MATERIAL HANDLING EQUIPMENTS ITS WORKING SAFETY MATERIAL HANDLING

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 Ø material should flow in a straight line Øuse gravity! It is free power Ømove more material at one time Ømechanize material handling Øautomaterial 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 Ø Pick the load Ø Transport the material Ø The material should be careful handled and placed at the desired point.

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

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, AS/RS systems. ØUnitizing Equipment: - palletizers storage,

FORKLIFT TRUCK A forklift truck (also called a lift 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 1920 s 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 FORK LIFT l l l l l 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.

l l l l 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 2 T, 4 T, 5 T, 10 T 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 l WHAT IS ITS CAPACITY? ITS SWL- SAFE WORKING LOAD e. g. 5 T, 20 T, 32 T, 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.

l PRINCIPLE OF OPERATION l THE TRAVERSER CONSISTS OF STEEL STRUCTURE MOUNTED ON 8 NO WHEELS MOUNTED ON ANTI FRICTION BEARINGS AND RUNNING ON TWO PARALLEL RAIL TRACKS. l ONE BROAD GAUGE TRACK IS FITTED ALONG THE LENGTH OF THE PLATFORM TO RECEIVE BG COACHES, WAGONS AND WHEEL SETS. l ALL THE DRIVING MECHANISMS AND CONTROL SYSTEM IS MOUNTED INSIDE THE OPERATORS CABIN WHICH IS RIGIDLY FIXED ON ONE SIDE OF TRAVERSER STRUCTURE. l POWER IS COLLECTED BY CURRENT COLLECTOR MOUNTED ON THE TRAVERSER.

l 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. l TRAVERSER WILL MOVE WITH THE COACH/WAGON OVER ITS PLATFORM BY THE DRIVING MECHANISM AND TRANSFER THE COACH/WAGON TO A PARALLEL TRACK.

CABIN l l l 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 l IT CONSISTS OF A SLIPRING MOTOR, COUPLING, ELECTROHYDRAULIC THRUSTER BRAKE, HELICAL GEAR BOX, JAW CLUTCH, CLUTCH SHIFTING ARRANGEMENT, GEAR AND CONTROL PANEL l POWER IS TRANSMITTED FROM MOTOR SHAFT TO GEAR BOX ENGINE SHAFT THROUGH BRAKE DRUM TYPE FLEXIBLE COUPLING l 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 l POWER FROM GEAR BOX OUTPUT SHAFT IS TRANSMITTED TO A CLUTCH GEARBOX UNIT THROUGH COUPLING

l GEAR BOX CONSISTS OF FEW GEARS AND ONE CLUTCH SHIFTING MECHANISM l TWO CLUTCH PINION ARE FREELY MOUNTED ON ROTATING POWER SHAFT. ONE SIDE OF EACH PINION HAS JAW TEETH. l ONE CLUTCH HAS JAW TEETH ON BOTH SIDES IS KEYED TO ROTATING SHAFT l CLUTCH CAN BE SHIFTED TO ENGAGE TO EITHER OF THE PINIONS. l ONE PINION IS ATTACHED TO THE TRAVELING SYSTEM AND OTHER IS ATTACHED TO THE HAULING WINCH

l 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 WHICH CHAIN SPROCKET IS FITTED. BEARING A CLUTCH IS FITTED ON MANUAL OPERATION UNIT SHAFT FOR ENGAGING OR DISENGAGING FROM THE DRIVING MECHANISM.

l AS/RS (Automated Storage/Retrieval System)

l AS/RS refers to a variety of computercontrolled 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.

l Problems of Conventional Storage System ØMuch time spend for searching ØOrders spending too much time in the factory, causing customer deliveries to be late. ØWaste much space Øexcess inventory ØWorkers are exposed dangers

ADVANTAGES OF AS/RS ØTo reduce labor cost and/or increase labor storage operation ØTo improve safety in the storage function ØTo improve control over inventories ØTo improve stock rotation ØTo improve customer service ØTo increase throughput productivity in

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