2.

0 Materials Handling

Jorge Luis Castañeda Gutiérrez

Mechanical Engineer- ITOrizaba. (1990)

Master of Science in Quality – UATx (1998)
PhD Logistics and Supply Chain Management – UPAEP (2013)

jorge.cg@apizaco.tecnm.mx

PhD @staneda jorge.cg@apizaco.tecnm.mx 1

Materials Handling,
Storage, Use, and
Disposal

Material Handling
System Design
 Outline
Definitions

Unit Load

Material Handling Equipment

 Importance of Material Handling
In a typical factory, material Handling accounts for:

MH
55%
MH
Factory Space

87%
Production
time
Product
70% Cost
15%
 Right amount
Material Handling Definitions
Right material

Right time
MH is the art and
science of moving, Right condition
storing, protecting, PROVIDE
and controlling Right place
material.
Right position

Right sequence

Right cost

Right methods
 New MHI Material Handling Definition

Material Handling is the movement, Operations

storage, control and protection of
materials, goods and products throughout
the process of manufacturing, distribution, Subjects
consumption and disposal. The focus is on
the methods, mechanical equipment, Business Processes
systems and related controls used to
achieve these functions.

Source: MHI website - Glossary

http://www.mhia.org/keywords/keyworddescr_templ
ate.cfm?keyword_id=762
Aligns with “progressive view”
of scope of material handling
defined by Apple, that is a
total system view (p. 166
text)
 Objectives of Material Handling

Increase the efficiency of

material flow

Reduce MH cost

Improve facilities utilization

Safety and working conditions

Manufacturing process

Increase productivity
Source: D.R.Sule, Manufacturing facilities
 Highlights of Definitions

Art and science

Right stuff in the right way

Efficient Storage and Movement

Movement of “parts” with

machines

Methods/Controls of movement
to meet facility objectives

Throughout the supply chain

 Material Handling is not restricted to
MH Examples the manufacturing or distribution
environment

Mass Transportation Hospitals

Mail Delivery Construction

 Material Handling Principles
Defined by the Material Handling Institute and the College-Industry Council on
Material Handling Education (CICME) (p.167 text):

1. Planning 6. Space Utilization (3-D)

(what,when,where) 7. System
2. Standardization 8. Automation
3. Work (cost x flow)
9. Environmental
4. Ergonomic
10. Life Cycle Cost
5. *Unit Load
(procurement-removal)

*Most important according to textbook authors

 Material Handling Systems Design

Define the objectives

& scope

Analyze the
requirements

Generate alternative
designs

Evaluate alternative
designs

Select the preferred

design

Implement the
preferred design
 Work simplification in MH

➢Framework for identifying MH solutions

Evaluate each movement:

1. Can the move be eliminated ?

Why? 2. Can the move be combined with another or within an in-
transit operation ?
3. Can the move be simplified ?
4. Can the sequence of moves be changed to advantages ?
 MH Planning Chart

➢Analyzing MH solutions

MH Planning Chart: (Figure 5.2, pg 173)

•Information w.r.t. a specific MH solution
•Record ALL movements (people + machines)

→ Reveals unnecessary movements and storage

 Unit Loads
• A unit load is the unit to be moved or handled at one time.
• A unit load includes the container, carrier, or support that will be used to
move materials.

Unit Load

Stacking Pallet sized by

ANSI (American National
Pallet Standard Institute)

Forklift
 Unit Load
• Examples: tote boxes, “cassette”, cartons, skids, pallets, pallet
boxes, intermodal container, one unit of product, etc.
• Most popular: plastic containers and pallets
• Factors for determining unit load/ container:
• Size of carrier
• Size and weight of items
• Space for storing loaded/unloaded container
• Equipment used for moving
• Cost, supply and maintenance
• Aisle widths, door sizes, and clear stacking heights
• Environmental regulations
 Unit Load and Handling System
The unit load is an integral
part of the material handling
system and a “simultaneous”
determination should be
made.

Design the
Handling/Storage
system

Design the
Unit Load
In-class Exercise: Unit Load and Cycle Time

We have a system with two

machines. Every unit of the product Machine 1 Machine 2
has to go through Machine 1 first
and then through Machine 2. 1 min/unit 1 min/unit

We move the product using forklift

trucks. The company has several of
them going around permanently. We
can use one whenever we need.
The move from Machine 1 to
Machine 2 takes two minutes. How many units should we move at
a time using the forklift truck to
minimize the time of completion of
The forklift truck moves a batch (or an order of 16 units?
a lot) of units at a time.
In other words, how big should the
unit load be to minimize completion
time?
M1 UL = 16 units Unit Load and Cycle Time
MH
M2
16 34

Lot size = 16 units

M1 UL = 8 units Machining = 1 min/unit
MH Operations 1 and 2
M2 MH = 2 min/trip
18 26

M1 UL = 2 units Large unit loads: longer cycle

MH times, fewer moves
M2
6 20

Small unit loads: lower cycle

M1 UL = 1 unit time, lower WIP, more frequent
MH handling
M2
4 34

MH time > processing time => MH constrained

 Unit Load Disadvantages

Time spent forming and

breaking down the unit
load.

Empty containers/pallets
may need to be returned to
their point of origin.

Cost of containers/pallets
and other load restraining
materials used in the unit
load
 Review Questions
1. The Unit Load remains the same throughout the
facility.
True or False?

2. Which statement is the most accurate?

a) Material Handling should be reduced as much as possible.
b) The materials, movements, and methods define the MH
system.
c) The unit load should be decided before any other MH
decisions.
d) The what, where, and when, defines the how and who.
 Classification of M.H. Equipment
I. Containers & unitizers

II. Material Transport Equipment

1. Conveyors
2. Industrial Trucks & Vehicles
3. Monorails, Hoists & Cranes
III. Storage & Retrieval
Equipment
IV. Automatic Identification &
Communication Equipment
MH Equipment Resources

• MHE Taxonomy (http://www.ise.ncsu.edu/kay/mhetax/index.htm)

• The Material Handling Multimedia Bank

(http://www.centor.ulaval.ca/MHMultimediaBank)

• Textbook (Appendix 5b)

• Material Handling Industry of America (http://www.mhia.org)

• CICMHE Website (http://www.mhia.org/cicmhe/)

• MaterialHandlingInfo.com (http://208.226.12.140/mhi/)
prevent hazards in MH

1. Identify types of material handling equipment.

2. Describe hazards associated with material
handling activities.
3. Identify methods to prevent hazards
associated with material handling equipment.
4. Recognize employer requirements to protect
workers from material handling hazards.
 Types of Equipment

Conveyors

Source: TEEX-Harwood

Source: OSHA

Powered
Industrial Trucks
 Types of Equipment

Cranes Slings

Source: TEEX

Source: OSHA
 Hazards Associated with Materials Handling

Factors contributing to injuries:

• Weight and bulkiness of objects
• Bending, twisting, turning movements

Source of photos: OSHA

 Hazards Associated with Materials Handling

Hazards:
• Improper operation of equipment
• Accumulated materials or clutter

Source: OSHA
Hazards Associated with Materials Handling

• Unsafe conditions of materials or containers

• Flammability or toxicity of some materials

Source: OSHA
 Hazards Associated with Materials Handling

• Weight of materials
• Binding ties or other devices that secure bundles
or bound materials

Source: OSHA
Hazards Associated with Materials Handling

• Falling objects
• Lifting, pushing, pulling, or otherwise manually
moving large, heavy items

Source: OSHA Source: OSHA

Hazards Associated with Materials Handling

• Improperly stacked materials

• Struck-by or caught-in/-between hazards

Source TEEX - Harwood Source: OSHA

Hazards Associated with Materials Handling

Types of injuries commonly reported:

• Sprains, strains, tears
• Soreness and pain
• Bruises and contusions
• Cuts, lacerations, punctures, crushing,
and amputations
Source: OSHA
Hazards Associated with Materials Handling

Examples of events or exposures leading to

injuries:

• Contact with objects

and equipment
• Transportation incidents Source: OSHA

• Exposure to harmful substances

or environments

Source: OSHA
Hazards Associated with Materials Handling

• Falls, slips, trips, or loss of

balance
• Repetitive motion Source: OSHA

• Overexertion

Source: OSHA
Preventing Hazards
Moving materials manually:
• Use devices to assist with holding
loads
• Wear PPE
• Use proper lifting technique
• Seek help for oversized loads
• Use blocking materials

Source of photos: OSHA

Preventing Hazards
Overhead and gantry cranes:
• Never move a load over co-workers or allow co-
workers to walk underneath
• Return the load block to its designated location
after use
• Do not leave the load
block low enough for
someone to run into
• Never leave a suspended
load unattended

Source: OSHA
Preventing Hazards
• Do not leave unused slings suspended on a
crane hook
• Store wall-mounted cranes against the wall
• Continuously observe equipment for any sign
of problems during operation.
• Don’t allow yourself to become distracted.
Preventing Hazards
• Operated only by thoroughly trained
and qualified workers

Source: UA
Preventing Hazards
Eliminate/reduce crane
hazards by:
• Knowing
• Load
• Capacity of the crane
• When the load is safe to lift Source: TEEX - Harwood

• Always checking crane

load chart and never
exceed load limits

Source: TEEX - Harwood

Preventing Hazards
• Inspection of crane by a qualified person
• Modified, repaired, or adjusted
• Post-assembly
• At least every 12 months
• Equipment not in regular use
• Visual inspection by a
competent person
• Prior to each shift
• Monthly
Source: OSHA
Preventing Hazards
• Slings
• Connects a crane hook to a load
• Proper selection
• Inspection

Source of photos: OSHA

Preventing Hazards

• Reduce sling hazards by:

• Lubricating
• Not shortening with knots, bolts, or other devices, or kink legs
• Keeping clear of loads
• Avoiding sudden movement
 Preventing Hazards
Forklifts
• Main causes of injuries
• Forklift overturns
• Forklift striking workers
on foot
• Persons crushed by forklifts
• Persons falling from forklifts

Forklift toppled sideways possibly due to shift in center of

gravity. Source: OSHA
Preventing Hazards
•Illegal forklift operators
• Anyone under 18
• Anyone not properly trained

Source of photos: OSHA

Preventing Hazards
•Driving the forklift
• Obstructed vision
• Travel path
• Approaching people
• Elevated platform
• Seat belts and ROPS
• Raising/lowering forks
• Safe distance

Source of photos: OSHA

Preventing Hazards

•Elevating workers with forklift

• Standing on forks
• Lifting personnel
• Approved lift platform
• Restraining means

Source: OSHA
Preventing Hazards

• Driving forklift on
grades/ramps
• Use extreme caution
• No turns
• Tilting and raising load
• Point load up the incline

Source of photos: OSHA

Preventing Hazards

•Forklift operating speed

• Tip-overs
• Turning
• Avoiding collisions
• Wet and slippery floors
• Ascending/descending
• Obstructed vision

Source of photos: OSHA

 Preventing Hazards

•Avoiding excess weight

• Do not exceed weight capacity
of forklift.
• Center loads and secure to keep
from shifting to maintain
balance of weight

Source of graphics: OSHA

Preventing Hazards

•Use of dock boards for

loading/uploading
• Bridging space
• Securing portable dock boards
• Handholds for dock boards

Source: OSHA
Preventing Hazards

•Exiting the forklift

• Set brake, lower forks/lifting
carriage, neutralize controls
• Stand-up type forklift

•Riding the forklift

• No passengers allowed
• Exception – seat is provided Source of photos: OSHA
Preventing Hazards
•Avoiding struck-by/crushed-by
• Don’t jump from an overturning, sit-down type
forklift.
• Stay with the truck, hold on firmly, and
lean in the opposite direction of the overturn.

Source: OSHA
Preventing Hazards
•Forklift training – do not operate a forklift
without proper training
•Reporting damage – any damage or
problems that occur to a forklift during a
shift should be reported to the supervisor.

Source: OSHA
Employer Requirements

Comply with OSHA standards related to materials

handling, including:
•Training requirements
•Inspection requirements

Source of photos: OSHA

Employer Requirements

•Comply with manufacturers’

requirements and recommendations for
materials handling equipment.

Source : OSHA
Recognizing Hazards

Identify potential hazards and possible solutions:

Source: OSHA
Recognizing Hazards
Identify potential hazards and possible solutions:

Source: OSHA Source: TEEX - Harwood

 Recognizing Hazards
Identify potential hazards and possible solutions:

Source of photos : OSHA -UFCW

Source of photos : TEEX Harwood
Knowledge Check
1. What is the minimum age requirement
for the operation of a forklift, regardless
of training?
a. 16
b. 18
c. 21
d. 25

Answer: b. You must be at least

18 years old to operate a forklift.
 Knowledge Check
2. A way to prevent materials handling hazards is
to ___.
a. refuse to allow personnel to ride equipment without
a seat and seatbelt
b. report all damaged equipment immediately
c. operate within manufacturer’s specifications
d. All of these

Answer: d. All of these are good ways

to prevent materials handling hazards.
Knowledge Check
3. Which of the following is a method
for eliminating or reducing crane
operation hazards?
a. A competent person should visually inspect the
crane once a year
b. Never exceed the load limit by more than 10%
c. Never move a load over co-workers
d. All of these

Answer: c. Never move a load over co-workers

or allow co-workers to walk underneath.
Knowledge Check
4. Employers must comply with OSHA
standards related to materials handling,
including training and _____.
a. equipment
b. operations
c. inspection
d. all of these

Answer: c. Employers must comply with OSHA

standards for training and inspection.
PhD @staneda jorge.cg@apizaco.tecnm.mx 63