*MATERIAL

HANDLING

*MATERIAL HANDLINGMATERIAL HANDLING MAY BE DEFINED AS THE ART AND SCIENCE OF MOVEMENT, HANDLING AND STORAGE OF MATERIALS DURING DIFFERENT STAGES OF MANUFACTURING CONSIDERED AS MATERIAL FLOW INTO , THROUGH AND AWAY FROM THE PLANT

* MATERIAL HANDLING IS THE TECHNIQUE OF GETTING RIGHT GOODS SAFELY TO THE RIGHT PLACE, AT THE RIGHT TIME AND AT THE RIGHT COST

*SYMPTOMS OF POOR MATERIAL HANDLINGLong queue of vehicles at the receiving store.Excessive loading time at despatch point.Transporters complaints of excess loading and unloading time.Congestion at receipt and despatch areas we may have to jump over the material hehehehOver crowded floors with blank overhead space.These indicators in insolation do not mean bad material handling, but then, all of them present together mean bad material handling. Cont.

*Frequent cases of material mix up and assembly being supplied wrong parts.Excessive loading & unloading time at the time of machine setup/testing.Piling of wip at different locations material waits for its turn.Damages during handling causing rework/rejection cont.

*Interrrupted workload due to improper mh next op doesnt work due to unfinished prior op.Large number of contract labour for mhEver rising mh costsToo many/too few gangwaysGangways blocked ( too frequent cases)Badly damaged floors Cont.

* Accidents while handling materialsPoor housekeepingDifficulty in locating things when required.Hunting for trolleys/trays/mh equipmentProduction people engaged in movement of materialsTransit damages leading to customer complaints

*OBJECTIVES OF MATERIAL HANDLINGSpeed and economy in movement of materials material shd move smoothly.Minimisation of cost of material handlingPrevention of damages to materialsSafety in materials handling cont.

*Minimisation of fatigue and drudgery

Higher plant efficiency

Better house keeping - appearance

Efficient store keeping finding inventory becomes easy.

Lower investment in work-in-process

*MATERIAL HANDLING PRINCIPLES1. PLANNING PRINCIPLES2.OPERATING PRINCIPLES3.EQUIPMENT PRINCIPLES4. COSTING PRINCIPLES5.GENERAL PRINCIPLESPlant Layout b. Delegation of responsibilityc. Minimization of RehandlingUnit loadb. Gravityc. Flow of materialMechanismb. Terminal timec. Dead Wt.d. Standardizatione. Maintenancef. Speedg. Versatilitya. Equip. selectionb. Replacementc. Handling CostSafety b. Training c. Location d. Treatmente. Identificationd. Space saving

*PLANNING

PRINCIPLES

*A. Plant layout principle

Good plant layout and minimum materials handling are akin to each other related to each other theyre cousin brothers.

*B. DELEGATION OF RESPONSIBILITY PRINCIPLE

EFFICIENCY IN MATERIAL HANDLING RESULTS WHEN IT IS RECOGNISED AS AN IMPORTANT FUNCTION AND IS GIVEN WEIGHTAGE EQUAL TO THAT OF OTHER COST CENTRES

Principles of Material Handling Planning Principles Operating principles Equipment principles Costing Principles General Principles

Planning Principlesa) Plant Layout PrincipleGood Plant layout minimizes material handling

b) Delegation of Responsibility PrincipleGiving equal weight-age to material handling Separate Department Separate Workers Not lifting the materials beyond waist height Mechanical Handling of heavy materials.

Planning Principles..contc) Minimization of Re-handling Principle direct movements of materials Materials to be kept at working height Use of Platforms, Pallets Not mixing the materials Elimination of similar movements Reduction of picking and putting

Planning Principles..contd) Space Saving Principle Not using floor space Use of fork lift trucks Preventing congestion use of monorail devices

Operating Principlesa) Unit Load Handling Principle Bulk handling Careful handling of fragile materials

b) Gravity Principle Self rolling & sliding of materials

Operating Principles.contc) Flow of Material Principle Linear movement of Material Avoidance of Re-handling

Equipment Principles a) Mechanization PrincipleHeavy materials should be lifted and moved mechanically Mechanization can help reduce expenditure incurred by a firm on labor chargesMechanize only the necessary part of material handling operations. For e.g. conveyors in process industries

Equipment Principles.cont b) Terminal Time PrincipleWaiting time at terminal points should be reducedPalletisation and unit load concepts should be usedc) Dead Weight PrincipleDead weight of the equipment should be reduced to minimumWeight of trays, trolleys should be least possible

Equipment Principles.cont d) Standardization PrinciplePermits interchangeability of equipment between departmentsReduces repair costReduces investment in spares inventory

Equipment Principles.cont e) Maintenance PrincipleRepairs and replacements must be anticipatedPreventive maintenance programme should be implemented for all key material handling equipment

f) Speed PrinciplePallets should be made square in shapeTwo-way traffic rule must be followedGangways should be kept clearSufficient number of boxes, pallets should be kept at work place

Equipment Principles.cont g) Versatility PrincipleEquipment with variety of uses should be preferredSpecial equipment with limited range will only be economical if total time is justified and no further changes in the plant are foreseenSuch a difficulty does not arise for larger plants

Costing Principles a) Equipment Selection PrincipleFactors to be considered while selection:Material to be handledPlant buildingsLayoutSpeed requirementsMaterial flow patternMethod of production

Costing Principlescont Factors to be considered while selection (cont.):Distance over which material is to be movedSafety requirementInstallation & operating costMaintenance of material handling equipmentSkill requirementsFlexibility of material handling equipmentHuman factor

Costing Principles.cont b) Replacement PrincipleEquipments should not be retained beyond their economic periodRetaining for too long can increase repairs cost and cause production hold ups due to eventual breakdowns

c) Handling cost appraisal principleMaterial handling cost should be analyzed periodically to highlight areas of improvement

General Principles a) Safety PrincipleHot materials should be handled & moved mechanicallyGangways should be kept well lightedAisles should be wideWorkmen should wear protective clothing Safety regulations should be strictly adhered to

General Principles.cont b) Training PrincipleEach employee should be given basic training in material handling techniquesWorkmen after performing the operation on a job should keep it in a position that is ready to move onc) Identification PrincipleMaterials must be labeled properly failing which it may be required to re-open the pallets and boxes

General Principles.cont d) Location PrincipleAll equipments should be placed at the right place and at the right time

e) Material Treatment PrincipleScrap and end pieces are as important as production materialsMaterial handling costs are not related to the cost of material but to their bulk and physical and chemical characteristics

*D. LOCATION PRINCIPLE

ALL HANDLING MATERIALS SHOULD BE PLACED AT THE RIGHT PLACE AND AT THE TIME TO AVOID HUNTING AND DELAYS IN MATERIALS HANDLING.

*MATERIAL TREATMENT PRINCIPLE

ALL TYPES OF MATERIALS SHOULD BE TREATED AS IMPORTANT SINCE MATERIAL HANDLING COSTS ARE NOT RELATED TO COST OF MATERIALS

*MATERIAL HANDLING EQUIPMENTSCRANES AND HOISTSCONVEYORSSLIDES AND CHUTES LIFTS RAILS ROPEWAYS AND CABLEWAYSPIPE LINESTRUCKS, TRACTORS AND TRAILORS

Selection of EquipmentMaterial to be handled Size & Shape Quantity & Weight Material Characteristics Susceptibility to damage

Selection of Equipment.contb) Plant building Temporary or permanent Width of doors/aisles Height of the ceiling Levels of floors Load bearing capacity of the floors Presence of columns and pillars

Selection of Equipment.contc) Layout Product layout or process layoutd) Speed requirements Minimum/ maximum and average speed to meet desired rate of productione) Material Flow Pattern Vertical Flow Pattern Horizontal Flow Pattern

Selection of Equipment.contf) Method of Production Mass & Flow Production Batch Productiong) Distance over which materials is to be moved Fixed Distance Long Distance Work Station

Selection of Equipment.conth) Safety requirements

i) Installation & Operating costs Initial investmentOperating costsMaintenance costs finance available for investment

Selection of Equipment.contj) Maintenance Amount of maintenance Statutory Requirements Special Precautionsk) Skills Requirementl) Flexibility regularity of material handling distance m) Acceptability & safety of operators

*CRANES & HOISTS

*CRANES & HOISTS

*LIFTSHYDRAULIC LIFTING PLATFORM LIFTS

*LIFTSHYDRAULIC LIFTING PLATFORM

*CONVEYORSGRAVITY ROLLER SPUR CONVEYORHORIZONTAL BELT CONVEYOR

ConveyorsIt is a fixed type of material handling system used for moving materials either continuously or intermittently between two fixed points.

creates relatively a fixed route occupy space continuously reduce handling

*PALLET TRUCKSELECTRIC PALLET TRUCK TILT PALLET TRUCKS

*PALLET TRUCKSALL TERRAIN PALLET TRUCKS

*STACKERS

*TROLLEYS

*TROLLEYS

*TRUCKS

*TROLLEYS

*TRUCK

*TRUCK

*TRUCK & TROLLEY

*TROLLEYS

*TROLLEYS

*TROLLEYS

*TROLLEYS

*TROLLEYS

*PALLETS

*PALLETS

*PALLETS

*PALLETS

*LIFT TRUCK

*CONVEYORS

*CONVEYORS

*CONVEYORS

*CONVEYORS

*CONVEYORS

*CRANES

*CRANES

*FORK LIFT TRUCK

*TRACTOR & TRAILOR

*TRACTOR & TRAILOR

HoistsUsed for loading and unloading of heavy or long objects.Types of Hoists: Chain Hoists Pneumatic Hoists Electric Hoists

RopewaysUsed for overhead transport of materials over greater distances

*MATERIAL HANDLING RATIOS RATIOS CAN BE USED TO MEASURE EFFECTIVENESS OF MATERIAL HANDLING

*

MATERIAL HANDLING COST PER UNIT (OR WEIGHT) :

= MATERIAL HANDLING COST PER PERIOD WT. OF RAW MATERIAL PROCESSED (QTY. PRODUCED PER PERIOD)

*

2. HANDLING TIME TO TOTAL TIME :

= TIME SPENT IN HANDLING TOTAL TIME SPENT IN PRODUCTION

*

3. MATERIAL HANDLING LABOUR RATIO (MHL): = PERSONNEL ASSIGNED TO MATERIALS HANDLING______ TOTAL OPERATING WORK FORCE

THIS RATIO MEASURES THE EXTENT OF EFFORTS NEEDED FOR MOVING MATERIALS

*

4. MOVEMENT OPERATION RATIO :

= TOTAL NUMBEROF MOVEMENTS TOTAL NUMBER OF PRODUCTIVE OPERATIONS

THIS RATIO INDICATES WHETHER TOO MANY MOTIONS ARE EMPLOYED DUE TO POOR ROUTING

*5.HANDLING TIME SPENT BY DIRECT LABOUR :

= TIME SPENT BY DIRECT LABOUR IN MH TOTAL DIRECT LABOUR TIME

*6. MATERIAL HANDLING COST INDEX :

= TOTAL MATERIAL HANDLING COSTS TOTAL VALUE OF MATERIALS RECEIVED AND ISSUED

*7. MATERIAL HANDLING LOSS INDEX :

= TOTAL VALUE OF LOSSES DUE TO MH TOTAL VALUE OF MATERIALS RECEIVED AND ISSUED

*8. MANUFACTURING CYCLE EFFICIENCY :

=SETUP TIME + OPERATION TIME ELAPSED TIME FOR THE JOB

*9. SPACE UTILISATION RATIO :

= SPACE OCCUPIED SPACE AVAILABLE

*10. EQUIPMENT UTILISATION RATIO :

= NO. OF MH EQUIPMENT IN USE TOTAL NO. OF MH EQUIPMENT

Momvement handling and storage within the plant IMP Q: Material handling only adds to the cost. Comment. Ans: NO. It is a prerequite. Coss can be reduced. But it is a non-value added activity, but without it, other activities canont be performed. Material handling is a necessar evil.*Important question!!! *Mh material handling**Research finding: 1. for every ton of material issued from the store, 50-6- tons of material 50-60 times mh2. 2/3rdof the manf cycle time is consumed by mh activities3. 50% of direct lab cost is consumed by mh related activities.4. Net 25% of direct lab cost can be reeduced by follwing principles of mh*