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Important concepts in Material Handling

Material Handling UnitizationPalletisationContainerization Inter-modal transportation and related benefits

• Lead-time

• Cost

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Material handling Definition: “the art & science of moving, packing &

storing substances in any form” * Receiving, moving, storing, dispatching activities* Impact on Quality, cost [capital as well as running],

Delivery & Safety Objectives of material handling1. Movement minimization2. Cost minimization3. Time minimization* Commonly used equipment- forklifts, EOT

Cranes, hoists, pulley blocks, trolleys, railroad cars, conveyers, ropes, slings, carousels, sortations, robotics

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Unitization, unit loads

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Benefits of Unitization & unit loads1. Ease of movement2. Standardization of handling equipment, 3. methods and training4. Reduction in time and cost of handling5. Inbound shipment checking is simplified6. product protection is improvedExamples: bottles in crates, steel sheets in coils,

steel ropes in coils etc. container is an example of unit load.

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Palletization

Pallet is a Unit load platform

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Benefits of Palletization

1. Unit load is secured on a pallet, pallet provides a secure base for the unit load

2. Leads to containerization, container is a (unit load) self contained, ie., unitized and palletized, shipping unit

3. Facilitates use of standardized handling equipment like a forklift or a crane

4. Palletized unit loads bring down time of handling and cost of handling

5. Ensures safe handling

6. Product is well protected

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Types of pallets1. Wooden pallets 2. Plastic pallets3. Composite pallets4. Refrigerated pallets: self-contained shipping

units for refrigerated materialsPallet poolscentral pools to collect pallets and issue pallets to

global business

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HOIST

EOT

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pulley block

forklift

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conveyers

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Automatic Guided Vehicles

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Principles of material handling1. Planning - high impact on cost2. Integration – material handling decision

should be part the corporate strategy-foundation, floors, layout, product

3. Standardization –handling methods, equipment, software

4. Work – minimum handling5. Ergonomics – tasks, equipment and human

beings6. Use of gravity-always use gravity to

advantage

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7. Unit load- handle only in unit loads8. Space utilization- use space and not area,

EOT rather than F/Ls 9. System – integrate handling & storage (O/H

tanks and pipe lines) and form Operational Material Handling System

10. Auomation - need based 11. Environment - explosive?

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Signs of Poor Material Handling1. Cluttered floor2. Accidents 3. Excess inventory4. High waiting time, high Through Put Time,

poor flow of material5. Excessive handling6. Poor quality of product, high scrap7. Lack of standardization8. Poor use of skilled labor

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Material handling system Types of Material Handling Systems: Manual,

mechanized, automatic, computerized Elements of the system: human, equipment,

storage, packaging Equipment selection & Purchase1. Full utilization of existing equipment2. Overall cost reduction3. Standardization 4. Integration with current system5. Alternate methods – production should not

halt

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6. Facility limitation, building, floors etc7. Future plan8. Maintenance support9. Life cycle cost