Material Handling

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Relationship between Plant Layout

and Material Handling
A good layout ensures minimum
material handling and eliminates
rehandling
The productive time of workers will
go without production if they are
required to travel long distance to
get the material tools
Space
It helps to keep material handling
shorter, faster and economical
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Introduction and Meaning

What is Material Handling?
Moving
Storing
Protecting
Controlling

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Objectives of Material
Handling
1. Minimize cost of material handling.
2. Minimize delays and interruptions by making
available the materials at the point of use at right
quantity and at right time.
3. Increase the productive capacity of the production
facilities by effective utilization of capacity and
enhancing productivity.
4. Safety in material handling through improvement in
working condition.
5. Maximum utilization of material handling equipment.
6. Prevention of damages to materials.
7. Lower investment in process inventory
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Material Handling Cost

Main costs involved in designing &
operating a material handling system
are:
1. Equipment Cost
2. Operating Cost
3. Unit Purchase Cost
4. Cost due to packaging &
damaged material
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CONSIDERATIONS IN MATERIAL
HANDLING SYSTEM DESIGN
1. Material Characteristics
Category
Physical state
Size
Weight
Shape
Condition
Safety risk and risk of
damage
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Measures
Solid, liquid, or gas
Volume; length, width, height
Weight per piece, weight per unit volume
Long and flat, round, square, etc.
Hot, cold, wet, etc.
Explosive, flammable, toxic; fragile, etc.
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CONSIDERATIONS CONT.
2. Flow rate
Quantity of
material
moved

High
Low

Conveyors

Conveyors
AGV train

Manual
handling
Hand trucks

Powered
trucks
Unit load AGV

Short
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Long

Move Distance
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CONSIDERATIONS CONT.
3. Plant Layout
Layout Type

Characteristics

Typical MH Equipment

Fixed position

Large product size, low

production rate

Cranes, hoists, industrial trucks

Process

Variation in product and

processing, low and medium
production rates

Hand trucks, forklift trucks,

AGVs

Limited product variety, high

production rate

Conveyors for product flow,

trucks to deliver components to
stations.

Product

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PRODUCTIVITY RATIOS
Productivity Ratios are used as
indicators of the Performance of a
system
These ratios are monitored
periodically to be sure that their
values are within acceptable
tolerances

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PRODUCTIVITY RATIOS
(Cont..)

1. Material-Handling-Labor (MHL)
Ratio
= Personnel assigned to Material
Handling/
Total Operating Personnel
- The ratio should be less than 1, & a
Reasonable value would be less
than 0.30 in a plant, while in a
warehouse a higher value should be
expected
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PRODUCTIVITY RATIOS
(Cont..)
2. Manufacturing Cycle Efficiency (MCE)
Time in actual production operations (machine time)

MCE:

time in production department

For increasing machine utilization, the delay

should be eliminated or at least minimized
- The performance index should be observed
over a time period for consistency

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EQUIPMENT USED FOR

MH
Equipment Types:
1. Fixed Points and limited Areas
2. Over Large Areas

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1. Fixed Points and limited Areas

Belt conveyor

Slat Conveyor
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Roller Conveyor

Screw Conveyor
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Chute conveyor

Chain conveyor
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1. Fixed Points and limited Areas

Overhead monorail
conveyor

Trolley
Conveyor
Buc
ket
con
vey
or

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Wheel Conveyor

Tow conveyor
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1. Fixed Points and limited

Areas

Cart-on-Track Conveyor

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1. Fixed Points and limited

Areas

Hoist
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Overhead crane

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Hydraulic scissor
lift
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2. Over Large Areas

Hand
truck

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Tier platform
truck

Hand lift truck

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2. Over Large Areas

Power driven hand truck

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Power driven platform truck

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2. Over Large Areas

Fork lift tuck

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Narrow aisle truck

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2. Over Large Areas

Tractor Trailer Train

Material lift
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2. Over Large Areas

Drum Truck

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Drum Lifter
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Dolly

22

Report Sources
http://tn.upi.edu/pdf/Production_and_O
perations_Management.pdf
http://dcetind.weebly.com/uploads/9/1/
6/3/9163431/lec_no._23_n_24....12.4.1
3.pptx
https://en.wikipedia.org/wiki/Material_h
andling

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