1. Material Handling System Design

2. Outline
Definitions
Unit Load
Material Handling Equipment

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

4. Material Handling Definitions
Right amount
MH is the art and science of moving, storing, protecting, and controlling material.
Right material
Right time
Right condition
PROVIDE
Right place
Right position
Right methods
Right cost
Right sequence
Material Handling means providing:
the right amount of
the right material, at the right time (not early OR late)
in the right condition (quality, what else?)
at the right place
in the right position (orientation)
in the right sequence
for the right cost (does this mean minimal?)
using the right method(s).

5. New MHI Material Handling Definition
Operations
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
Subjects
Business Processes
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
Material Handling is not restricted to the manufacturing or distribution environment
Mass Transportation
Hospitals
Mail Delivery
Construction

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
Define the objectives & scope
Analyze the requirements
Generate alternative designs
Evaluate alternative designs
Select the preferred design
Implement the preferred design

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. 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 Pallet sized by Stacking ANSI (American National
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 minimize the 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 TimeMH M2 16 34
UL = 16 units
Unit Load and Cycle Time M1 MH M2 18 26
UL = 8 units
Lot size = 16 units
Machining = 1 min/unit
Operations 1 and 2
MH = 2 min/trip M1 MH M2 6 20
UL = 2 units
Large unit loads: longer cycle times, fewer moves M1 MH M2 4 34
UL = 1 unit
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 (
MaterialHandlingInfo.com (