Materials handling is

the art and science of moving,

packing and storing of
substances in any form.
 Function of production control
 Concerned with scheduling of production
control
 Material Handling adds value to product cost

 Material Handling increases effectiveness of in

plant layout by reducing the cost
 To Lowers unit materials handling cost
 To reduce manufacturing cycle time
 To provide better control of the flow of materials
 To provide better working conditions
 To provide Contribution for better quality
by avoiding damages to products
 To Increase storage capacity
 To provide higher at lower
productivity manufacturing costs
 Material should be moved as little as possible
 Reduction in time by using shortest routers and
mechanical material handling equipment
 The material movement should be in lots rather
than in individual units
 Design of material handling equipment should
be such that it can increase the effectiveness
 Gravity should be used
 Rehandling and back tracking of materials
should be avoided
 Periodically Repairing ,Maintaince & Checkup
of existing material handling equipments
 Factors affecting
the Selection of
Materials Handling
Equipment

Capabilities of the
Production Human element handling
problem involved equipment
available
 Volume of
Production to be
maintained

Production Layout of plant &

Problem building
facilities

Class of materials
to be handled
 Adaptability
Flexibility
Speed

Load
capacity

Space
Equipments requirements

Factors
Power

Supervision
required

Ease of
Maintaince
Cost Environment
 Human Factors

Capabilities of Safety of Personnel

manpower
MATERIAL HANDING EQUIPMENTS
Broadly material handling equipment’s can be classified into
two categories, namely:
(a)Fixed path equipment's, and
(b) Variable path equipment's.

(a) Fixed path equipment's which move in a fixed path. Conveyors,

monorail devices, chutes and pulley drive equipment's belong to this
category. A slight variation in this category is provided by the overhead
crane, which though restricted, can move materials in any manner within
a restricted area by virtue of its design.

(b) Variable path equipment's have no restrictions in the direction of

movement although their size is a factor to be given due consideration
trucks, forklifts mobile cranes and industrial tractors belong to this category.
1. Conveyers
2. Cranes, Elevators and
Hoists
3. Industrial Trucks
4. ROBOTS
Material Handing Equipments may be
classified in four major categories.
1.CONVEYORS - Conveyors are useful for moving material
between two fixed workstations, either continuously or
intermittently. They are mainly used for continuous or mass
production operations—indeed, they are suitable for most
operations where the flow is more or less steady.

Conveyors may be of various types, with rollers, wheels or

belts to help move the material along:
1. Conveyors-
 Gravity or powered devices
 Used for moving loads from one point to
point over fixed paths.
CRANES AND HOISTS The major advantage of
cranes and hoists is that they can move heavy
materials through overhead space.

However, they can usually serve only a limited area.

Here again, there are several types of crane and
hoist, and within each type there are various
loadingcapacities.
Cranes and hoists may be used both for
intermittent and for continuous production.
3.INDUSTRIAL TRUCKS
. Industrial trucks are more flexible in use than
conveyors since they can move between various
points and are not permanently fixed in one place.

They are, therefore, most suitable for intermittent

production and for handling various sizes and
shapes of material.
There are many types of truck petrol-driven,
electric, hand-powered, and so on.
4.ROBOTS
Many types of robot exist. They vary in size, and in
function and maneuverability(planned &regulated
movement).
While many robots are used for handling and
transporting material, others are used to perform
operations such as welding or spray painting.

An advantage of robots is that they can perform in

a hostile environment such as unhealthy
conditions or carry on arduous tasks such as
the repetitive movement of heavy materials.
SELECTION OF MATERIAL HANDLING
EQUIPMENTS
The following factors are to be taken into account while
selecting material handling equipment.
 
1. PROPERTIES OF THE MATERIAL
Whether it is solid, liquid or gas, and in what size, shape and weight it is
to be moved, are important considerations and can already lead to a
preliminary elimination from the range of available equipment under review.

2. LAYOUT AND CHARACTERISTICS OF THE BUILDING

Another restricting factor is the availability of space for handling. Low-
level ceiling may preclude the use of hoists or cranes, and the presence of
supporting columns in awkward places can limit the size of the
material-handling equipment. If the building is multi-storeyed, chutes or
ramps for industrial trucks may be used.
3. PRODUCTION FLOW
If the flow is fairly constant between two fixed positions that are
not likely to change, fixed equipment such as conveyors or chutes
can be successfully used.
4. COST CONSIDERATIONS
This is one of the most important considerations. The above factors
can help to narrow the range of suitable equipment, while costing can
help in taking a final decision. Several cost elements need to be
taken into consideration when comparisons are made between various
items of equipment that are all capable of handling the same load.
5. NATURE OF OPERATIONS
Selection of equipment also depends on nature of operations like
whether handling is temporary or permanent, whether the flow is
continuous or intermittent and material flow pattern-vertical or
horizontal.
6. ENGINEERING FACTORS
Selection of equipment also depends on engineering factors like door
and ceiling dimensions, floor space, floor conditions and
structural strength.
7. EQUIPMENT RELIABILITY
GUIDELINES FOR EFFECTIVE
UTILISATION OF MATERIAL HANDLING
EQUIPMENTS
1. As material handling adds no value but increases the production
cycle time, eliminate handling wherever possible. Ideally there should
not be any handling at all!
2. Sequence the operations in logical manner so that handling is
unidirectional and smooth.
 
3. Use gravity wherever possible as it results in conservation of power
and fuel.
 
4. Standardize the handling equipment's to the extent possible as it
means interchangeable usage, better utilisation of handling
equipments, and lesser spares holding.
 
5. Install a regular preventive maintenance programme for material
handling equipments so that downtime is minimum.
6. Location of stores should be as close as possible to the
plant which uses the materials. This avoids handling and
minimizing investment in material handling system.
7.Application of OR techniques such as queueing can be
very effective in optimal utilization of materials handling
equipment's.
8. A very important aspect in the design of a material
handling system is the safety aspect. The system designed
should be simple and safe to operate.
9. Avoid any wasteful movements-method study can be
conducted for this purpose.
10.Ensure proper coordination through judicious selection
of equipments and training of workmen.
 MATERIAL HANDLING COSTS
Here are the five areas of material handling that are
likely to cost you the most.
1. Over-Handling Material
Each time an item is touched, it's taking employee time and therefore
your money. Attention to detail is important, but for each time that
materials are moved, sorted, counted, stocked, or prepared for
storage or shipment, it's wasting a little more profit. Handling of any
item is no more than the minimum necessary.
2. Workflow Bottlenecks
With a poor material handling system, machines may sit idle waiting on raw
material, which is impacting productivity. It's important that the correct
materials in sufficient quantities be on hand before production starts.
Material handling should follow the shortest path possible.
3. Damaged Materials
Accidents or rough handling leading to breakage of goods is costly over
time. Incorrect techniques, outdated materials, and inadequate equipment
are usually to blame.
Everything that gets damaged, whether it's product loss, equipment
wear, or torn packaging, is a needless expense. It's estimated that
reusable packaging in the food industry alone could save over $2.5
million per year on costs.
4. Poor Space Management
Having adequate storage space is essential, but maximizing
existing space should be a priority before you consider buying or
leasing more. There are a variety of flexible steel construction options,
such as taller racks, overhead ceiling racks, and raised platforms in open
areas that can create multiple levels of storage area.

5. Inefficient Equipment
Equipment like forklifts can be very useful, but also bulky and
expensive. Lift trucks cost money to maintain.
The equipment you buy should be chosen for efficiency and economy
as well as functionality. Having the right equipment for the job, such as
scissor lifts or smaller electric forklifts, can reduce your need for bulkier
equipment.
 How to Reduce Material Handling Costs
Reduce Touch Labor
The best way to increase employee productivity and profit is to reduce
the number of times a worker is required to handle material. Material
handling doesn't create value – production does. Every minute spent
moving, sorting, preparing or storing material equates to lost productivity.
Material handling can be greatly reduced by delivering as many
materials as possible directly to the production floor.
Optimize Material Flow
When materials move through production, it's important for this path to
be as short as possible. Time spent transporting materials to and
from different operations on the assembly floor is time not spent in
production.
Prevent Damage
Damaged material equals lost profit. Proper storage procedures –
including monitoring shelf life, temperature and moisture levels – can
ensure products will be usable.
Increase Storage Capacity
Because real estate is expensive to buy and maintain, every inch of
storage space should be used to capacity. Packing a warehouse with
supplies should resemble filling a cube from side-to-side and top-to-
bottom. All available horizontal and vertical space should be filled
and organized before adding more space.

Deploy Equipment
Material-handling costs can be reduced by deploying the right
equipment in the right places.
Take advantage of gravity-fed movement before adding power-driven
equipment, by installing gravity conveyors, chutes and slide lines.
Using capital equipment like a forklift should be reviewed in combination
with alternatives such as pallet jacks to determine if less expensive
equipment can perform the required tasks.