can also consist of sorting and picking, as well as automatic guided vehicles.
Material handling is the function of moving the right material to the right place in the right time, in the right amount, in sequence, and in the right condition to minimize production cost.
A material-handling system can be simply defined as an in tegrated system involving
ASSIGNMENT MATERIAL HANDLING
HIMANSHU SONI 11113030 IPE
has very broad meaning, covering all kinds of raw materials, work in process, subassemblies, and finished assemblies.
Objectives
1) Reduced Costs 2) Increased Capacity 3) Improved Working Condition 4) Value Addition to Products In brief, the primary objectives of Material Handling are; 1. To save money 2. To save time 3. To save men 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. The primary objective of using a material handling system is to ensure that the material in the right amount is safely delivered to the desired destination at the right time and at minimum cost.
ASSIGNMENT MATERIAL HANDLING
HIMANSHU SONI 11113030 IPE
OTHER OBJECTIVES The material handling system is properly designed not only to ensure the minimum cost and compatibility with other manufacturing equipment but also to meet safety concerns. The cost of MH estimates 20-25 of total manufacturing labor cost.
Lower unit material handling costs
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
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
ASSIGNMENT MATERIAL HANDLING
HIMANSHU SONI 11113030 IPE
The primary goal is to reduce unit costs of production
Maintain or improve product quality, reduce damage of materials
Promote safety and improve working conditions
Promote increased use of facilities
Reduce tare weight (dead weight)
Control inventory
Promote productivity
material should flow in a straight line
use gravity! It is free power
move more material at one time
mechanize material handling
automate material handling
ASSIGNMENT MATERIAL HANDLING
HIMANSHU SONI 11113030 IPE
Material handling equipment includes: Transport Equipment :
industrial trucks, Automated Guided vehicles
(AGVs), monorails, conveyors, cranes and hoists. Storage Systems:
bulk storage, rack systems, shelving and bins,
drawer storage, automated storage systems. Unitizing Equipment : palletizers
Identification and Tracking systems
o
Manufacturing
o
Processing
o
Construction
o
Mining
o
Power
o
Machine Tools
o
Truck building
ASSIGNMENT MATERIAL HANDLING
HIMANSHU SONI 11113030 IPE
o
Rail road car builders
o
Barge and Ship building
o
Aircraft
Efficient material handling is important to manufacturing operations. Materials sent by vendors must be unloaded, moved through inspections and production operations to stores and finally to the shipping department.
These movements do not add value to the product but they do add value to the cost Material handling is an integral part of any industrial activity. With growing business, a greater emphasis is laid on productivity, profitability as well as resource conservation and ecological preservation. Material handling plays a very crucial role in sustaining efficiency in financial and human resources. Material handling analysis is a subset of plant layout. Method study, plant layout and material handling are all part of the design of a production facility.
ASSIGNMENT MATERIAL HANDLING •
HIMANSHU SONI 11113030 IPE
Material handling system and plant layout enhance effectiveness of each other.
•
Efficient operation of appropriate material handling methods reduces costs and enables maximum capabilities to be derived from a given production facility
CONSIDERATIONS IN MATERIAL HANDLING SYSTEM DESIGN
CATEGORY
MEASURES
Physical state
Solid, liquid, or gas
Size
Volume; length, width, height
Weight
Weight per piece, weight per unit volume
Shape
Long and flat, round, square, etc.
Condition
Hot, cold, wet, etc.
Safety risk and risk of damage
Explosive, flammable, toxic; fragile, etc.
ASSIGNMENT MATERIAL HANDLING
HIMANSHU SONI 11113030 IPE
Layout Type
Characteristics
Fixed – position
Large
Typical MH Equipment
product
size,
low
production rate
Process
Variation
Product
in
Cranes, hoists, industrial t Hand trucks, forklift tr
product
and
processing, low and medium production rates Limited product variety, high
AGVs Conveyors for product trucks to deliver compon to stations.
production rate
THE PLANNING PRINCIPLE
Large-scale material handling projects usually require a team approach.
Material handling planning considers every move, every storage need, and any delay in order to minimize production costs.
ASSIGNMENT MATERIAL HANDLING
HIMANSHU SONI 11113030 IPE
The plan should reflect the strategic objectives of the organization as well as the more immediate needs.
THE SYSTEM PRINCIPLES
MH and storage activities should be fully integrated to form a coordinated, operational system that spans receiving, inspection, storage, production, assembly…, shipping, and the handling of retur ns.
Information flow and physical material flow should be integrated and treated as concurrent activities.
Methods should be provided for easily identifying materials and products, for determining their location and status within facilities and within the supply chain.
SIMPLIFICATION PRINCIPLE
Simplify handling by reducing, eliminating, or combining unnecessary movement and/or equipment.
Four questions to ask to simplify any job:
Can this job be eliminated?
ASSIGNMENT MATERIAL HANDLING
HIMANSHU SONI 11113030 IPE
If we can’t eliminate, can we combine movements
to reduce
cost? (unit load concept) If we can’t eliminate or combine, can we rearrange the
operations to reduce the travel distance? If we can’t do any of the above, can we simplify?
GRAVITY PRINCIPLE
Utilize gravity to move material whenever practical .
SPACE UTILIZATION PRINCIPLE
The better we use our building cube, the less space we need to buy or rent. Racks, mezzanines, and overhead conveyors are a few examples that promote this goal. UNIT LOAD PRINCIPLE
Unit loads should be appropriately sized and configured at each stage of the supply chain.
The most common unit load is the pallet
ASSIGNMENT MATERIAL HANDLING
cardboard pallets
plastic pallets
wooden pallets
HIMANSHU SONI 11113030 IPE
AUTOMATION PRINCIPLE
MH operations should be mechanized and/or automated where feasible to improve operational efficiency, increase responsiveness, improve consistency and predictability, decrease operating costs. THE STANDARDIZATION PRINCIPLE
standardize handling methods as well as types and sizes of handling equipment
too many sizes and brands of equipment results in higher operational cost.
A fewer sizes of carton will simplify the storage.
EQUIPMENT SELECTION PRINCIPLE
Why? What? Where? When? How? Who?
ASSIGNMENT MATERIAL HANDLING
HIMANSHU SONI 11113030 IPE
If we answer these questions about each move, the solution will become evident. THE MAINTENANCE PRINCIPLE
Plan for preventive maintenance and scheduled repairs of all handling equipment.
Pallets and storage facilities need repair too. THE DEAD WEIGHT PRINCIPLE
Try to reduce the ratio of equipment weight to product weight. Don’t buy equipment that is bigger than necessary.
Reduce tare weight and save money. THE CAPACITY PRINCIPLE
use handling equipment to help achieve desired production capacity
i.e. material handling equipment can help to maximize production equipment utilization.
ASSIGNMENT MATERIAL HANDLING
HIMANSHU SONI 11113030 IPE
TYPES OF MATERIAL HANDLING EQUIPMENT Conventional Material Handling Equipment 1. Storage Equipment
2. Bulk Material Handling
3. Industrial Trucks Conventional Material Handling Equipment
1. Robotic Delivery System
2. Computer Controlled Conveyor System
3. Automated Guided Vehicles MATERIAL HANDLING EQUIPMENT
Industrial trucks include hand trucks such as two-wheeled, four-wheeled, hand lift, and forklift and powered trucks such as forklift, tractor-trailer trains, industrial crane trucks, and side loaders.
Conveyors such as belt, chute, roller, wheel, slat, chain, bucket, trolley, tow, screw, vibrating, and pneumatic.
Monorails, hoists, and cranes such as bridge, gantry, tower, and stacker.
ASSIGNMENT MATERIAL HANDLING
HIMANSHU SONI 11113030 IPE
Automated guided vehicle systems such as unit load carriers, towing, pallet trucks, fork trucks, and assembly line.
Automated storage and retrieval systems (AS/RS) such as unit load, miniload, person-on-board, deep lane, and storage carousel systems.
Types of Material Handling Equipment
Basically there are three types of materials handling equipments. 1. Static
Platforms
Pallets
Still ages
2.FIXED TYPES
Flat Conveyors
Roller Conveyors
Wheel Conveyors
ASSIGNMENT MATERIAL HANDLING
Trolley Conveyors
Bridge Crane
Electricity Hoist
Jib Crain
Chain Hoist
Gantry Crane 3. VEHICLES
Pallets Trucks
Fork lift trucks
Industrial Vehicles
PROS:
Lessen manual labor. Less shipping errors. Minimal damage on goods and materials. Less shipping and production costs.
HIMANSHU SONI 11113030 IPE
ASSIGNMENT MATERIAL HANDLING
HIMANSHU SONI 11113030 IPE
Lessen employees compensation claims therefore allows you to save more in the long run. CONS:
Require fast data tracking and processing. Require reliable and fool-proof inventory management system. Require more free floor spaces so that equipment can move properly. Buying your own material handling equipment may require you to raise initial capital. Require you to set aside funds for maintenance and repair. Factors Affecting the selection of Material Handling Equipment
Adaptability
Flexibility
Load capacity
Power
Speed
Space requirements
Supervision required
Ease of maintenance
Environment
funds or
ASSIGNMENT MATERIAL HANDLING
HIMANSHU SONI 11113030 IPE
