MATERIAL HANDLING

EQUIPMENTS,
ITS WORKING & SAFETY
 MATERIAL HANDLING

Material handling is the function of moving the

right material to the right place in the right time, in the
right amount, in sequence, and in the right condition to
minimize production cost.

The cost of MH estimates 20-25% of total manufacturing

labor cost
 TO PROMOTE PRODUCTVITY

 material should flow in a straight line

use gravity! It is free power
move more material at one time
mechanize material handling
automate material handling
 TYPE OF MATERIAL HANDLING

MANUAL MATERIAL HANDLING

MECHANICAL MATERIAL HANDLING

manual material handling accounted for 35% of

the more serious (lost-workday) injuries at surface
locations.
 PARTS OF MATERIAL HANDLING

 Pick the load

 Transport the material
 The material should be careful handled and placed
at the desired point.
 MATERIAL CHARACTERISTICS

Category Measures
Physical state Solid, liquid, or gas
Size Volume; length, width, height
Weight Weight per piece, weight per unit
volume
Shape Long and flat, round, square, etc.
Hot, cold, wet, etc.
Condition Explosive, flammable, toxic; fragile,
etc.
Safety risk and risk of
damage
OVER VIEW OF MATERIAL HANDLING
EQUIPMENT

Material handling equipment includes:

Transport Equipments :- Fork lift trucks, E.O.T.

Crane, traversar, conveyors, cranes, trucks, and hoists.

Storage Systems:- bulk storage, rack systems, storage,

AS/RS systems.

Unitizing Equipment:- palletizers

 FORKLIFT TRUCK

A forklift truck (also called a lift truck, a fork

truck, a forklift, or a tow-motor) is a powered
industrial truck used to lift and transport
materials. The modern forklift was developed in
the 1920s by various companies including the
transmission manufacturing company Clark and
the hoist company Yale & Towne Manufacturing
. The forklift has since become an
indispensable piece of equipment in
manufacturing.
 SAFETY PRECAUTION FOR FORK LIFT

 Fork lift truck should be used for industrial purpose &

not for carrying passangers.
 Drive it carefully and slowly.
 While driving do not move the forks up and down.
 On taking turn , slow down the fork lift truck.
 While picking the load the height of the lift from the
ground should be above 8 inch.
 Ensure to handle only stable load.
 No riders, unless there is an approved seat.
 Do not drive with forks in raised condition.
 See left and right & drive carefully.
 Body parts should not be outside the fork lift truck.
 When the fork lifter is empty, it should be driven
slowly and carefully.
 When the load is infringing the vision of driver, the
fork lifetr should be driven in backward direction.
 Do not apply brake on acceleration.
 Traffic rules must be followed.
 Driver must slow down and sound the horn at cross
and blind spot.
 On visualizing any hydraulic oil leakage, the fork lifter
should be immediately stopped .
 Damaged or defective parts must be replaced from
the fork lift truck immediately & preventive
maintenance schedules should be adhered strictly.
ELECTRICAL OVERHEAD TRAVELLING CRANE
DO YOU KNOW SWL OF SLING?
SLING HAS ITS OWN CALACITY i.e. SWL.
IT IS IN FORM OF 2T,4T,5T,10T etc.

HOW TO READ SWL ON SLING?

IT IS MENTIONED ON SLING CRIMPING.

HOW TO USE SLING SAFELY?

DO NOT USE SLINGS WITH TWIST, BROKEN STRANDS,
KNOTTING, BOLTING,OR BY ANY SHORTNED WAY.
 SAFE EOT OPERATION

 WHAT IS ITS CAPACITY?

ITS SWL- SAFE WORKING LOAD

e.g. 5T, 20T, 32T, etc.

it is tested annually by COMPETANT PERSON.
IT IS RISKY. CRANE CAN BE LAID FOR BREAKDOWN.
DO NOT OVERLOAD SAID CRANE CAPACITY.
TAKE TRIAL OF EOT AT START OF EVERY SHIFT.

CONCENRTATE ON YOUR WORK. DO NOT CHIT-CHAT WHILE

CRANE IS WORKING & MATERIAL IS BEING SHIFTED.

ALWAYS LIFT THE MATERIAL LOAD STRAIGHT UP.

LIFT THE MATERIAL LOAD ONLY AFTER CONFIRMATION OF

BALANCE IS MADE BETWEEN LOAD AND SLINGS.

HANDS & FINGERS SHOULD NOT BE PLACED ON LIFTED LOAD

NEVER SHORTEN SLINGS BY KNOTTING, BOLTING OR BY ANY

MEANS.
DO NOT KEEP MATERIAL HANGING IN AIR. IT CREATES LOAD
ON SLINGS,WIRE ROPE,CRANE.

BE ALERT & KEEP AWAY THE PEOPLES MOVING UNDER THE

EOT WHILE TRAVELLING OF MATERIAL IS BEING CARRIED
OUT

DO YOU KNOW ALL SWITHES,BUTTONS ON PENDANT?

GROUND SWITHES ARE WORKING.

REPORT ANY VIBRATION,ABNORMALITY WHILE

RUNNING/LOADING/UNLOADING OF MATERIAL.

ANY SPECIFIC LOCATION WHERE CRANE IS ABNORMAL?

REPORT TO COMPETENT AUTHORITY.
TRAVERSER
IT IS A MATERIAL HANDLING EQUIPMENT USED IN RAILWAY
WORKSHOP. IT IS USED FOR TRANSPORTING RAILWAY
COACHES FROM A RAILWAY TRACK TO HORIZONTALLY
SHIFTED PARALLEL RAIL TRACK IN OUTDOOR CONDITION.

IT IS BUILT IN ADEQUATE SAFETY MARGINS TO MEET THE

NORMAL IMPACT DURING LOADING AND UNLOADING OF
COACHES AND THE WAGONS ON THE CAR.
 PRINCIPLE OF OPERATION

 THE TRAVERSER CONSISTS OF STEEL STRUCTURE MOUNTED

ON 8 NO WHEELS MOUNTED ON ANTI FRICTION BEARINGS
AND RUNNING ON TWO PARALLEL RAIL TRACKS.

 ONE BROAD GAUGE TRACK IS FITTED ALONG THE LENGTH OF

THE PLATFORM TO RECEIVE BG COACHES, WAGONS AND
WHEEL SETS.

 ALL THE DRIVING MECHANISMS AND CONTROL SYSTEM IS

MOUNTED INSIDE THE OPERATORS CABIN WHICH IS RIGIDLY
FIXED ON ONE SIDE OF TRAVERSER STRUCTURE.

 POWER IS COLLECTED BY CURRENT COLLECTOR MOUNTED

ON THE TRAVERSER.
 WHEN MOTOR ROTATES AND THE JAW CLUTCH IS ENGAGED
TO THE TRAVELLING MECHANISM , THE TRAVERSER MOVES
OVER THE RUNWAY TRACK AND WHEN THE CLUTCH IS
ENGAGED TO THE HAULING MECHANISM , AND THE WINCH
PULLS THE COACH /WAGON OVER THE TRAVERSER
PLATFORM.

 TRAVERSER WILL MOVE WITH THE COACH/WAGON OVER ITS

PLATFORM BY THE DRIVING MECHANISM AND TRANSFER
THE COACH/WAGON TO A PARALLEL TRACK.
 CABIN

 IT IS BUILT UP FROM ROLLED

STEEL SECTION.
 TWO DOORS ARE FITTED AT
TWO SIDES.
 TOP OF THE CABIN IS COVERED
WITH INDUSTRIAL TOUGHED
SHEET.
 COMPLETE DRIVING UNIT IS
MOUNTED INSIDE THE CABIN.
 WINDOWS ARE ALSO PROVIDED
FOR VENTILATION.
 WHEEL BOGIE ASSEMBLY

THERE ARE FOUR

DRIVING AND FOUR
NON DRIVING WHEELS

DIA OF EACH WHEEL

IS 500 MM AND EACH
IS OF DOUBLE
FLANGED TYPE AND
FITTED ON THE
MACHINE AXLE BY 2
NO. ANTIFRICTION
SPHERICAL ROLLER
BEARING.
 DRIVING MECHANISM

 IT CONSISTS OF A SLIPRING MOTOR, COUPLING, ELECTRO-

HYDRAULIC THRUSTER BRAKE, HELICAL GEAR BOX, JAW CLUTCH,
CLUTCH SHIFTING ARRANGEMENT, GEAR AND CONTROL PANEL

 POWER IS TRANSMITTED FROM MOTOR SHAFT TO GEAR BOX

ENGINE SHAFT THROUGH BRAKE DRUM TYPE FLEXIBLE
COUPLING

 ONE BRAKE ACTS ON BRAKE DRUM FITTED ON MOTOR

EXTENSION SHAFT AND MANUALLY OPERATED HYDRAULIC
FOOT LEVER TYPE BRAKE IS FITTED ON THE BRAKE DRUM
NEOPRENE BUSH PIN TYPE FLEXIBLE COUPLING

 POWER FROM GEAR BOX OUTPUT SHAFT IS TRANSMITTED

TO A CLUTCH GEARBOX UNIT THROUGH COUPLING
 GEAR BOX CONSISTS OF FEW GEARS AND ONE CLUTCH
SHIFTING MECHANISM

 TWO CLUTCH PINION ARE FREELY MOUNTED ON ROTATING

POWER SHAFT .ONE SIDE OF EACH PINION HAS JAW TEETH .

 ONE CLUTCH HAS JAW TEETH ON BOTH SIDES IS KEYED TO

ROTATING SHAFT

 CLUTCH CAN BE SHIFTED TO ENGAGE TO EITHER OF THE

PINIONS.

 ONE PINION IS ATTACHED TO THE TRAVELING SYSTEM AND

OTHER IS ATTACHED TO THE HAULING WINCH
  HAULING WINCH

IT CONSISTS OF ONE DRUM

ASSEMBLY, WIRE ROPE AND
GEAR FOR TAKING POWER
FROM THE DRIVE UNIT.

THE WINCH IS USED TO HAUL

WAGONS, COACHES AND
WHEEL AXLES ON THE
TRAVERSER AND OFF THE
TRAVERSER.

A HAULING ROPE IS WOUND

ON THE DRUM.
 MANUAL OPERATION UNIT

TRAVERSER CAN BE OPERATED

MANUALLY BY TWO OPERATING
HANDLES ARE FITTED AT BOTH SIDE OF
MOUNTED SHAFT ON
BEARING
WHICH CHAIN SPROCKET IS
FITTED.

A CLUTCH IS FITTED ON MANUAL

OPERATION UNIT SHAFT FOR
ENGAGING OR DISENGAGING
FROM THE DRIVING MECHANISM.
 AS/RS
(Automated Storage/Retrieval System)
 AS/RS refers to a variety of computer-controlled
methods for automatically depositing and retrieving
loads from defined storage locations.

AS/RS are used widely in both Manufacturing and Distribution

operations to hold and buffer the flow of material moving through
the process to the ultimate end-user.
 Problems of Conventional Storage System

Much time spend for searching

Orders spending too much time in the factory, causing

customer deliveries to be late.
Waste much space
excess inventory
Workers are exposed dangers
 ADVANTAGES OF AS/RS

To reduce labor cost and/or increase labor productivity in

storage operation
To improve safety in the storage function
To improve control over inventories
To improve stock rotation
To improve customer service
To increase throughput
THANKS