MATERIALS HANDLING Material handling Defined as the art
- Slides: 45
MATERIALS HANDLING
Material handling • Defined as the art and science of moving, packing and storing of substances in any form. – Creation of time and place utility – Movement and storage of material at the lowest possible cost through the use of proper methods and equipments. – Lifting, shifting and placing of materials which effect a saving in money, time and place – Art and science of conveying, elevating, positioning, transporting, packaging and storing of materials
Importance of M H Efficient material handling is important to manufacturing operations. Materials sent by vendors must be unloaded, moved through inspections and production operations to stores and finally to the shipping department. These movements do not add value to the product but they do add value to the cost
• • • Material handling analysis is a subset of plant layout. Method study, plant layout and material handling are all part of the design of a production facility Material handling system and plant layout enhance effectiveness of each other. Efficient operation of appropriate material handling methods reduces costs and enables maximum capabilities to be derived from a given production facility
Objectives Main objective is to reduce the number of handlings as well as the overall cost of material handling equipment and reducing the distances through which the materials are handled. The other objectives:
Lower unit material handling costs Reduction in manufacturing cycle time through faster movement of materials and by reducing the distance through which the materials are moved. Reduction in manufacturing cycle time results in reduced work –in –progress inventory costs. Improved working conditions and greater safety in movement of materials Contribute to better quality by avoiding damage to products by inefficient handling Increased storage capacity through better utilisation of storage areas Higher productivity at lower manufacturing cost
Material handling principles • Eliminate handling • Keep moving • Use simple patterns of material flow • Carry pay loads both ways • Carry full loads • Use gravity – If not, make handling distance as short as possible – If not, reduce the time spent at terminal points of a route as short as possible – The simplest path is a straight line, if not, avoid back tracking, cross overs – If not, minimise time spent on transport empty by changing speed in return route -- If not, decrease carrying capacity by lowering the speed – If not use, use a cheaper power source
Material handling costs Cost of owning and maintaining the equipment Cost of operating the system ◦ This is generally elusive
The product will not be worth any more to the customer simply because it was moved Reduction of the cost ◦ Eliminating the handling itself whenever, wherever possible. ◦ Mechanising, largely by power conveyors, whatever handling still remains ◦ Making the necessary handling more efficient.
Organisation for materials handling The structure varies with industry, type of manufacturing process, the product manufactured, its bulk and its value In small firms, it may be one of the functions assigned to the plant engineer, purchasing manager or production manager. Big firms , a separate dept. itself is developed to study procedures and devise better handling techniques. When thus organised, they form part of industrial engineering division.
Unit load concept Unit load is a number of items, or bulk material, so arranged that the mass can be picked up and moved as a single object, too large for manual handling. Advantages: Disadvanatages: ◦ ◦ ◦ Cost of unitising & de unitising Equipment Bare weight of unitising medium Problem of returning empty pallet Transfer equipment often not available at both ends of the move
Flow pattern When drawn on paper, the flow pattern becomes a flow chart, which will help locate needless criss crossing and back tracking of material movements. Once unwanted movements are known, steps can be taken to eliminate or reduce such moves.
Advantages of a good flow pattern Increased efficiency of production Better utilisation of floor space Simplified handling activities Better equipment utilisation, less idle time Reduced in-process inventory More efficient utilisation of work force Reduced product damage Reduced walking distance Minimal accident hazards Basis for an efficient layout Faster supervision
Minimal back tracking Smooth production flow Improved scheduling process Reduced crowded conditions Better house keeping Logical work sequencing
Factors affecting selection of M H Equipments
Factors affecting the Selection of Materials Handling Equipment Production problem Human element involved Capabilities of the handling equipment available
Volume of Production to be maintained Production Problem Layout of plant & building facilities Class of materials to be handled
Adaptability Flexibility Speed Load capacity Space requirements Equipments Factors Power Supervision required Ease of Maintaince Cost Environment
Human Factors Capabilities of manpower Safety of Personnel
Types of Material Handling Systems 1. Equipments oriented systems : a) Convey or Systems b) Tractor transfer system c) Fork lift truck d) Industrial truck system e) Underground system 2. Material Oriented Systems a) Unit handling system b) Bulk handling system c) Liquid handling system
3. Methods oriented system a) Manual systems b) Automated systems c) Job shop handling system d) Mass production system 4. Function oriented system a) Transportation systems b) Conveying systems c) Transferring systems d) Elevating systems
Types of Materials Handling Equipment 1. 2. 3. 4. Conveyers Cranes, Elevators and Hoists Industrial Trucks Auxiliary Equipments
1. ConveyorsØ Gravity or powered devices Ø Used for moving loads from one point to point over fixed paths.
Belt Conveyor-Motor driven belt usually made of metal fabric
Chain Conveyor-Motor driven chain that drags material along a metal side base.
Roller Conveyor- Boxes , large parts or units loads roll on top of a series of rollers mounted on a rigid frame.
Pneumatic Conveyor. High volume of air flows through a tube carrying materials along with air flow.
2. Cranes, Elevators and Hoists These are overhead devices used for moving varying loads intermittently between points within an area.
Cranes –Devices mounted on overheard rail or ground wheels or rails. They lift, swing and transport large and heavy materials
Elevators –Types of cranes that lift materials –usually between floors or buildings
Hoists- Move vertically or horizontally. May be air hoist , electric hoist, chain hoist
3. Industrial Trucks- May be electric, deisal, gasoline or gas powered
Fort lift Truck
Pallet truck-
Auxiliary Equipments-Devices or attachments used with handling equipments to make their use more effective and versatile
Skid boxes
Expendable pallet
Miscellaneous Handling equipments Pipe lines Automatic transfer devices Automatic Guided vehicles ◦ No operators, flexibility in paths, signals through wires on floor. A remote control computer reqd. Industrial Robots ◦ Built in control – can be programmed – hence very versatile
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