MATERIAL HANDLING

Haynes defines “Material handling embraces the basic operations in connection with

the movement of bulk, packaged and individual products in a semi-solid or solid state by

means of gravity manually or power-actuated equipment and within the limits of individual

producing, fabricating, processing or service establishment”. Material handling does not add

any value to the product but adds to the cost of the product and hence it will cost the customer

more. So the handling should be kept at minimum. Material handling in Indian industries accounts

for nearly 40% of the cost of production. Out of the total time spent for manufacturing a product,

20% of the time is utilised for actual processing on them while the remaining 80% of the time

is spent in moving from one place to another, waiting for the processing. Poor material handling

may result in delays leading to idling of equipment.

Materials handling can be also defined as ‘the function dealing with the preparation,

placing and positioning of materials to facilitate their movement or storage’. Material

handling is the art and science involving the movement, handling and storage of materials during

different stages of manufacturing. Thus the function includes every consideration of the product

except the actual processing operation. In many cases, the handling is also included as an integralFollowing are the principles of material handling:

1. Planning principle: All handling activities should be planned.

2. Systems principle: Plan a system integrating as many handling activities as possible and

co-ordinating the full scope of operations (receiving, storage, production, inspection, packing,

warehousing, supply and transportation).

3. Space utilisation principle: Make optimum use of cubic space.

4. Unit load principle: Increase quantity, size, weight of load handled.

5. Gravity principle: Utilise gravity to move a material wherever practicable.

6. Material flow principle: Plan an operation sequence and equipment arrangement to

optimise material flow.

7. Simplification principle: Reduce combine or eliminate unnecessary movement and/or

equipment.

8. Safety principle: Provide for safe handling methods and equipment.

9. Mechanisation principle: Use mechanical or automated material handling equipment.

10. Standardisation principle: Standardise method, types, size of material handling equipment.

11. Flexibility principle: Use methods and equipment that can perform a variety of task

and applications.

12. Equipment selection principle: Consider all aspect of material, move and method to

be utilised.

13. Dead weight principle: Reduce the ratio of dead weight to pay load in mobile equipment.

14. Motion principle: Equipment designed to transport material should be kept in motion.

15. Idle time principle: Reduce idle time/unproductive time of both MH equipment and

man power.

16. Maintenance principle: Plan for preventive maintenance or scheduled repair of all

handling eq

part of the process. Through scientific material handling considerable reduction in the cost as well

as in the production cycle time can be achieved

Selection of Material Handling equipment is an important decision as it affects both cost and

efficiency of handling system. The following factors are to be taken into account while selecting

material handling equipment.

1. PROPERTIES OF THE MATERIAL

Whether it is solid, liquid or gas, and in what size, shape and weight it is to be moved, are

important considerations and can already lead to a preliminary elimination from the range of

available equipment under review. Similarly, if a material is fragile, corrosive or toxic this will

imply that certain handling methods and containers will be preferable to others.

2. LAYOUT AND CHARACTERISTICS OF THE BUILDING

Another restricting factor is the availability of space for handling. Low-level ceiling may

preclude the use of hoists or cranes, and the presence of supporting columns in awkward

places can limit the size of the material-handling equipment. If the building is multi-storeyed,

chutes or ramps for industrial trucks may be used. Layout itself will indicate the type of

production operation (continuous, intermittent, fixed position or group) and can indicate some

items of equipment that will be more suitable than others. Floor capacity also helps in selecting

the best material handling equipment.

3. PRODUCTION FLOW

If the flow is fairly constant between two fixed positions that are not likely to change, fixed

equipment such as conveyors or chutes can be successfully used. If, on the other hand, the

flow is not constant and the direction changes occasionally from one point to another because

several products are being produced simultaneously, moving equipment such as trucks would

be preferable.

4. COST CONSIDERATIONS

This is one of the most important considerations. The above factors can help to narrow the range

of suitable equipment, while costing can help in taking a final decision. Several cost elements

need to be taken into consideration when comparisons are made between various items of

equipment that are all capable of handling the same load. Initial investment and operating and

maintenance costs are the major cost to be considered. By calculating and comparing the total

cost for each of the items of equipment under consideration, a more rational decision can be

reached on the most appropriate choi