MATERIAL HANDLING

INDO-MIM
22nd JUNE 2021
What is material handling?
Material handling is the movement, protection, storage and control
of materials and products throughout manufacturing, warehousing,
distribution, consumption and disposal.

Mechanical materials handling is the movement of materials, articles or

things by such means as lift trucks, conveyors, or cranes and hoists. One
of the more frequent, higher risk outcomes of manual material
handling is musculoskeletal disorders (MSDs).

Manual material handling (MMH) means manually moving

or handling things by lifting, lowering, pushing, pulling, carrying, holding
or restraining. MMH is also the most common cause of occupational
fatigue, low back pain and lower back injuries.
The Importance of Material Handling in any Industry
For many large companies, their warehouse is the hub of their
operations. The success of their business depends on the safe and
efficient transport of their product from one area of the warehouse to
another. Here are 5 reasons why strict materials handling guidelines are
crucial to avoiding unnecessary costs.
1. Avoiding Workplace Accidents/Workplace Compensation Costs
About 21% of permanent disabilities and over 25% of temporary
disabilities can be attributed to workplace accidents due to the
mishandling of materials. The key to avoiding this is having the correct
equipment and machinery along with the well-trained staff. This will
greatly reduce employee injuries and lost sick days.
2. Efficiency Saves You Money
A well-organized warehouse with the most efficient materials handling
tools will translate into fewer misplaced items. Employees will waste
less time searching for products. This will save you money.
 
3. Reduces Product Loss
No company wants to incur product damage and loss in their warehouse
which will decrease your profit margin. Implementing good materials
handling practices in your warehouse will go a long way to preventing
product damage and loss.
4. The Importance of Warehouse Layout
Smart storage solutions will create a safe environment for your
employees. An open plan of your warehouse will facilitate easy materials
handling while minimizing hazardous conditions.
5.Customer Service Matters
As a consumer, I typically choose a company based on the quality of their
customer service. The faster employees can find the products in your
warehouse, the faster you can deliver them to your customers. Correct
materials handling contributes to streamlining the coordination of your
warehouse operations. Better customer service gives your company the
edge over your competition
Objectives of Material handling.

• Reduced cost using a material handling

• Reduced waste of material
• Improved work condition
• Enhanced distribution
• Optimized warehouse capacity
• Improved flow of material
• Full equipment utilization
• Workers’ safety
• Increase storage capacity.
Manual Handling

 Three components

Planning the lift

Lifting technique
Moving the load
Manual handling – before you start

 Stop and think - Plan the lift

 Does it need to be carried?
 Where is it going?
 Is it heavy?
 Does it need more than one person?
 Are you dressed for the job?
4 Key factors for
manual handling are

• TASK
• INDIVIDUAL
• LOAD
• ENVIRONMENT.
Manual Handling – lifting technique

 Place feet apart

 Placing one leg forward will improve

balance and control

 Try sliding the load towards you first

if you have to stretch
Manual Handling – lifting technique

 Bend your knees NOT your back

 Keep shoulders level and in line with
your hips
 Avoid jerking movements
 Lift head then your back
 Grip with your palms
 Keep arms close to your body
Manual Handling – Moving the load

 Keep the load close to the body

 Keep the heaviest side nearest your
body
 When pulling or pushing use your
body weight to move the load
 Avoid twisting your body when
turning
Excessive weight
(1) No woman or young person shall unaided by another person, lift, carry
or move by hand or on head, any material, article, tool or appliance
exceeding the maximum limit in weight set out in the following schedule

103[SCHEDULE Persons Maximum weight of material, article, tool or

appliance Lbs.
(a) Adult Male 55 Kgs.
(b) Adult female 30 Kgs.
(c) Adolescent male 30 Kgs.
(d) Adolescent female 20 Kgs.
(e) Male child (above 14 years) 16 Kgs.
(f) Female child (above 14 years) 14 Kgs.
Manual Handling

 Maximum recommended
load depends on the
height it is being lifted or
lowered

 The lower weights are

guidelines for women
Hazards Associated with Manual Handling - Heavy

 Lifting over 25kg load can result in back injury

Hazards Associated with Manual Handling - Heavy
Hazards Associated with Manual Handling - Sharp

 Potential Cuts on the fingers

Hazards Associated with Manual Handling –
Odd shapes

 Absence of grip to hold the load

 Obstruction of walking view

Hazards Associated with Manual Handling – Toxic
substances

 Skin exposure to chemicals

Coolant

Lubricants
Hazards Associated with Manual Handling – Toxic
substances

 Exposure to chemical dust, fumes & vapours

Common Injuries From Manual Handling

 Neck Strain
Common Injuries From Manual Handling

 Wrist Sprains  Back Sprains

Common Injuries From Manual Handling

 Shoulder pain  Upper back pain

Common Injuries From Manual Handling

 Slips, trips and fall

Common Injuries From Manual Handling

 Cuts
Health Hazards Resulting From Chemical
Handling

 Skin dermatitis
Health Hazards Resulting From Chemical
Handling

 Skin dermatitis
Health Hazards Resulting From Chemical
Handling

 Occupational respiratory & lung diseases

Health Hazards Resulting From Chemical
Handling

 Occupational eye diseases

Preventing Hazards
 Operated only by thoroughly trained
and qualified workers
Preventing Hazards
Eliminate/reduce crane
hazards by:

 Knowing
 Load

 Capacity of the crane

 When the load is safe to lift
 Always checking crane
load chart and never
exceed load limits
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
Preventing Hazards
 Slings
 Connects a crane hook to a load
 Proper selection
 Inspection
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
Preventing Hazards
 Illegal forklift operators
 Anyone under 18
 Anyone not properly trained
Preventing Hazards
 Driving the forklift
 Obstructed vision
 Travel path
 Approaching people
 Elevated platform
 Seat belts and ROPS
 Raising/lowering forks
 Safe distance
Preventing Hazards
 Elevating workers with forklift
 Standing on forks
 Lifting personnel
 Approved lift platform
 Restraining means
Preventing Hazards
 Driving forklift on grades/ramps
 Use extreme caution
 No turns
 Tilting and raising load
 Point load up the incline
Preventing Hazards
 Forklift operating speed
 Tip-overs
 Turning
 Avoiding collisions
 Wet and slippery floors
 Ascending/descending
 Obstructed vision
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
Preventing Hazards
 Use of dock boards for loading/uploading
 Bridging space
 Securing portable dock boards
 Handholds for dock boards
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
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.
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.
Employer Requirements
Comply with OSHA standards related to materials handling,
including:

 Training requirements
 Inspection requirements
Employer Requirements
 Complywith manufacturers’
requirements and recommendations for
materials handling equipment.
Recognizing Hazards
Identify potential hazards and possible solutions:
Recognizing Hazards
Identify potential hazards and possible solutions:
Recognizing Hazards
Identify potential hazards and possible solutions:
ANY QUERY