PGCHM 2nd SEMESTER

Submitted To: Prof. Vijay Parekh

Topic:

Material Handling

Techniques in

Pharma Industry

Contribution: Done research.

Contribution: Done research.

Contribution: Done research and documentation

Contribution: Done research and documentation

Contribution: Done research and documentation

Acknowledgement

We take this opportunity to express our deep sense of gratitude to all at

KCCMS and, who have been very kind and helpful to us.

We lend our sincere and heartfelt acknowledgment towards our mentor Mr.

Vijay Parekh Sir for his right kind of guidance and motivation at our work.

We greatly appreciate his skillful approach towards the learning process.

Our words are never less to thank our beloved parents and friends who

encouraged us in every failure we faced.

Thanks …..

At last, but not the least, we would like to thank to those whom we may

have forgotten to mention, who helped and encouraged us throughout the

project, a

Heartfelt thanks.

Introduction

The handling of material is a human activity which has been performed since time

immemorial. The construction of the great pyramids and other historical monuments all

over the world called for the handling of various types of materials in various form

methods. Material handling has now become an important and specialized function of

all industrial activity. It is as important as, costs and the production process.

The manufacturing establishment first receives the raw material or spare parts which go

into the making of the product. They are conveyed to the place where they are stored.

Then they are taken to the preliminary fabrication or manufacture or the first production

process. Thereafter, they are again sent to the storage before they are moved into the

various stages of manufacturing operations.

Once the machine and processing operations are finished, the semi-manufactured or

finished product moves to final inspection and packaging. When all the manufacturing

operations are completed, it is again sent into storage to await transportation to

consumers.

Material handling is an essential production function. Organizations do not pay

adequate attention to this function. On an average, fifteen to twenty percent of the cost

of a product is incurred on material handling. The material handling cost must be

minimized by designing a proper system.

Material handling is undertaken at every stage of logistics activity, and is an integral part

of the other elements of logistics function. Material is handled during the production

process, warehouses or storage, in transport, during packing and when goods are

returned by the customer for one reason or the other. This would insure cost reduction

in the operation of the overall material handling function and increase productivity.

Material handling involves the following point:

a) Receiving or dispatching of goods involving unloading, loading;

b) Flow of material within the production unit and warehouse;

c) Weighing of raw materials and finished products at warehouse;

d) Sampling of raw materials, intermediate products and finished products at nominated

stages;

e) Documentation.

Material Handling Equipments

In any given set up the material handling equipments the layout of the stores,

production shops is to be coordinated well. They are closely related with each other.

Manual material handling

Here the initial investment is low. The equipment used in such systems are racks,

drawers, bins, hand trucks, and gravity conveyors. The operations are done manually.

So the problems related to labour control exist. The systematic working, handling higher

loads, speed of operation is generally at low level. Utilisation of available space cannot

be done beyond certain height due to natural human constraints

Mechanised systems

Mechanized and automatic equipments need higher level investment. On long term they

may be economical. Machine power, electrical energy or mechanical engineering

techniques are used in place of labour. They use forklift trucks, tow tractors, order

picker trucks, cranes and conveyors

Automated systems

The concept of a totally automated storage and retrieval system has been inviting the

attention of professionals to match the storage system/ with the rapid developments in

the technology. In automated systems computer programs are used to achieve controls

on the movements of equipments. Here the total movement is co-coordinated and

perfectly synchronized.

Pharmaceutical Manufacturing

Efficient handling and processing of particulates is critical to profitable manufacture of

pharmaceutical products. Over 75 percent of all pharmaceutical products are in the solid

dosage form and particulates are involved in almost every stage of the manufacturing

process. A recent US-FDA report on the pharmaceutical industry estimated that

worldwide cost savings from manufacturing improvements could be as high as US$ 90

billion per year. Regulatory constraints have traditionally encouraged an empirical and

incremental approach to process improvement. Quality assurance through inspection

rather than through design has previously been the norm. However, this is now

changing and there is a growing awareness of the need for improvement in the science

and engineering of drug development

Material Handling Equipments in Pharmaceutical Industry

Work Positioners

Stronger motor, larger battery 12Ah, Low

voltage protection.

A range of highly maneuverable, lightweight

lifts designed to take the strain out of any

lifting job from ground level to over shoulder

height.

Ideal for use in narrow aisles and confined

spaces. Perfect for all applications in

pharmaceutical industry.

Manual models: Operated via a manual hand winch. Auto brake system prevents

uncontrolled lowering.

Electric models: Automatic electronic overload protection system ensures safety.

Maintenance free and sealed batteries, automatic charger.

Quick change attachment options available.

MECHANIC LIFTER

Pallets are simply lifted by pulling the handle

backward (the leverage principle).

Saves a lot of time as no pumping is required.

Extremely low weight, about 25 kg.

Thanks to the low weight, the mechanic lifter can

easily be carried to other floors, put into a car.

Foldable. When not in use, it can be hung up on

a hook on the wall.

No hydraulic pump to repair, no oil can leak out,

no seals to replace.

Hydraulic Lift Pantograph

The Self Guided Vehicle (SGV) System operates 24/7 and is responsible for

transporting finished good pallets from six

production lines to eight flow racks.

All material movement requests are made

via pushbutton panels at the production

lines.

Once a finished good pallet is ready for

pickup at the production lines an operator

presses the appropriate pushbutton to

request removal of the pallet. An SGV is then

assigned to pick up the finished good pallet

and delivers it to an available flow rack. Forklift operators then take the finished

goods pallets from the flow racks and place them onto the stretch wrapper.

The SGV Manager software is responsible for controlling and monitoring the

entire SGV System and ensures efficient material movement throughout the

facility.

The system is equipped with opportunity charging which maintains the charge

level of the batteries during the 24/7 operation without requiring manual swap-

outs.

Benefits

• Reduced labor costs

• Improved operational efficiency

• Safe, reliable, timely delivery of materials.

Unit Load with Lift Deck

The Self-Guided Vehicle System proves efficient handling of production and

packaging materials when called upon to support the site’s “Work-In-Process”

(WIP) requirements.

The SGVS is responsible for transporting

material between two inbound conveyors and

two outbound conveyors.

Raw material or WIP items are introduced

into the system for storage until they are

needed by production or packaging. The

inbound process requires the SGVS to verify

that the load at the end of the inbound

conveyor is the appropriate load that the

site’s upper level system desires to have stored.

Once verified, the SGVS than transports the pallet to the correct AS/RS crane

aisle for storage. The outbound process calls for the SGVS to pull product from

the AS/RS outbound drop-off point and take it to the appropriate Chemical Stock

or Outbound Conveyors for use at other production locations throughout the

facility. During both operations, the site’s upper level host is kept informed of the

status of the load / order.

Automatic guided vehicles (AGVs) Moving finished goods from manufacturing to storage or shipping is the final

movement of materials before they are delivered to customers. These

movements often require the most gentle

material handling because the products are

complete and subject to damage from rough

handling.

Automatic guided vehicles (AGVs) operate

with precisely controlled navigation and

acceleration and deceleration minimizing the

potential for damage with even the most

challenging floor conditions. Other benefits

of using an AGV System include:

...Improved Safety with AGVs that move in a

controlled and predictable manner with safety

sensors for obstacle detection.

...Reduced Labor Costs by eliminating simple jobs related to material movement, and

reassigning those workers to areas where they can add more value to the company’s

products.

...Reduced Product Damage with gentle handling of loads.

...Improved Material Tracking is easy with computer controlled vehicles which

communicate with plant controls.

...No Plant Modifications/Bulky Conveyors Needed – which represent a permanent

obstacle and are inflexible for future plant modification.

Conveyors

When you think about hospitals, the emergency ward is the mission critical point.

But when you think about being a pharmaceutical company the distribution center is the

most critical point. This is because here the products have to be segregated and

shipped to its respective locations as per the

orders. As this is smart conveyor and only

runs when needed instead of continuously,

the added benefit is a reduction of power.

This reduction of power, along with other

benefits already expected.

The system is designed to activate

individual conveyor zones only when

a product is present. At other times,

the rollers shut off, which substantially

reduces electrical needs and decreases noise levels.

When an order is received, the message is sent to the order picker via a wireless

terminal. Picking occurs at several different places in the warehouse. Messages

are sent to the order pickers in a two level pick module where over-the-counter

and health and beauty aids are Components Of The System picked.

There are verification stations that digitally record the contents of each outgoing

carton and then they are put on a sliding shoe sorter which has been designed to

conserve energy and lower noise levels within a distribution center.

The orders are then sorted to one of ten shipping docks. The replenishment of

the carton flow rack is designed to include a conveyor so that the product is

delivered to the stocker reducing walk time and touch times.

The stocker has a specially designed step ladder that arches over the conveyor

to reach the top of the rack to replenish. This system is using MDR conveyor and

it is easy to repair in addition to being the most energy efficient conveyor in the

industry.

LIFT TABLE

Standard Safety Features

Upper platform lifted with aluminium

safety bar preventing descent on contact with obstructions.

Low- tension (24v) control box with up - down buttons.

Internal power pack equipped

with relief value against

overloading and

compensated flow valve for

controlled lowering speed.

Heavy duty cylinders with

drainage system and check

valve to stop the lift table

lowering in case of hose

burst.

Safety clearance between scissors to prevent trapping during operation.

Self Lubricating bushings on pivot points.

Removable lifting eye to facilitate handling and lift table installation.

STAINLESS STEEL DRUMS

Open Head:

Stainless steel open head drums

Modular design - use our funnels for dustfree

feeding

Capacities ranging from 0.5 liter to 1000 liter

Typical construction, 304, or 316L stainless steel

Ideal for Pharmaceutical, Cosmetic, specialty and Chemical Industries

Typical 320-grit finish

Pharmaceutical grade seals, FDA compliant

Smooth walled, ribbed, stackable, base ring.

Closed Head:

Safe transportation, storage and handling of

hazardous and high purity liquids

Can be designed to meet individual requirements

such as special connections, fittings, and coatings.

Stainless Steel Pharma Containers

Wide range of Capacities and Styles

Typical Construction Material is 304 or 316L Stainless Steel

Ideal for Pharmaceutical, Chemical and Food Processing

Industries

Designed in Conjunction with our Lifting and Blending Systems

Safe Transportation, Storage and Handling of Sensitive

Powders and High-Purity Liquids

Forkover w/ Single Fork Platen

A fleet of 6 Self Guided Vehicles (SGVs)

transport egg tray trolleys throughout the

facility.

The SGVs operate in 3 main areas of the

plant and are responsible for transporting full

trolleys between the inoculation machines,

incubation chambers, chillers, and harvesting

machines. The SGVs also transport empty

trolleys from the harvesting machines to the

washers.

Orders for material movement are generated by operators using handheld PDAs.

An operator simply selects an area in the plant, and is able to chose the pick-up

and drop-off locations from drop down menus on the screen.

As the SGVs travel throughout the facility, they interface with automatic doors to

facilitate load movement. At the harvester all orders are automatically generated

through a plant signal. When the harvester has emptied a trolley, an operator

moves it to a buffer location.

A plant signal indicates that an empty trolley is ready for transport to the

washers, and an order is assigned the SGV which can most efficiently complete

the task.

Conclusion

Automating DCs

Automated distribution systems enable distributors of pharmaceutical products to

manage inventory in real time, process orders quicker for shipment, customize the

auditing requirements prior to shipment, and also provide a host of reporting services.

These reporting services are customizable so that distributors can make operational

decisions that improve their customer’s satisfaction level. Switching to an automated

system inside the DC typically means using multiple technologies along with a discipline

of frequent re-slotting of products to make sure the proper SKUs are stored and picked

from the right systems.

Healthcare’s quality culture

When designing a material handling system for the healthcare industry, it also becomes

quickly apparent that there is a unique mindset among management and workers that

isn’t often seen in other industries. Workers moving cases of pet food don’t feel like they

work in a pet store; workers handling cartons of rum don’t feel like they work in a liquor

store. There is, however, a “medical culture” in the healthcare distribution community

that permeates the industry, from the skills and education of the worker to the

environment they work in.

The healthcare industry appears to have a more narrowly focused and trained “industry-

specific” workforce that tends to take their jobs seriously, because if they don’t

someone’s life could be in jeopardy. The industry as a whole demands a high level of

system accuracy and a healthier and cleaner work environment with less noise, which

immediately sets it apart from more traditional warehouse and distribution center

operations. These DCs often start the clean and quiet tone with the type of equipment

they select.

Quiet, efficient, conveyor systems

Perhaps one of the major advancements in reaching these industry goals was the

introduction of the 24V MDR (motorized drive roller) conveyor, which is not only 40% to

60% more energy-efficient, but also 45% quieter than traditional conveyor systems.

Also, since this type of conveyor is driven off of low-voltage motors, the need for large,

greasy, and loud A/C motors is eliminated. A conveyor system can be noise-free for one

of two reasons: Because it’s an efficient, environmentally friendly system, or because

it’s not running. That critical interruption is what needs to be avoided in an industry that

can literally live and die on the need for speed, accuracy, and minimum downtime. This

is where proper maintenance becomes paramount to keeping productivity at its peak.

Recommendations

The material handling industry must keep in step with the need for this ongoing growth

and change. This can be as simple as configuring a system that is flexible enough to be

manipulated with the ever-changing work environment, to literally “grow” as the

company grows.

“When we went into a new building,” says Exactech’s Godwin, “it was important for us

not to have a rigid system in place. TriFactor gave us a system that was very flexible,

that actually allowed us to move 10-foot sections of our conveyor around to fit our

requirements, like the train tracks you used to play with as a kid. This flexibility allowed

us to handle our growth rate without any negative impact to our customers.”

The material handling industry must realize that the healthcare industry has its share of

special requirements that make it unique. Only by staying abreast of the latest

technologies and regulations governing the healthcare industry will the industry be able

to stay ahead of the curve on the latest innovations in inventory management and

automation, which will ultimately result in more efficient distribution solutions.

Bibliography

Bowersox Textbook

CASE STUDY on MCKESSON

http://ttclifting.co.uk/materialhandling/material_handling_division.html

http://www.trifactor.com/Material-Handling-Case-Studies/West-Pharmaceutical

www.fmcsgvs.com

http://www.trifactor.com/

http://www.jbtc-agv.com/