Material Handling

➢Material handling is the movement of materials and goods from one

location to another.
➢It includes protecting, storing and controlling the materials from
manufacturing to distribution.
➢Material can be- raw material, semi finished or finished goods, packed
goods, scraps, waste etc.
➢Material handling can be used across industries, but is typically utilized
in warehousing, where goods need to be securely stored,retrieved and
shipped.
➢Material handling equipment utilizes manual, semi automated and
automated equipment to assist the movement and storage of materials
within the warehouse.

➢Material handling can be classified into 2 types:

○Manual handling
○Mechanised handling
➢In a typical manufacturing facility:
○25% of the workforce is used in material handling
○55% of the factory floor is reserved for it
○87% of the production time
○It may represent 15% to 70% of the total cost generated in the company

Goals of Material Handling

➢Reduce unit costs of production
➢Maintain or improve product quality, reduce damages and provide for
protection of materials
➢Promote safety and improve working conditions
➢Promote productivity
➢Promote increased use of facilities
➢Control
Types Of Material Handling Equipment

Material handling equipment usually falls under four main categories:

1. BULK HANDLING MATERIAL EQUIPMENT

2. ENGINEERED SYSTEMS
3. INDUSTRIAL TRUCKS
4. STORAGE AND HANDLING EQUIPMENT

1. Bulk Handling Material Equipment

These are equipment that transports, stores, and controls bulk materials.
They generally, move and store materials in a loose form. Following are
some of the bulk handling material types of equipment.

Hoppers: They are large funnel-shaped objects with openings that

close. They are used to pour loose materials into containers.

Reclaimers: These are large machines designed to pick up loose

materials from a company’s stockpile.
Conveyor belts: These are part of a conveyor system. Uses drums or
pulleys to rotate their belts and move materials in bulk from one location
to another.

Stackers: They are key to bulk material handling. There is automated

equipment that moves loose materials to stockpiles on their own.

Bucket or grain elevators: They are sometimes referred to as grain

legs. They vertically move bulk materials and transport these materials
on a production pathway and sometimes store them.

2. Engineered Systems

They are known as automated systems and are automated bulk material
handling equipment made to help transport and store materials. They
remove the need for manual labor to complete various tasks. Following
are some examples of this kind of equipment.
Automated Storage and Retrieval Systems (AS/RS):

It can handle lots of work and utilizes a shuttle to pick up loose materials
and then place them on needed parts of the system, and the picking
process can be manually operated or automated. These systems also
feature racks, shelves, and aisles for easy processing. They can also be
connected to a company’s network, making it easy for managers to
monitor their stock.

Automated guided vehicles (AGVs): AGVs are computer-operated

trucks featuring sensors and detectors. These vehicles can be entirely
autonomous, moving materials safely around your facility on preset
pathways.

Robotic delivery systems: Many facilities utilize automated robotic

delivery systems to transport materials. Companies typically use these
systems to transport materials on an assembly line.

Conveyor systems: Conveyor systems feature several devices and

mechanical assemblies that automatically transport materials throughout
a facility. These systems come in multiple varieties, like apron, cleated,
chain, overhead, and vehicle conveyor systems.

Apron conveyor systems Cleated conveyor systems Chain conveyor systems

3. Industrial Trucks

Industrial trucks (material handling trucks) refer to the different kinds of

transportation items and vehicles used to move materials and products
in materials handling. These transportation devices can include small
hand-operated trucks, pallet jacks, and various kinds of forklifts. These
trucks have a variety of characteristics to make them suitable for
different operations. Some trucks have forks, as in a forklift, or a flat
surface with which to lift items, while some trucks require a separate
piece of equipment for loading. Trucks can also be manual or powered
lift and operation can be walk or ride, requiring a user to manually push
them or to ride along on the truck. A stack truck can be used to stack
items, while a non-stack truck is typically used for transportation and not
for loading.
 Stacking Trucks

Non-stacking Trucks

Primary kinds of industrial trucks:

● Hand Trucks

Hand Trucks is one of the most basic pieces of material handling

equipment, feature a small platform to set the edge of a heavy
object on, and a long handle to use for leverage. Whatever is
being moved must be tipped so that it rests on the handle, and is
carried at a tilt to its destination.
 ● Side Loaders

Sideloaders, also known as VNA (Very Narrow Aisle) trucks, are

meant to fit in narrow warehouse aisles, as they can load objects from
different directions. They’re also good for long, awkward products that
need moving.It is a piece of materials handling equipment designed for
long loads.The operator’s cab is positioned up front on the left hand
side. The area to the right of the cab is called the bed or platform. This
contains a central section within it, called the well, where the forks are
positioned.The mast and forks reach out to lift the load at its central point
and lower it onto the bed.The load can then be safely carried on the bed
with the operator facing forward.
● Pallet Trucks

Pallet Trucks, also known as pallet jacks, are a type of truck

specifically for pallets. They slide into a pallet and lift it up to move
it. Pallet trucks come in both manual and electrical types.This is a
device that can greatly facilitate moving and lifting goods within the
working environment. This internal transport equipment makes
loading and unloading more efficiently, which results in a more
productive working day.

● Order Pickers

Order pickers lift the operator several feet above the ground on a
platform so they can retrieve or store goods on high shelves.These
are used at elevations higher than the second level of racking in a
warehouse or distribution center and can reach heights up to 390″
and will be used where pallet trucks, rolling ladders, and other
piece-picking methods are traditionally used.
4. STORAGE AND HANDLING EQUIPMENT

Storage equipment is usually limited to non-automated examples, which

are grouped in with engineered systems. Storage equipment is used to
hold or buffer materials during “downtimes,” or times when they are not
being transported. These periods could refer to temporary pauses during
long-term transportation or long-term storage designed to allow the
buildup of stock. The majority of storage equipment refers to pallets,
shelves or racks onto which materials may be stacked in an orderly
manner to await transportation or consumption. Many companies have
investigated increased efficiency possibilities in storage equipment by
designing proprietary packaging that allows materials or products of a
certain type to conserve space while in inventory.
some of the most common storage and handling equipments:

● Racks

Racks such as pallet racks, drive-through or drive-in racks,

push-back racks, and sliding racks, are a basic but important
method of storage, saving floor space while keeping their contents
accessible.
● Stacking frames

Stacking frames are stackable like blocks, as their name implies.

They allow crushable pallets of inventory, such as containers of
liquid, to be stacked to save space without damage.

● Shelves, bins, and drawers

Shelves, another basic storage method, are less open than racks.
Used with bins and drawers, they’re more able to keep smaller and
more difficult to manage materials and products stored and
organized. Shelving types can include boltless, cantilever,
revolving, and tie-down.
● Mezzanines

Mezzanines is a type of indoor platform, help to create more floor

space in a warehouse or other storage building for offices or more
storage. Typical types include modular, movable, rack supported,
building supported, and free-standing versions.
Manual Handling
Manual handling means using physical strength for moving materials
.This increases the possibilities of injuries and adds to the cost of
product.To reduce the number of material handling injuries and increase
the efficiency, material handling to be minimized by combining and
eliminating operations or mechanization.

Factors to be considered before

attempting to lift a load

➢ Material to be handled, terrain or the surface.

➢ The distance to be moved.
➢ The direction of the load to be taken.
➢ Volume and weight, shape and size.
➢ Frequency.
➢ Mode of handling.
Training and constant supervision will reduce the unsafe acts :

➢ Inspect materials for sleeves, jagged edges burns, rough or slippery

surfaces.
➢ Get a firm grip on the object.
➢ Keep fingers away from material resting points, especially when
setting down on the rollers.
➢ When handling timber, pipe or other long objects keep hands away
from the ends to prevent them from being pinched.
➢ Most strains and back injuries occur while lifting and setting down
objects by hands.

PROPER METHOD OF MANUAL HANDLING

➢ Consider the size, weight and shape of the object to be carried.

➢ Do not lift more than the object that can be handled comfortably. If
necessary get help from others.

➢ Set feet solidly.

➢ Straighten the legs to lift the object, and at the same time bring the
back to a vertical position.Look upward when beginning to lift

➢ Never carry a load you cannot see over or around.Make sure the
path of Travel is clear.

Handling materials of Specific Shapes

Sheet Metal:
Sharp edges of sheet metal is to considered and leather hand gloves and
safety boot to be used.
Barrel and Drum:
Barrel lifting handle or manila rope to roll up or down on a ramp to be
used.
Long Objects:
Long pieces of pipes, bars, timber should be carried over the shoulders
with the front end raised to prevent striking other employees. Shoulder
pads to protect abrasion on the
shoulder to be used.
Scrap Metals:
The irregularly shaped jagged, mingled objects and strips or pieces
may fly when
piece is removed from a pile. Workmen should wear goggles,
leather gloves, safety boot,leg guard and apron.
Gas Cylinders:
Compressed gas cylinders should be handled carefully. Do not drag
the cylinders on floors.
Boxes,cartons sacks:
The best way to handle boxes and cartons is to grasp the alternate
top and bottom corners.

Mechanical Material Handling Safety