Unit-VI: Basic Material handling Systems

Basic Material handling Systems: Selection, Material handling method-path, equipment, function oriented systems.

6.1 Selection of Material Handling Equipment
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.

6.1.1. Properties of the Material
Whether it is solid, liquid or gas, and in what size, shape and weight it is to be transported are the main factors to be taken into consideration and can lead to a preliminary elimination from the range of available equipment under review. If a material is fragile, corrosive or toxic this will imply that certain handling methods and containers will be preferable to others.

6.1.2. Layout and characteristics of the building
Another limiting factor is the convenience of space for handling. Low-level ceiling may exclude the use of hoists or cranes, and the presence of supporting columns in difficult places can restrict the size of the material-handling equipment. If the building is multi-storied, 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 suggest some items of equipment that will be more proper than others. Floor capacity also aids in selecting the best material handling equipment.

6.1.3. Production Flow
If the flow is properly constant between two immovable positions, fixed equipment such as conveyors or chutes can be effectively used. If, the flow is not continuous and the direction changes rarely from one point to another because several products are being produced simultaneously, moving equipment such as trucks would be desirable.

6.1.4. Cost considerations
The previous factors can help to limit the range of suitable equipment, while costing can help in taking a final decision. Several cost features need to be taken into consideration, when the comparisons are made between several items of equipment that are capable of handling the same load. Initial investment and operating and maintenance costs are the major cost to be measured. By comparing the total cost for each of the items of equipment, a more rational decision can be made on the most appropriate choice.

6.1.5. Nature of Operations
Equipment Selection also depends on mode of operations like whether handling is temporary or permanent, whether the flow is continuous or discontinuous and material flow pattern-vertical or horizontal.

6.1.6. Engineering Factors
Selection of equipment also depends on engineering factors like door and ceiling dimensions, floor space, floor conditions and structural strength.

6.1.7. Equipment Reliability
Reliability of the equipment and supplier reputation and the after sale service also plays an important role in selecting material handling equipment.

6.2 Importance of Materials Handling
The importance of materials handling is that it helps productivity and increases profitability. Many enterprises go out of business because of inefficient materials handling practices. In many cases it is seen that rival industries are using same or similar production equipment, and one who uses improved materials handling system stays forward of their competitors. A well designed materials handling system attempts to achieve the following:

• Improve efficiency of a production system by ensuring the right quantity of materials delivered at the right place at the right time most economically.
• Cut down indirect labor cost.
• Reduce damage of materials during storage and movement.
• Maximize space utilization by proper storage of materials and thereby reduce storage and handling cost.
• Minimize accident during materials handling.
• Reduce overall cost by improving materials handling.
• Improve customer services by supplying materials in a manner convenient for handling.
• Increase efficiency and salability of plant and equipment with integral materials handling features
  
  Apart from these, for certain industries, like process industries, heavy manufacturing industries, construction industries, mining industries, and shipbuilding or aircraft industries etc., the materials are so large and heavy that these industries just cannot run without appropriate materials handling system.
  
  All the above points clearly portray the importance of materials handling in an industry or a material transportation system. However, the negative aspects of materials handling should also not be overlooked. These are:
  
• Additional capital cost involved in any materials handling system.
• Once a materials handling system get implemented, flexibility for further changes gets greatly reduced.
• With an integrated materials handling system installed, failure/stoppage in any portion of it leads to increased downtime of the production system.
• Materials handling system needs maintenance, hence any addition to materials handling means additional maintenance facilities and costs.

6.3 Systems Concept
In the previous sections materials handling have already been referred to as a system and it will be repeated many times in future. It is, therefore, important to understand the systems concept of materials handling. The term ‘‘system’’ has many senses depending on the field where used. A general definition of the term could be: a complex unity formed of many often diverse parts subject to a common plan or serving a common purpose. The important characteristics of a system are that the parts, called subsystems, are interrelated and guided by an purpose for which the system exists. In an industry, materials handling is a subsystem (or part) of the production system. Materials handling can be reflected to be a system whose subsystems are:

• Design or method to be adopted,
• Types of materials handling equipment to be used,
• Different operations like packing /unpacking, movement and storage involved,
• Maintenance required for the equipment employed,
• Mode of transportation by the raw materials suppliers, distributors / customers, waste / scrap collectors etc. The common objective by which the different subsystems are guided is the lowest cost solution of the materials handling system.

In actual exercise, the system concept of materials handling means the different types of materials handling needed at different parts of an industry and associated suppliers’ and customers’ end are to be considered in whole. Only this methodology will ensure an overall cost effective materials handling solution for the industry.

A handling engineer could think about the handling downside of a specific space as a personal, isolated case and produces the solution. He could have made the foremost economic solution for that downside alone; however it should not cause the lowest price answer for the complete plant. There were several industries in United Nations agency area unit persecution which were over hundred sizes of containers/boxes at intervals constant plant! This can be the results of determination handling issues of various areas in isolation. From systems purpose of read, the handling downside of a plant at the side of its associated suppliers’ and customers’ issues ought to be thought of together system and therefore the subsystems got to be designed and operated consequently. This systems construct may be a logical approach which may bring home the bacon the target of any handling theme that is lowest price answer.

6.4 Five major types of materials handling methods
Movement - Involves the actual transportation or transfer of material from one point to the next.

Quantity - Dictates the type and nature of the material handling equipment and also cost per unit for the conveyance of the goods.

Time - How quickly the material can move through the facility Space - concerned with the required space for the storage of the material handling equipment and their movement, as well as the queuing or staging space for the material itself.

Control - Racking of the material, positive identification, and inventory management. A major competitive advantage due to its impact on quality, cost, productivity, inventory, and response time; in total a revenue enhancer not a cost contributor.

Advantages of correct materials handling

• Savings in storage and operating space
• Better stock control
• Improved working conditions
• Improved quality
• Lower risk of accidents
• Reduced processing time
• Lower production costs
• Less waste of time and materials

In order to perform the activities of materials handling the basic goal is to minimize the production costs. This general objective can be further subdivided into specific objectives as follows:

1. To reduce the costs by decreasing inventories, minimizing the distance to be handled and increasing productivity.
2. To increase the production capacity by smoothing the work flow,
3. To minimize the waste during handling.
4. To improve distribution through better location of facilities and improved routing.
5. To increase the equipment and space utilization.
6. To improve the working conditions.
7. To improve the customer service.

Basic Materials Handling Systems
The different material handling systems can be classified according to the type of equipment used, material handled, method used or the function performed. Equipment-Oriented Systems: Depending upon the type of equipment used, there are several systems.

1. Overhead systems
2. Conveyer systems
3. Tractor-trailor system
4. Fork-life truck and pallet system
5. Industrial truck systems
6. Underground systems

Material Oriented Systems:
These may be of the following types:

1. Unit handling systems
2. Bulk handling systems
3. Liquid handling systems

A unit load consists of a number of items so arranged that it can be picked up and moved as a single entity such as a box, bale, roll etc. Such a system in more flexible and requires less investment.

Method Oriented Systems
According to the method of handling and method of production, the material handling systems can be:

1. Manual systems
2. Mechanized or automated systems
3. Job-shop handling systems, or
4. Mass-production handling systems

Function Oriented Systems:
The systems can be defined according to the material handling function performed as follows:

1. Transportation systems
2. Conveying systems
3. Transferring systems
4. Elevating systems

Selection and Design of Handling System:
The selection and design of the material system should be done alongside the development of the layout as each one affects each other. Hence, an integrated approach to the design process is usable. A computerized technique known as COFAC (Computerized Facilities Design) has been developed for integrated handling system and layout design. The steps to be followed in the selection and design of handling systems are as follows:

1. Identification of system
2. Review of design criteria and objectives of the handling system
3. Data collection regarding flow pattern and flow requirements
4. Identification of activity relationships
5. Determining space requirement and establishing material flow pattern
6. Analysis of material and building characteristics
7. Preliminary selection of basic handling system and generation alternatives considering feasibility of mechanization and equipment capabilities
8. Evaluation of alternatives with respect to optimal material flow, utilizing gravity, minimum cost, flexibility, ease of maintenance, capacity utilization and other objectives of the system design considering various tangible and intangible factors
9. Selection of the best suited alternative and checking it for compatibility
10. Specification of the system
11. Procurement of the equipment and implementation of the system

Published date : 17 Mar 2015 12:02PM