CHAPTER I

1.1 INTRODUCTION

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. See also, Supply Chain, Supply Chain
Management, Logistics and Third Party Logistics. Note that all of referenced terms are
highly interrelated and their definitions are frequently intermingled.

Material handling may be considered a specialized activity for modern

manufacturing units. From the time, the input material or raw materials enter the
industrial unit and go out of the unit in the form of finished products, these are handled at
all stages in between, no matter, on the shop floor or in the stores.

Definitions of Material Handling

Materials handling may be defined as the art and science of movement, handling
and storage of materials during different stages of manufacturing considered as material
flow into, through and away from the plant. It is in fact, the technique of getting the right
goods safely, to the right place, at the right time and at the right cost.

According to Henry Fayol, “It is a system of auxiliary equipment that improves

flow of material which intern reduces stoppage in production machines and thus increases
productivity of machine. These equipment are designed in order to supplement the
production machines”.

1
1.2 Theoretical perspective

Functions of Material Handling:

(i) To select machines/equipment and plant layout to eliminate or minimize material

handling requirements, i.e., to select most efficient, safe and appropriate material
handling equipment, which can fulfil material handling requirement at minimum cost.

(ii) To minimize the material handling cost by way of:

(a) Minimization of movement of semi-finished items during the production process.

(b) Planning movement of optimum necessary pieces in one unit.

(c) Minimization of distance moved.

(d) Increasing speed of material handling operation through mechanization.

(e) By elimination/minimization of back tracking and duplicate handling.

(f) By utilization of gravity for material handling.

To employ mechanical aids instead of manual labour to accelerate material movements.

Objectives of Material Handing:

(1) Costs Reduction by:

(i) Decreasing inventory level.

(ii) Utilising space to better advantage.

(iii) Increasing productivity.

2
(2) Waste Reduction by:

(i) Eliminating damage to material during handling.

(ii) Being flexible to meet specific handling requirements of different nature.

(iii) Making proper control over stock during in and out handling.

(3) Improve Productivity by:

(i) Increasing productivity per man-hour.

(ii) Increase in machine efficiency through reduction of machine down time.

(iii) Smoothing out workflow.

(iv) Improving production control.

(4) Improve Working Conditions by:

(i) Providing safe working conditions.

(ii) Reducing worker’s fatigue.

(iii) Improving personal comfort.

(iv) Upgrading employees/workers to productive work.

(5) Improve Distribution by:

(i) Decreasing damage to products during handling and shipping.

(ii) Improving routing.

(iii) Improving location of storage facilities.

3
(iv) Increasing the efficiency of shipping and receiving.

Principles of Material Handling:

(1) Using the principles of containerization, unit load or palletization, materials to be

moved should be aggregated into a larger unit size and the unit size should be same for
all materials. The materials are typically carried on a pallet or some other standard size
container for convenience in handling. The materials and containers are known as unit
load. So the load should be as large as possible/practical.

(2) Transport the full unit load whenever possible instead of practical loads. Load the
material handling equipment to its maximum safe limit loading.

(3) Minimize the distances moved by adopting shortest distances possible. Generally the
realization of this principle is layout design dependent.

(4) Follow the straight-line flow rule i.e. the material-handling path should be a straight
line. This rule is consistent with the principle of shortest distance.

(5) Minimize the non-move of terminal times. The total time required for movement of
material is sum of the actual move time and time taken in loading, unloading and other
allied activities which do not involve actual transport of material.

(6) Utilize gravity principle for assisting the movement of materials wherever possible
with due consideration to safety and risk of product damage.

(7) Follow the mechanization principle. Employ mechanical aids in place of manual
labour in order to speed up material movement, increase the efficiency and economy of
the system where possible.

4
(8) Integrate the materials handling system with the other system working in the
enterprise including receiving, production, inspection, packaging, storage, warehousing
and transportation etc.

(9) Integrate the material flow with the flow of information required for handling and
storage systems. Such information for various items moved should include identification,
picks point and destination point in order to improve the efficiency of the system.

1.3 OBJECTIVES OF THE STUDY

Primary objective

 To study the material handling system in AVTEC Limited, Hosur

Secondary objectives

 To identify the material handling tools used by the company

 To study the problems facing in handling the materials
 To analyze the satisfaction level in existing methods of materials handling in the
company
 To assess the requirement of modern equipment’s to handle materials in the
company
 To analyze the safety, enough space and less motion time in material handling
system in the company

5
 1.4 SCOPE OF THE STUDY

The study is only confined with the company AVTEC Limited, Hosur. The
researcher focuses the study towards materials handling system in the company. The
study is taken the survey with the employees of the company. It throws the light on the
perception of the employees about how effectively the company handle the materials.
This study would also help to analyze the problems in material handling system and
suggest provisions to further need of modern equipments in the organisation.

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 CHAPTER II

2.1 REVIEW OF LITERATURE

2.1 Introduction

A literature review is an account of what has been published on a topic by

accredited scholars and researchers. Occasionally you will be asked to write one as a
separate assignment (sometimes in the form of an annotated bibliography—see the
bottom of the next page), but more often it is part of the introduction to an essay, research
report, or thesis. In writing the literature review, your purpose is to convey to your reader
what knowledge and ideas have been established on a topic, and what their strengths and
weaknesses are. As a piece of writing, the literature review must be defined by a guiding
concept (e.g., your research objective, the problem or issue you are discussing, or your
argumentative thesis). It is not just a descriptive list of the material available, or a set of
summaries

2.2 International reviews

Mandyam M. Srinivasan A , Yavuz A. Bozer B &Myeonsig Cho(1994) presented

a general purpose analytical model to compute approximate throughput capacity of trip
based material handling system used in manufacturing setting. The author claimed that
model would be useful in early design phase and prior to simulation.

Yang and Peters (1997) use a modified quadratic set covering problem
formulation to solve the fab layout design problem. They propose a network flow
formulation to determine the number and location of shortcuts for the inter bay transport
system in a spine layout fabrication. Their objective function minimizes construction cost
and the decrease in material handling costs.

7
 Meller (1997) proposes a mixed integer and dynamic programming approach to
determine an optimal layout. Ting and Tanchoco (2001) propose two rectilinear layout
configurations, single spine and double spine (where the two spines are perpendicular),
and they present mathematical models to optimize both configurations. Agrawal and
Heragu (2006) and Montoya-Torres (2006) discuss various approaches for automated
materials handling in semiconductor manufacturing and review the literature on various
aspects of factory design, such as facility layout, AMHS design and AMHS operational
issues.

DimaNazzal a & Leon F. McGinnis(2008) did analysis of the throughput

performance of a closed-loop multi-vehicle automated material handling system (AMHS)
used in highly automated 300 mm wafer fabrication facilities (fabs). A numerical
example is analyzed and simulated using AutoMod to demonstrate and validation of the
stochastic model.

J. S. Noble and C. M. Klein, A. Mid ha have examined several aspects of the

integrated material flow system design problem. However, as problem complexity has
increased the ability to obtain solutions to the more integrated problem formulations has
become more difficult. They present a model which integrates material handling
equipment selection and specification (including interface equipment between different
types of equipment), and path/load dependent unit load size and variable unit load size.
The formulation is solved using the meta-heuristic procedure of tabu search to find a
"good" solution to a more integrated formulation.

Ramazan YAMAN develop a knowledge-based system for material handling

equipment selection and pre-design of these 111equipments in the facility layout is
discussed. The study comprises two sections.

J. D. Tew, S. Manivannan, D. A. Sadowski, and A. F. Seila were illustrate the

simulation methodologies used in the design of Automated Material Handling Systems
(AMHS) at Intel wafer fabs for semiconductor manufacturing. The models used in

8
AMHS design has categorized as AMHS models and production models. The AMHS
models support the design of Interbay and Intrabay systems. The Inter bay systems
handle the material flow between different bays (production centers).

CHAPTER III
3.1 INTRODUCTION TO THE INDUSTRY

Automobile Parts Manufacturing Industry Profile

Companies in this industry manufacture automobile parts, including transmission and

power train components, engines and engine parts, body parts and trim, electronics,
braking systems, and steering and suspension components. Economic expansion in
emerging markets worldwide is expected to drive healthy growth in the auto
manufacturing sector over the next several years, which should bolster demand for auto
parts.

COMPETITIVE LANDSCAPE

Demand for auto parts is driven by new bike sales, which are strongly affected by
interest rates, and by the replacement market. Company profitability depends partly on
the difficulty of manufacturing products and partly on demand volume, since many costs
are fixed. Small companies can compete successfully by focusing on a small number of
products or some highly technical ones.

Factors determining the growth of the industry

 Fuel economy and demand for greater fuel efficiency is a major factor that affects
consumer purchase decision that will bring leading companies across two-wheeler
and four-wheeler segment to focus on delivering performance-oriented products.
 Increased affordability, heightened demand in the small bike segment and the
surging income of the Indian population
 India is the third largest investor base in the world

9
  The Government technology modernization fund is concentrating on establishing
India as an auto-manufacturing hub. 
 Availability of inexpensive skilled workers
 Industry is perusing to elevate sales by knocking on doors of women, youth, rural
and luxury segments
 Market segmentation and product innovation

Two-Wheeler Spare Parts

 Air Filter Assembly  Gear Change Mechanism

 Auto Valve  Handlebar

 Brake Pedal  Magneto Assembly

 Camshafts  Meter Assembly

 Chain Case  Muffler

 Chain Cover  Oil Pipe

 Chassis Frame  Oil Pump

 Clutch Assembly  Petrol Tank

 Control Cables  Rear Hub

 Crankcase  Shift Fork

 Crankshaft  Swing Arm

 Cylinder And Piston Assembly  Tail Light Assembly

 Cylinder Head  Tool Kit

 Fork Front  Transmission Parts

 Front Fender  Turn Signal Lamps

10
  Front Hub  Wheel Rim

3.2 COMPANY PROFILE

AVTEC is one of the largest independent manufacturers of powertrain and

precision-engineered products in India. It is a part of CK Birla Group – a leading global
business house, with over 20,000 employees and a combined turnover of USD 1.8 billion.

With years of experience in manufacturing, AVTEC delivers competency across

the entire value chain of design & manufacture of engines; transmissions and high
precision components like cylinder heads, cylinder blocks, crank shafts, cam shafts, cam
rods and transmission gears for Automotive, Off-Highway, Defence, Agriculture and
Railway industry, in areas of both proprietary products and contract manufacturing. The
company serves some of the best-known domestic and global Automotive and Off-
Highway companies, including global OEMs such as Allison, BEML, Caterpillar,
Daimler, Ford, ISUZU , PSA , Punch Powertrain, Renault-Nissan, Tata-Jaguar and
several other established brands.

AVTEC's domestic units comprise of an in-house tech centre in Hosur, R&D

facilities in Hosur and Pithampur, and state-of-the-art manufacturing facilities in Hosur,
Chennai, and Pithampur. MEPZ, Chennai plant is a completely export oriented unit
equipped with modern casting and forging machines to meet expanding global demand of
heavy duty transmission components for the Off- Highway industry. All the facilities are
TS 16949 and QS 14001 certified and are equipped with high-tech machinery, and
manned by experienced personnel.

With its global R&D and manufacturing footprint which includes face gear and
innovative drive systems through the Switzerland- based subsidiary ASSAG, AVTEC
aspires to reinforce its commitment to customers as a 'one-stop-shop' for Powertrain and
Precision Engineered Products, across the globe.

11
 With its Switzerland based Design, patenting and batch production facility
ASSAG-pioneer in face gear technology, AVTEC aspires to reinforce its commitment to
customers as a ‘one-stop-shop’ from concept to design, patenting and series production of
Powertrain & Precision Engineered Products & services across the Globe.

Vision

We shall create a value proposition for our customers, shareholders, business

partners and employees through becoming a first choice supplier in powertrain and
precision-engineered products & services.

Mission

We aim to grow with profitability and continuously improve product quality and
services through employee involvement, adoption of best-in-class manufacturing systems
and processes. By forging mutually beneficial relationship with all stake holders we want
to achieve:

o Customer confidence

o Benchmarked level of return on investment

o Growth in revenue in line with our long-term strategy

Milestones

2010

License agreement with Peugeot Citroen Moteurs for engines

2012

Acquisition of ASSAG, Switzerland

12
 License and technical assistance agreement with ZVD, Russia for transmissions

2013

50:50 joint venture formed with Russian engine manufacturer ZVD to set up a
manufacturing unit for engines and transmissions.

CHAPTER IV

RESEARCH METHODOLOGY

4.1 RESEARCH DESIGN

Analytical research is a type of research that utilises thinking to find out facts
about a given topic and from the answers obtained to develop new and useful ways of
doing things. Critical thinking is a method of thinking that puts assumptions into question

13
to decide whether a given claim is true or false. The major purpose of this study is to
analyses and interprets the data items and its relationships.

The research design adopted for the studies is descriptive design. The researcher
has to describe the present situation in order to know the behavior of the buyers. Hence
descriptive research study is used. Descriptive research can only report what has
happened and what is happening. Research Methodology is a systematic way to solve a
research problem; It includes various steps that are generally adopted by a researcher in
studying the problem along with the logic behind them.

4.2 DATA COLLECTION

Research instrument are the instruments which is used for gathering or collecting
information. The used in the study are

1.Direct questions

2.Close end questions

3.Dichotomous questions

3.Multiple choice questions

Direct Questions

Direct questions are just what their names indicate. They explicitly ask for the desired
data. However the directness of the question also relates to the way a response is
interpreted.

Close End Questions

14
Such questions are also called fixed alternative questions they refer to those questions in
which the respondent is given a limited number of alternative response frame which
he/she is to select one that most closely matches his/her opinion or attitude.

Dichotomous Questions

A dichotomous question refers to one which offers the respondent a choice between only
two alternatives and reduces the issue to its simple terms. The fixed alternatives are of the
type, yes/no, agree/disagree, true/false etc.

Multiple Choice Questions

A multiple choice question refers to one which provides several set alternatives for its
answers. Thus, it is a middle ground between free answers and dichotomous question.

Data in the study are of two types:

 Primary data

 Secondary data

Data Collection methods

PRIMARY DATA

Primary data refers to the information obtained firsthand by the researcher on the
variables of interest for the specific purpose of study. In case of descriptive research
primary data can be obtained through observation or through direct communication with
respondents in one form or another or through personal interviews or through
questionnaires. Questionnaires were employed to collect data.

15
SECONDARY DATA

Secondary data refers to information gathered from sources already existing. Some
sources of secondary data are data available from previous research, information
available from any published or unpublished sources available either within or outside the
organization, library records, online data, websites and the internet. The secondary data
of information of this study were obtained through web sites, books, annual report, and
internet.

4.3 SAMPLING METHOD

Population

The aggregate elementary units in the survey are referred to as the population. Here it
covers the entire employees of Avtec Limited, Hosur.

Sample Size

The study based only on the opinion and expectation of employees. Total number
of sample taken for the study is 100 respondents.

SAMPLING UNIT:

Sampling unit is in Avtec Limited, Hosur.

Sample design

Random sampling techniques were used for the study.

4.4 TOOLS USED

 Percentage Method

Percentage methods are used in marketing comprehension between two more series
of data. Percentage are used to compare the relatives terms, the distribution of two or

16
more series of data and are presently by way of bar diagram and pie diagram in order to
have a better understanding.

In this method frequency of the various criteria factors are tabulated and the
percentage for each value with respect to total is found out. They are presented
pictorially by way of graphs in order to have better understanding.

Number of employees
Percentage = ________________________× 100
Total number of employees

 Chi-Square Analysis:

Chi-square is a non-parametric test of statistical significance for bivariate tabular

analysis. A non-parametric test, like chi square, is a rough estimate of confidence.Chi-
square is used most frequently to test the statistical significance of results reported in
bivariate tables and interpreting bivariate tables is integral to interpreting the results of a
chi-square test.

The Chi-Square statistic is most commonly used to evaluate Tests of

Independence when using a crosstabulation (also known as a bivariate table).
Crosstabulation presents the distributions of two categorical variables simultaneously,
with the intersections of the categories of the variables appearing in the cells of the table.
The Test of Independence assesses whether an association exists between the two
variables by comparing the observed pattern of responses in the cells to the pattern that
would be expected if the variables were truly independent of each other.  Calculating the
Chi-Square statistic and comparing it against a critical value from the Chi-Square
distribution allows the researcher to assess whether the observed cell counts are
significantly different from the expected cell counts.

Chi – Square Test Method:

4.5 HYPOTHESIS

17
 A hypothesis is an approximate explanation that relates to the set of facts that can
be tested by certain further investigations. There are basically two types, namely, null
hypothesis and alternative hypothesis. A research generally starts with a problem. Next,
these hypotheses provide the researcher with some specific restatements and
clarifications of the research problem.

Null Hypothesis (H0):

A null hypothesis is a type of hypothesis used in statistics that proposes that no

statistical significance exists in a set of given observations. The null hypothesis attempts
to show that no variation exists between variables or that a single variable is no different
than its mean. It is presumed to be true until statistical evidence nullifies it for an
alternative hypothesis.

Alternative Hypothesis (H1):

In statistical hypothesis testing, the alternative hypothesis (or maintained

hypothesis or research hypothesis) and the null hypothesis are the two rival hypotheses
which are compared by a statistical hypothesis test.

Statistical Test:

(O  E ) 2
 E
Chi–square test (2) =

Degree of freedom = (R-1) (C-1)

Whereas, O = Observed frequency

E = Expected frequency

R = Number of rows

C = Number of columns

18
To find E:

Row Total  Column Total

Expected Frequency = -----------------------------------
Grand Total

The directional hypothesis is a kind that explains the direction of the expected
findings. Sometimes this type of alternative hypothesis is developed to examine the
relationship among the variables rather than a comparison between the groups.

The non directional hypothesis is a kind that has no definite direction of the
expected findings being specified.

The purpose and importance of the null hypothesis and alternative hypothesis are
that they provide an approximate description of the phenomena. The purpose is to
provide the researcher or an investigator with a relational statement that is directly tested
in a research study. The purpose is to provide the framework for reporting the inferences
of the study.

CHAPTER V
TABLE NO: 5.1
GENDER OF THE RESPOINDENTS
Cumulative
Frequency Percent Valid Percent
Percent
Male 72 72.0 72.0 72.0
Valid Female 28 28.0 28.0 100.0
Total 100 100.0 100.0
Source: Primary data

19
INFERENCE:
`1The above table shows that 72% of respondents are male and 28% of the
respondents are female.
Thus the majority of the respondents are male.

CHART NO: 5.1

20
TABLE NO: 5.2

21
 AGE OF THE RESPONDENTS
Cumulative
Frequency Percent Valid Percent
Percent
Below 20 21 21.0 21.0 21.0
21-30 20 20.0 20.0 41.0
31-40 24 24.0 24.0 65.0
Valid
41-50 19 19.0 19.0 84.0
Above 50 16 16.0 16.0 100.0
Total 100 100.0 100.0
Source: Primary Data

INFERENCE:
The above table shows that 21% of respondents are in the age group of below 20
yrs, 20% of the respondents are in the age group of 21-30 yrs, 24% of the respondents are
in the age group of 31-40 yrs, 19% of the respondents are in the age group of 41-50 years,
16% of the respondents are in the age group of above 50 years.
Thus the majority of the respondents are in the age group of 31-40 yrs.

CHART NO: 5.2

22
23
 TABLE NO: 5.3
EDUCATIONAL QUALIFICATION OF THE RESPONDENTS
Cumulative
Frequency Percent Valid Percent
Percent

Higher secondary 30 30.0 30.0 30.0

Graduate 16 16.0 16.0 46.0

Valid Post graduate 19 19.0 19.0 65.0
Diploma 14 14.0 14.0 79.0
Others 21 21.0 21.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:
The above table shows that 30% of respondents have completed Hr. sec., 16% of
the respondents have completed Graduate, 19% of the respondents have completed PG
degree,14%of the respondents have completed Diploma and 21% of the respondents
have completed other educational qualification.
Thus the majority of the respondents have completed higher secondary.

24
CHART NO: 5.3

25
 TABLE NO: 5.4

SALARY OF THE RESPONDENTS

Cumulative
Frequency Percent Valid Percent Percent
Valid Below 10,000 24 24.0 24.0 24.0
10,000-20,000 27 27.0 27.0 51.0
20,001-30,000 34 34.0 34.0 85.0
Above 30,000 15 15.0 15.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:

The above table shows that 24% of respondents have below 10,000, 27% of the
respondents have Rs.10, 001-20,000, 34% of the respondents have Rs.20, 001-30,000 and
15% of the respondents have above Rs.30, 000 as their income level.

Thus the majority of the respondents have Rs.20, 001-30,000.

26
CHART NO: 5.4

27
 TABLE NO: 5.5
SYSTEM USED BY THE ORGANIZATION IN MATERIAL HANDING
Valid Cumulative
Frequency Percent Percent Percent
Valid Manual material
45 45.0 45.0 45.0
handing
Mechanical material
37 37.0 37.0 82.0
handing
Both 18 18.0 18.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:

The table above show that 45% of the respondents said that manual material
handing, 37% of the respondents said that mechanical material handing, 18% of the
respondents said that both as their system used in organization,
Thus the majority of the respondents said that manual material handling.

28
CHART NO: 5.5

29
 CHART NO: 5.6

Valid Cumulative
Frequency Percent Percent Percent
Valid Forklift 48 48.0 48.0 48.0
Power
23 23.0 23.0 71.0
trolleys
Hand trolleys 10 10.0 10.0 81.0
Pallet stacker 19 19.0 19.0 100.0
Total 100 100.0 100.0

Source: Primary data

INFERENCE:

The above table show that 48% of the respondents said that forklift, 23% of the
respondents said that power trolleys, 10% of the respondents said that hand trolleys,19%
of the respondents said that pallet stacker towards the type of equipments are frequently
used in the company.

Thus the majority of the respondents said that forklift towards the type of
equipments are frequently used in the company

30
CHART NO: 5.6

31
 TABLE NO: 5.7

PROBLEM FACING FREQUENTLY IN HANDING THE MATERIALS

Cumulative
Frequency Percent Valid Percent Percent
Valid Labour cost 14 14.0 14.0 14.0
Unsafe 31 31.0 31.0 45.0
Shortage of place 34 34.0 34.0 79.0
None 21 21.0 21.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:

The above table show that 14% of the respondents said that labour cost,31% of
the respondents said that unsafe,34% of the respondents said that shortage of place,21%
of the respondents said that none towards is the problem in handling the materials.

Thus the majority of the respondents said that shortage of place towards is the
problems in handling the materials.

32
CHART NO: 5.7

33
 TABLE NO: 5.8
TIME TAKEN TO LOAD/UNLOAD THE MATERIALS

Cumulative
Frequency Percent Valid Percent Percent
Valid <15 mins 13 13.0 13.0 13.0
15-30 mins 31 31.0 31.0 44.0
30-45 mins 35 35.0 35.0 79.0
>45 21 21.0 21.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:

The above table show that 13% of the respondents said that below 15 mins ,31%
of the respondents said that 15-30 mins,35% of the respondents said that 30-45mins,21%
of the respondents said that above 45 towards as the time taken to load/unload the
materials.

Thus the majority of the respondents said that below 15 mins towards as the time
taken to load/unload the materials.

34
CHART NO: 5.8

35
 TABLE NO: 5.9
EXISTING MATERIAL HANDLING MATERIALS
Cumulative
Frequency Percent Valid Percent Percent
Valid Yes 63 63.0 63.0 63.0
No 37 37.0 37.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:

The above table show that 63% of the respondents said that existing
material handling system is effective and 37% of the respondents said that not
existing material handling system is effective.
Thus the majority of the respondents said that existing material handling
system is effective.

36
CHART NO: 5.9

37
 TABLE NO: 5.10
SATISFIED WITH EXISTING METHOD OF STORIES THE MATERIALS
Cumulative
Frequency Percent Valid Percent Percent
Valid Highly Satisfied 11 11.0 11.0 11.0
Satisfied 30 30.0 30.0 41.0
Neither satisfied nor
28 28.0 28.0 69.0
dissatisfied
Dissatisfied 12 12.0 12.0 81.0
Highly dissatisfied 19 19.0 19.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:
The above table shows that 11% of respondents are highly satisfied, 30% of the
respondents are satisfied, 28% of the respondents are neither satisfied nor dissatisfied,
12% of the respondents are dissatisfied, and 19% of the respondents are highly
dissatisfied towards the satisfied towards the satisfied with existing method of stories the
materials
Thus the majority of the respondents are satisfied towards the satisfied with
existing method of stories the materials

38
CHART NO: 5.10

39
 TABLE NO: 5.11

SAFETY FOR HANDING THE MATERIALS IN THE COMPANY

Cumulative
Frequency Percent Valid Percent Percent
Valid Forklift 23 23.0 23.0 23.0
Pallet stracker 27 27.0 27.0 50.0
Power trolley 36 36.0 36.0 86.0
Hand trolley 14 14.0 14.0 100.0
Total 100 100.0 100.0

Source: Primary data

INFERENCE:

The above table show that 23% of the respondents said that forklift, 27%
of the respondents said that pallet stacker, 36% of the respondents said that power
trolleys 14% of the respondents said that hand trolleys, towards the is safety for
handling the material in the company.

Thus the majority of the respondents said that forklift towards the safety
for handling the material in the company.

40
CHART NO: 5.11

41
 TABLE NO: 5.12
SATISFIED WITH THE EQUIPMENTS CURRENTLY USED
Valid Cumulative
Frequency Percent Percent Percent
Valid Highly satisfied 15 15.0 15.0 15.0
Satisfied 20 20.0 20.0 35.0
Neither satisfied nor
31 31.0 31.0 66.0
dissatisfied
Dissatisfied 19 19.0 19.0 85.0
Highly dissatisfied 15 15.0 15.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:
The above table shows that 15% of respondents are highly satisfied, 20% of the
respondents are satisfied, 31% of the respondents are neither satisfied nor dissatisfied,
19% of the respondents are dissatisfied, and 15% of the respondents are highly
dissatisfied towards the satisfied towards the satisfied with the equipments currently used
Thus the majority of the respondents are satisfied towards the satisfied with the
equipments currently used

42
CHART NO: 5.12

43
 TABLE NO: 5.13

WEIGHT LIFTED BY THE EXISTING FORKLIFT

Cumulative
Frequency Percent Valid Percent Percent
Valid 1 tons 12 12.0 12.0 12.0
1.5 tons 43 43.0 43.0 55.0
2 tons 29 29.0 29.0 84.0
> 2 tons 16 16.0 16.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:
The above table show that 12% of the respondents said that 1tons,43% of the
respondents said that 1.5 tons, 29% of the respondents said that 2tons,16% of the
respondents said that above 2 tons towards the weight lifted by the existing forklift.
Thus the majority of the respondents said that 1.5 tons towards the weight lifted by the
existing forklift.

44
CHART NO; 5.13

45
TABLE NO; 5.14

46
 TYPE OF MODERN EQUIPMENTS ARE REQUIRED
Valid Cumulative
Frequency Percent Percent Percent
Valid Bay crane 12 12.0 12.0 12.0
Scissor lift 43 43.0 43.0 55.0
Forklift 29 29.0 29.0 84.0
Order picker 16 16.0 16.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:
The above table show that 12% of the respondents said that bay crane,43% of the
respondents said that scissor lift,29% of the respondents said that forklift,16% of the
respondents said that order picker towards type of modern equipment are required.

Thus the majority of the respondents said that bay crane.

CHART NO: 5.14

47
48
 TABLE NO; 5.15

IMPLEMENTATIONS OF ALTERNATIVE METHOD IN MATERIAL HANDLING

Cumulative
Frequency Percent Valid Percent Percent
Valid Strongly agree 44 44.0 44.0 44.0
Agree 18 18.0 18.0 62.0
Neither agree nor disagree 10 10.0 10.0 72.0
Disagree 17 17.0 17.0 89.0
Strongly disagree 11 11.0 11.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:
The above table shows that 44% of respondents are strongly agree, 18% of the
respondents are agree, 10% of the respondents are neutral, 17% of the respondents are
disagree and 11% of the respondents are strongly disagree towards theimplementations of
alternative method in material handling
Thus the majority of the respondents are strongly agree towards the
implementations of alternative method in material handling

49
CHART NO; 5.15

TABLE NO: 5.16

50
 THE SAFETY IN MATERIAL HANDLING EQUIPMENTS IN COMPANY

Cumulative
Frequency Percent Valid Percent Percent
Valid Excellent 21 21.0 21.0 21.0
Good 20 20.0 20.0 41.0
Average 25 25.0 25.0 66.0
Poor 18 18.0 18.0 84.0
Worst 16 16.0 16.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:
The above table shows that 21% of respondents said that excellent, 20% of the
respondents said that good, 25% of the respondents said that bad and 18% of the
respondents said that poor and 16% of the respondents said that worst towards the safety
in material handling equipments in company
Thus the majority of the respondents said that Average towards the safety in
material handling equipments in company

CHART NO: 5.16

51
52
 TABLE NO: 5.17
EQUIPMENTS MINIMIZE THE TIME TO HANDLE THE INVENTORIES
Valid Cumulative
Frequency Percent Percent Percent
Valid Strongly agree 11 11.0 11.0 11.0
Agree 20 20.0 20.0 31.0
Niether agree nor
35 35.0 35.0 66.0
disagree
Disagree 19 19.0 19.0 85.0
Strongly disagree 15 15.0 15.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:
The above table shows that 11% of respondents are strongly agree, 20% of the
respondents are agree, 35% of the respondents are neutral, 19% of the respondents are
disagree and 15% of the respondents are strongly disagree towards theequipments
minimize the time to handle the inventories.
Thus the majority of the respondents are agree towards theequipments minimize
the time to handle the inventories.

CHART NO: 5.17

53
54
 TABLE NO: 5.18
WORKERS EFFECTIVELY USING THE MATERIAL HANDLING
EQUIIPMENTS
Valid Cumulative
Frequency Percent Percent Percent
Valid Strongly agree 44 44.0 44.0 44.0
Agree 15 15.0 15.0 59.0
Neither agree nor
15 15.0 15.0 74.0
disagree
Disagree 17 17.0 17.0 91.0
Strongly disagree 9 9.0 9.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:
The above table shows that 44% of respondents are strongly agree, 15% of the
respondents are agree, 15% of the respondents are neutral, 17% of the respondents are
disagree and 9% of the respondents are strongly disagree towards theworkers effectively
using the material handling equipments.
Thus the majority of the respondents are strongly agree towards the workers
effectively using the material handling equipments.

CHART NO: 5.18

55
56
 TABLE NO: 5.19

COMPANY HAVE ENOUGH SPACE TO HANDLE THE MATERIALS

EFFECTIVELY
Valid Cumulative
Frequency Percent Percent Percent
Valid Strongly agree 23 23.0 23.0 23.0
Agree 31 31.0 31.0 54.0
Neither agree nor
12 12.0 12.0 66.0
disagree
Disagree 18 18.0 18.0 84.0
Strongly disagree 16 16.0 16.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:
The above table shows that 23% of respondents are strongly agree, 31% of the
respondents are agree, 12% of the respondents are neutral, 18% of the respondents are
disagree and 16% of the respondents are strongly disagree towards thecompany have
enough space to handle the materials effectively.
Thus the majority of the respondents are agree towards the company have enough
space to handle the materials effectively.

CHART NO: 5.19

57
58
 TABLE NO: 5.20

MATERIAL HANDLING SYSTEM REDUCE THE MOTION OF GOODS

Valid Cumulative
Frequency Percent Percent Percent
Valid Strongly agree 24 24.0 24.0 24.0
Agree 27 27.0 27.0 51.0
Neither agree nor
12 12.0 12.0 63.0
disagree
Disagree 22 22.0 22.0 85.0
Strongly disagree 15 15.0 15.0 100.0
Total 100 100.0 100.0
Source: Primary data

INFERENCE:
The above table shows that 24% of respondents are strongly agree, 212% of the
respondents are agree, 6% of the respondents are neutral, 22% of the respondents are
disagree and 15% of the respondents are strongly disagree towards the material handling
system reduce the motion of goods.
Thus the majority of the respondents are agree towards the material handling
system reduce the motion of goods.

59
 CHART NO: 5.20

.CHI-SQUARE ANALYSIS-1
Step1:

Null hypothesis (Ho):

There is no significance difference between the salary of the respondents and
equipments minimize the time to handle the inventories.

60
 Alternative hypothesis (H1):
There is some significance difference between the salary of the respondents and
equipments minimize the time to handle the inventories.

Step 2:
Level of significance at 5%

Step 3:

Case Processing Summary

Cases
Valid Missing Total
N Percent N Percent N Percent
SALARY OF THE
RESPONDENTS *
EQUIPMENTS MINIMIZE 100 100.0% 0 .0% 100 100.0%
THE TIME TO HANDLE
THE INVENTORIES

Step 4:

61
SALARY OF THE RESPONDENTS * EQUIPMENTS MINIMIZE THE TIME TO HANDLE THE
INVENTORIES Crosstabulation
Count
EQUIPMENTS MINIMIZE THE TIME TO HANDLE THE
Total
INVENTORIES
Strongly Niether agree Strongly
Agree Disagree
agree nor disagree disagree
Below
5 6 10 1 2 24
10,000
10,000-
3 3 7 10 4 27
SALARY OF THE 20,000
RESPONDENTS 20,001-
2 8 13 5 6 34
30,000
Above
1 3 5 3 3 15
30,000
Total 11 20 35 19 15 100
Step 5:

Chi-Square Tests

Value df Asymp. Sig. (2-sided)

Pearson Chi-Square 14.668a 12 .260
Likelihood Ratio 15.076 12 .237
Linear-by-Linear Association 3.061 1 .080

N of Valid Cases 100

a. 11 cells (55.0%) have expected count less than 5. The minimum expected count is 1.65.

RESULT:
It is insignificant or false in the rejection region. Hence we accept the null hypothesis are
5 % level of significance and conclude that, there is no significance difference between
the salary of the respondents and equipments minimize the time to handle the inventories
CORRELATION ANALYSIS

62
 RELATIONSHIP BETWEEN EDUCATIONAL QUALIFICATION OF THE
RESPONDENTS AND WEIGHT LIFTED BY THE EXISTING FORKLIFT

Correlations

EDUCATIONAL
WEIGHT LIFTED
QUALIFICATION
BY THE EXISTING
OF THE
FORKLIFT
RESPONDENTS

EDUCATIONAL Pearson Correlation 1 .086

QUALIFICATION OF THE
Sig. (2-tailed) .392
RESPONDENTS
N 100 100

Pearson Correlation .086 1

WEIGHT LIFTED BY THE
EXISTING FORKLIFT Sig. (2-tailed) .392
N 100 100
** Correlation is significant at the 0.01 level (2-tailed).

INFERENCE:

the above table depicts the relationship educational qualification of the respondents and
weight lifted by the existing forklift. These two variables have some degree of
correlation i.e. 0.086. So there is a relationship between these two variables.

63
 CHAPTER VI
SUMMARY OF FINDINGS, SUGGESTIONS AND CONCLUSION

6.1 FINDINGS

 72 % of the respondents are male.

 24% of the respondents are in the age group % of 31-40 yrs.
 30 % of the respondents have completed higher secondary.
 34 % of the respondents have Rs.20, 001-30,000.
 45 % of the respondents said that manual material handling.
 48 % of the respondents said that forklift towards the type of equipments are
frequently used in the company.
 34 % of the respondents said that shortage %of place towards is the problems in
handling the materials.
 35 % of the respondents said that below 15 mins towards as the time taken to
load/unload the materials.
 63 % of the respondents said that existing material handling system is effective.
 30 % of the respondents are satisfied towards the satisfied with existing method f
stories the materials
 36 % of the respondents said that forklift towards the safety for handling the
material in the company.
 31% of the respondents are satisfied towards the satisfied with the equipments
currently used
 43 % of the respondents said that 1.5 tons towards the weight lifted by the
existing forklift.
 43 % of the respondents said that bay crane.
 44 % of the respondents are strongly agree towards the implementations of
alternative method in material handling
 25 % of the respondents said that Average towards the safety in material handling
equipments in company

64
 6.2 SUGGESTIONS

 The concern should practice effective and suitable material handling system in the

organisation.

 The frequently using materials must be stored and it should have alternatives to

use any time.

 The problems should be identified and eliminate in material handling in order to

bring productivity in the concern.

 The material must reduce the time to load and unload all the materials.

 The materials must be ensure the safe to the employees to handle I the concern.

 The employees must be trained and should have aware to handle the materials

properly.

 Modern materials must be identified and used in order to avoid wastage of the

resources.

 The materials must ensure to reduce timing of handlness in the workplace in the

organisation.

 There must be proper place to handle the materials in the organisation.

 The materials handling system must be reduce the motion of the time to move

from one place to other.

6.3 CONCLUSION

65
 From the above study it is observed that the material handling is important
activity in manufacturing industry. The selection of the most appropriate material
handling equipment for any particular application can be influence the profit of any
manufacturing company. The literature review has shown that researchers have consider
the design problems in material flow system and overcome with adequate knowledge
base approach, properly design, 3d modeling ,analyzing and using simulation model to
validate the system performance for acquiring the material handling equipment selection.
Thus it concludes that material handling system plays a major role in productivity.
Distribution, manufacturing, and warehousing and helps to give the best optimization to
increase the productivity, reduced cost and idle time, proper utilization of labour, product
quality and safety.

6.4 LIMITATIONS OF THE STUDY

 The employees provide data from their memory. The data furnished by the sample

employees may not be accurate.

 The data are qualitative in nature which is collected from the employees.

 The population for the study was 100 only.

 The sample size for this study was small compared to the total employee’s

strength of the organization.

66
 QUESTIONNAIRE

A STUDY ON MATERIAL HANDLING SYSTEM IN AVTEC LIMITED, HOSUR

1. Name :

2.Gender : a) Male b) Female

3.Age :

a) Below 20 b) 21-30 c) 31-40 d) 41-50 e)

Above 50

4.Educational Qualification:

a) Higher Secondary b) Graduate c) Post Graduate d)

Diploma

e) Others

5 .Salary:

a) below 10, 000/- b) 10,000-20,000/- c) 20,001- 30,000/- d) above

30,000/-

6. Which system is used by the organization in material handling?

a) Manual material handling b) Mechanical material handling c) Both

7) What type of equipments are frequently used for material handling materials in your
company?

a)Forklift b) Power trolleys c) Hand trolleys d) Pallet stacker

e) Others

67
8) What problem you are facing frequently in handling the materials?

a)Labour cost b) Unsafe c) Shortage of place d) None

9) How much time is taken to load/unload the materials of a tonne manually?

a) < 15 mins b) 15 – 30 mins c) 30– 45 minsd) > 45

10) Whether the existing material handling system is effective or not?

a) Yes b) No

11) Are you satisfied with the exiting method of storing the materials adopted in the
company?

a) Highly Satisfied b) Satisfied c) Neither satisfied nor dissatisfied

d) Dissatisfied e) Highly Dissatisfied

12) Which equipment is most safety for handling the materials in the company?

a) Forklift b) Pallet Stacker c) Power Trolley d) Hand trolley

13) Are you satisfied with the equipments currently used in the company?

a) Highly Satisfied b) Satisfied c) Neither satisfied nor dissatisfied

d) Dissatisfied e) Highly Dissatisfied

14) How much weight could be lifted by the existing forklift?

a) 1 ton b) 1.5 ton c) 2 ton d) > 2 ton

68
15) What types of modern equipments are required for better material handling in the
company?

a) Bay Crane b) Scissor Lift c) Forklift d) Order Picker

16) How do you agree with the implementations of alternative methods in material
handling?

a) Strongly agree b) Agree c) Neither agree nor disagree d) Disagree

e) Strongly disagree

17) How do you assess the safety in material handling equipments in your company?

a) Excellent b) Good c) Average d) Poor e) Worst

18) How do you agree that your equipments minimize the time to handle the inventories
in your company?

a) Strongly agree b) Agree c) Neither agree nor disagree d) Disagree

e) Strongly disagree

19) How do you agree that your workers effectively using the material handling
equipments?

a) Strongly agree b) Agree c) Neither agree nor disagree d) Disagree

e) Strongly disagree

20) How do you agree that your company have enough space to handle the materials
effectively?

a) Strongly agree b) Agree c) Neither agree nor disagree d) Disagree

69
 e) Strongly disagree

21) How do you agree that your material handling system reduces the motion of goods
from one place to other place?

a) Strongly agree b) Agree c) Neither agree nor disagree d) Disagree

e) Strongly disagree

22) Suggestions

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70