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Material Handling

Material Handling

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Material Handling

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  1. Material Handling Material Handling System Design

  2. Outline Definitions Unit Load Material Handling Equipment

  3. Importance of Material Handling MH 55% MH Factory Space 87% Production time Product Cost 70% 15% In a typical factory, material Handling accounts for:

  4. Material Handling Definitions Right amount Right material Right time Right condition Right place Right position Right sequence Right cost Right methods MH is the art and science of moving, storing, protecting, and controlling material. PROVIDE

  5. New MHI Material Handling Definition Operations Subjects Business Processes Material Handling is the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal.  The focus is on the methods, mechanical equipment, systems and related controls used to achieve these functions. Source: MHI website - Glossary Aligns with “progressive view” of scope of material handling defined by Apple, that is a total system view (p. 166 text)

  6. Objectives of Material Handling Increase the efficiency of material flow Reduce MH cost Improve facilities utilization Safety and working conditions Manufacturing process Increase productivity Source: D.R.Sule, Manufacturing facilities

  7. Highlights of Definitions Art and science Right stuff in the right way Efficient Storage and Movement Movement of “parts” with machines Methods/Controls of movement to meet facility objectives Throughout the supply chain

  8. MH Examples Hospitals Mass Transportation Construction Mail Delivery Material Handling is not restricted to the manufacturing or distribution environment

  9. Material Handling Principles Defined by the Material Handling Institute and the College-Industry Council on Material Handling Education (CICME) (p.167 text): • Planning • (what,when,where) • Standardization • Work (cost x flow) • Ergonomic • *Unit Load 6. Space Utilization (3-D) 7. System 8. Automation 9. Environmental 10. Life Cycle Cost (procurement-removal) *Most important according to textbook authors

  10. Material Handling Systems Design Analyze the requirements Generate alternative designs Evaluate alternative designs Select the preferred design Implement the preferred design Define the objectives & scope

  11. Work simplification in MH • Framework for identifying MH solutions Evaluate each movement: 1. Can the move be eliminated ? 2. Can the move be combined with another or within an in-transit operation ? 3. Can the move be simplified ? 4. Can the sequence of moves be changed to advantages ? Why?

  12. MH Planning Chart • Analyzing MH solutions MH Planning Chart: (Figure 5.2, pg 173) • Information w.r.t. a specific MH solution • Record ALL movements (people + machines) • Reveals unnecessary movements and storage

  13. Unit Loads • A unit load is the unit to be moved or handled at one time. • A unit load includes the container, carrier, or support that will be used to move materials. Unit Load Pallet sized by ANSI (American National Standard Institute) Stacking Pallet Forklift

  14. Unit Load • Examples: tote boxes, “cassette”, cartons, skids, pallets, pallet boxes, intermodal container, one unit of product, etc. • Most popular: plastic containers and pallets • Factors for determining unit load/ container: • Size of carrier • Size and weight of items • Space for storing loaded/unloaded container • Equipment used for moving • Cost, supply and maintenance • Aisle widths, door sizes, and clear stacking heights • Environmental regulations

  15. Unit Load and Handling System The unit load is an integral part of the material handling system and a “simultaneous” determination should be made. Design the Handling/Storage system Design the Unit Load

  16. In-class Exercise: Unit Load and Cycle Time We have a system with two machines. Every unit of the product has to go through Machine 1 first and then through Machine 2. Machine 1 1 min/unit Machine 2 1 min/unit We move the product using forklift trucks. The company has several of them going around permanently. We can use one whenever we need. The move from Machine 1 to Machine 2 takes two minutes. How many units should we move at a time using the forklift truck to minimizethe time of completion of an order of 16 units? In other words, how big should the unit load be to minimize completion time? The forklift truck moves a batch(or a lot) of units at a time.

  17. Unit Load and Cycle Time UL = 16 units M1 MH M2 16 34 M1 UL = 8 units MH M2 18 26 M1 UL = 2 units MH M2 6 20 UL = 1 unit M1 MH M2 4 34 Lot size = 16 units Machining = 1 min/unit Operations 1 and 2 MH = 2 min/trip Large unit loads: longer cycle times, fewer moves Small unit loads: lower cycle time, lower WIP, more frequent handling MH time > processing time => MH constrained

  18. Unit Load Disadvantages Time spent forming and breaking down the unit load. Empty containers/pallets may need to be returned to their point of origin. Cost of containers/pallets and other load restraining materials used in the unit load

  19. Review Questions • The Unit Load remains the same throughout the facility. True or False? • Which statement is the most accurate? • Material Handling should be reduced as much as possible. • The materials, movements, and methods define the MH system. • The unit load should be decided before any other MH decisions. • The what, where, and when, defines the how and who.

  20. Classification of M.H. Equipment I. Containers & unitizers II. Material Transport Equipment 1. Conveyors 2. Industrial Trucks & Vehicles 3. Monorails, Hoists & Cranes III. Storage & Retrieval Equipment IV. Automatic Identification & Communication Equipment

  21. MH Equipment Resources • MHE Taxonomy ( • The Material Handling Multimedia Bank ( • Textbook (Appendix 5b) • Material Handling Industry of America ( • CICMHE Website ( • (