Material Handling And

Maintenance Engineering
Course No :ME 4057
Course Teacher:
Dr. Sobahan Mia
Md. Harun-Or-Rashid Molla
 INTRODUCTION AND IMPORTANCE

# Defination of Material Handling:

 The movement of materials (raw materials, scrap, semifinished,
and finished) to, through, and from productive processes; in
warehouses and storage; and in receiving and shipping areas.
 “Material handling is the movement and storage of material at
the lowest possible cost through the use of proper method and
equipment”.
 Importance of Material Handling:

• Material handling is a necessary and significant component of any productive

activity. It is something that goes on in every plant all the time. Material handling
means providing the right amount of the right material, in the right condition, at
the right place, at the right time, in the right position and for the right cost, by
using the right method. It is simply picking up, moving, and lying down of materials
through manufacture. It applies to the movement of raw materials, parts in
process, finished goods, packing materials, and disposal of scraps. In general,
hundreds and thousands tons of materials are handled daily requiring the use of
large amount of manpower while the movement of materials takes place from one
processing area to another or from one department to another department of the
plant. The cost of material handling contributes significantly to the total cost of
manufacturing.
• In the modern era of competition, this has acquired greater importance due to
growing need for reducing the manufacturing cost. The importance of material
handling function is greater in those industries where the ratio of handling cost to
the processing cost is large. Today material handling is rightly considered as one of
the most potentially lucrative areas for reduction of costs. A properly designed and
integrated material handling system provides tremendous cost saving
opportunities and customer services improvement potential.
OBJECTIVES OF MATERIAL HANDLING

The primary objective of a material handling system is to

reduce the unit cost of production. The other subordinate
objectives are:

1. Reduce manufacturing cycle time

2. Reduce delays, and damage
3. Promote safety and improve working conditions
4. Maintain or improve product quality
5. Promote productivity
6. Promote increased use of facilities
7. Reduce tare weight
8. Control inventory
LIMITATIONS OF AUTOMATED MATERIAL HANDLING SYSTEMS:

A good management practice is to weigh benefits against the

limitations or disadvantages before contemplating any
change. Material handling systems also have
consequences that may be distinctly negative. These are:

1. Additional investment
2. Lack of flexibility
3. Vulnerability to downtime whenever there is breakdown
4. Additional maintenance staff and cost
5. Cost of auxiliary equipment.
6. Space and other requirements.
 Principle of material handling

1. Orientation Principle
Study the system relationships thoroughly prior to preliminary
planning in order to identify existing methods and problems,
physical and economic constraints, and to establish future
requirements and goals.
2. Planning Principle
Establish a plan to include basic requirements, desirable options,
and the consideration of contingencies for all material handling
and storage activities.
3. Systems Principle
Integrate those handling and storage activities which are
economically viable into a coordinated system of operation
including receiving, inspection, storage, production, assembly,
packaging, warehousing, shipping and transportation.
 Principle of material handling
4. Unit Load Principle
Handle product in as large a unit load as practical.
5. Space Utilization Principle
Make effective utilization of all cubic space.
6. Standardization Principle
Standardize handling methods and equipment wherever
possible.
7. Ergonomic Principle
Recognize human capabilities and limitations by designing
material handling equipment and procedures for effective
interaction with the people using the system.
 Principle of material handling
8. Energy Principle
Include energy consumption of the material handling
systems and material handling procedures when
making comparisons or preparing economic
justifications.
9. Ecology Principle
Minimize adverse effects on the environment when
selecting material handling equipment and procedures.
10. Mechanization Principle
Mechanize the handling process where feasible to
increase efficiency and economy in the handling of
materials.
 Principle of material handling
11. Flexibility Principle
Use methods and equipment which can perform a variety of tasks
under a variety of operating conditions.
12. Simplification Principle
Simplify handling by eliminating, reducing, or combining
unnecessary movements and/or equipment.
13. Gravity Principle
Utilize gravity to move material wherever possible, while respecting
limitations concerning safety, product damage and loss.
14. Safety Principle
Provide safe material handling equipment and methods which
follow existing safety codes and regulations in addition to accrued
experience.
 Principle of material handling
15. Computerization Principle
Consider computerization in material handling and
storage systems, when circumstances warrant, for
improved material and information control.
16. System Flow Principle
Integrate data flow with the physical material flow in
handling and storage.
17. Layout Principle
Prepare an operational sequence and equipment
layout for all viable system solutions, then select the
alternative system which best integrates efficiency and
effectiveness.
 Principle of material handling
18. Cost Principle
Compare the economic justification of alternate
solutions in equipment and methods on the basis of
economic effectiveness as measured by expense per
unit handled.
19. Maintenance Principle
Prepare a plan for preventive maintenance and
scheduled repairs on all material handling equipment.
20. Obsolescence Principle
Prepare a long range and economically sound policy for
replacement of obsolete equipment and methods with
special consideration to after-tax life cycle costs.
 Classification of Industrial transport

Industrial transport is divided into internal and external transport depending

on the area in which the conveyance occurs and its relationship to the
production process. In the manufacturing industry, internal transport
includes transport within a production shop (intrashop) and between shops
(intershop);
in the mining industry, it encompasses underground transport, surface
transport, and quarry transport (in open pit mining).
Intrashop industrial transport, an integral part of the production process,
is used to move workpieces and assemblies between working areas, sections,
and departments within a shop.
Intershop transport, which is generally not related to the production process
is used to move materials, semifinished goods, and finished products
between shops and warehouses located on the enterprise’s premises or
in the same industrial area.
• unit load: unit loads include piece-goods usually counted the
number of pieces( for example, machine parts and assemblies,
moulding boxes etc. ) and tared goods ( boxes, bags, barrels,
packaged items, containers etc.) and also other goods handled en
masse compromising more or less large-sized items of a definite
shape( ingots, building blocks, rolled beam logs etc.)
• Unit loads are characterized by their overall dimensions, shape,
piece weight convenience of stacking or suspension and by specific
properties, if any. The latter include temperature (for hot moulding
boxes or castings), explosiveness, inflammabilty, fragility etc.
• Bulk load: Bulk loads(materials)include various heap-
loaded,granular and powdered materials ( ore, coal, peat,
moulding sand, sawdust, cement etc.)
• Bulk loads are characterized by their physical and mechanical
properties such as lump-size, bulk (heaped) and specific
weight,moisture content, mobility of particles, angle of repose,
abrasivity and specific properties.
• Lump size: The quantitative distribution of the particles of a bulk
load, according to their sizes, is known as the granulometric
composition or lump size.
 Angle of repose
• Mobility of a bulk material is generally determined by its angle of repose.
• Angle of repose: When bulk granular materials are poured onto a
horizontal surface, a conical pile will form. The internal angle between the
surface of the pile and the horizontal surface is known as the angle of
repose and is related to the density, surface area and shapes of the
particles, and the coefficient of friction of the material. Material with a
low angle of repose forms flatter piles than material with a high angle of
repose. The term has a related usage in mechanics, where it refers to the
maximum angle at which an object can rest on an inclined plane without
sliding down.

• Repose Angle As shown in above figure, when bulk material is dropped on

the horizontal surface (ground), it forms a conical heap with certain
inclination (angle) with the horizontal surface. This inclination remains
more or less of fixed value and is known as repose angle (θ). Repose angle
depends on flowability of the material.
Angle of repose
 Measuring Angle of repose:
• Measuring Angle of repose: The static angle of repose can be determined with
various simple device, a hollow cylinder, for example(see fig.).The material is filled
into the hollow cylinder and when the latter is carefully raised, the material pours
out and forms a cone on the horizontal supporting surface. The angle of the
generatix of the cone is the angle of static repose. The angle of repose is measured
with angle gauges of different type. The dynamic angle of repose is obtained when
the horizontal supporting surface vibrates vertically.
• This angle is equal to the arctangent of the coefficient of static friction μs between
the surfaces. μs = tanφ (where φ is the angle of repose)
• The higher value of repose angle signifies less flowability of the material. The
repose angle for liquid is zero. The repose angle of material is an important
parameter because it decides the shape and volume of material in stockpiles,
storages and conveyance. It may be noted that the repose angle of a material is
susceptible to variation in moisture content.
• Typically, the lower the angle of repose of a dry material, the more flowable the
material is, and vice versa (Carr, 1965a). Higher angles (i.e., 50–60) indicate
material with difficult flow, while a lower angle, such as 30–40, represents a
material with relatively easy flow. Angle of repose gives a reproducible numerical
value, so it has been adopted as a common method to assess flow properties
(Craik and Miller, 1958). Generally the magnitude of angle of repose increases with
increase in moisture content.
 Properties
• Abrasivity: The property of particles of bulk materials
to wear away the surface they are in contact with when
motion is called the abrasivity of material. The extent
of abrasion depend on the hardness, surface condition,
shape and size of composing material .
• Other properties: moisture content,ability to pack,
stickness,fragility,toxicity, corrosiveness and
explosiveness etc. All the properties are should be
taken into account when conveying machines and
auxiliary equipment are designed and effective
measures taken to neutralize their harmful influence
on the equipment and ambient medium.
 (H.W) 1. Classification of conveying machine with example .

##Components of conveying machine

1. The load carrying member;

2. The pulling member transmitting motive power to the
load carrying member;
3. Intermediate support ( usually pulleys and rollers)
supporting the load carrying and pulling members;
4. The take up device giving the pulling member its initial
tension;
5. The drive unit setting the pulling member in motion, and
6. The framing.
Factors are considered for selection of conveying machine

I. Nature and properties of material

II. Required capacity of the equipment
III. Direction and length of conveying run
IV. Storage of the material at the head and tail ends
V. Processing steps and the movement of loads
VI. Specific local condition
VII. The type of power available
VIII. Hygienic consideration and
IX. Safety regulation
The choice of conveying machine will also be greatly
influenced by the unification and standardization of the
equipment
 Assignment:

i.) The capacity of continous conveying machine is Q= (GZ/1000), tons per hour

ii.) The relation between efficiency(η) and capacity(Q) of a conveying machine is η =

(QH/270N) (where N is motion power in hp)

iii.) The relation between efficiency(η) and friction factor(ω) of a conveying machine
is given : 1 / η = 1+ ω ,

iv.) Discuss manual handling system in Bangladesh.

 Belt Conveyor

• Belt Conveyor general construction: The essential of belt

conveyor are frame(1),both ends of which accommodate
pulleys: driving pulley (2) at the end, and take up pulley (3)
at the tail end ; the endless belt (4) wrapped around these
pulleys and supported on both runs, going and coming by
idler rollers or pulleys, the upper (5) and lower (6), secured
on frame (1) .the driving pulley receives its rotation from
drive unit (7). The material to be conveyed is loaded onto
the belt by one or more feed hopper (8) mounted on the
conveyor. The load conveyed by the belt is discharged over
the tail end pulley into discharge spout (9) or at any point
along the conveying run by means of special discharge
device. Belt cleaner (10) removes material adhering to the
outer belt face. (fig. see reference book)
Belt Conveyor
 Belt conveyor
Application: Belt conveyor are employed to convey a great variety of unit
loads and bulk loads along horizontal or gently inclined paths and also to
carry articles of light weight in line production from one production to
another. Belt conveyor are extensively used in all branches of industry and
are the principal conveying devices used in mechanize handling operations
in foundries(delivery and distribution of moulding sand), deliver fuel in
power plants, for ground level and underground haulage of coal and cores
in coal mining, delivery of coke and fluxes in metallurgy, transportation of
grain and all sorts of unit loads in stores and grain elevators for
mechanization of handling operations in each constructions and building
work, between processing steps in the light food industries.

Advantages:
1. High capacity (500 to 5000 m3/hr and more) ability to transport loads for
long distances (500 to 1000 m and up).
2. Simplicity of design and comparatively low own weight.
3. Reliable service and convenient operation.
 Belt conveyor

Why ply is used in belt conveyor?

• Rubberized textile belt are made from several layers, known as ply.
The plies are connected by vulcanization with natural synthetic
rubber.
• The plies in the belt form the carcass, absorbing longitudinal tensile
stresses and the impact of the load falling in the belt; the rubber
cover and “skim coats” serving to cement the plies, protect them
against moisture and mechanical damages. It also protect from
abrasive abrasion and cutting of the material conveyed.
Belt fastening vulcanization method: Vulcanization is the most reliable
method. To vulcanize the belt, the two ends of the belt are cut back a ply
at a time, cleaned, washed with gasoline, covered with rubber glue, fitted
together and pressed between the metal plates of a vulcanizing press. The
plates are heated by electric current (sometimes steam is used) to a
temperature of 140 to 1500 C. The belt is kept in the press under proper
pressure and temperature for about 25 t0 60 minutes, depending on the
number of plies and thickness of the covers. Fig. Rubberized textile belt
prepared for vulcanization.

Fig. Rubberized textile belt prepared for vulcanization.

 Function of idler & driving unit in a belt conveyor:

• Idler are used mainly in conveyors handling bulk loads, less

frequently unit loads, while runways and combined supports are
predominantly used for piece goods. According to their location on
the conveyor, idlers are classified as upper(supporting the loaded
stand on the belt) and lower(supporting the idle return strand of
the belt).
• Drive units: In the belt conveyors motive power is transmitted to
the belt by friction as it wraps around the driving pulley rotated by
an electric motor. The drive comprises the following parts: the
pulley, motor, and the transmission gear between the motor and
pulley. Drives of inclined conveyors include a braking device which
prevents slipping back of the loaded belt under the weight of the
material conveyed if the current supplying the motor is interrupted.
 APRON CONVEYOR:
• As distinct from belt conveyors, Apron conveyors usually handle heavy, larged-lumped,
abrasive and hot materials(shakeout foundry sand,castings, forged piece etc.). Washing,
painting, cooling, drying, annealing,quenching, or sizing operayions may be done en route.

Advatages:
1. They are able to handle heavy, large-lumped and hot materials.
2. They have a large capacity of 2000 tons per hour and over.
3. Apron conveyors are furnished with strong pulling chains, allowing for long distances between
the centres.
4. Run smoothly and noiselessly.
5. May be fed from overhead hoppers.
6. Follow a wide range of complex paths at a steeper transition from one direction to other and at
smaller curve radii then belt conveyor.
Disadvantages:
1. Considerable own weight of the apron and chains.
2. Complicated manufacture
3. High cost
4. A great number of hinged joints calling for continuously maintenance if the conveyor is to
function efficiently
Apron Conveyor
 Flight conveyor

• Flight conveyor: Flight conveyor are used to handle various powdered, granular and free
flowing lumpy materials.They are far less adapted for the transportation of fragile, moist,
sticky, packing and caking loads. Flight conveyors have found extensive application in coal
mining, where they are employed for coal handling, in concentration plants, chemical
industries etc. They are also used for transportation of hot ashes and slag. Special cable-disk
conveyors are employed for handling piece-goods delivered en masse, such as wood,
pulpwood, etc.

Advantages:
 Simplicity of design and ruggedness of construction.
 Ability to convey loads in two direction-on the upper and lower strands.
 Easy loading and unloading at any point along the convey run.
Disadvantages:
 Crushing and breaking of material during transportation.
 Rapid wear of the trough and moving parts.
 Considerable power consumption.
 Lower capacity (not over 150 to 200 tons per hour)
Flight conveyor
 Industrial truck
 Industrial trucks are trucks that are not licensed to travel on public roads
(commercial trucks are licensed to travel on public roads. Industrial trucks are used
to move materials over variable paths and when there is insufficient (or
intermittent) flow volume such that the use of a conveyor cannot be justified. They
provide more flexibility in movement than conveyors and cranes because there are
no restrictions on the area covered, and they provide vertical movement if the
truck has lifting capabilities. Different types of industrial trucks can be
characterized by whether or not they have forks for handling pallets,
provide powered or require manual lifting and travel capabilities, allow the
operator to ride on the truck or require that the operator walk with the truck
during travel, provide load stacking capability, and whether or not they can
operate in narrow aisle.

Uses: 1. Industrial trucks are used for predominantly for inter and intrashop
conveyance of piece-goods; bulk materials are sometimes conveyed in containers,
less frequently heaped in the body.
2. Industrial trucks are applied with profit where the path is complicated and contains
many branching, load traffic is not heavy and where conveyors, rail and overhead
equipment or expensive cranes are not expedient.
3. Industrial trucks are most often used in factories and plants to convey articles
between works places or to take them to the store, for the movement of loads at
railway stations, landings etc
 Industrial tractor

• A tractor is an engineering vehicle specifically designed to deliver a high tractive

effort (or torque) at slow speeds, for the purposes of hauling a trailer or machinery
used in agriculture or construction. Most commonly, the term is used to describe
a farm vehicle that provides the power and traction to mechanize agricultural
tasks, especially (and originally) tillage, but nowadays a great variety of
tasks. Agricultural implements may be towed behind or mounted on the tractor,
and the tractor may also provide a source of power if the implement is
mechanised.

Uses:
In factory and plant conditions, where the path is irregular and branched, the laying of
wires is generally unpredictable and therefore battery powered tractors are used
almost exclusively. Tractors are used in a wide field of activities, starting from
agriculture to earth moving, municipal waste handling, construction and
industries. A tractor may be fitted with different attachments to do different jobs
like sweeping, sidewalks, plough snow, excavate ground, scoop loading, bull dozing
etc.
Industrial truck
Tractor