Course of MT- 362 Material Handling Lecture 2

Overview of previous lecture • MH definitions • Historical background • Importance and requirements of MH • Advantages and disadvantages of MH • Types of loads

Stages in Material Handling • It is important to consider different options for material management • These options mainly depends on the The same can also be - Material written in the form: - Economy Man Money - Equipment Material Machine - Resources (human) These options contributes towards efficient transfer of material

Stages in Material Handling • The material management group should always ask these questions: - Why? - What? Thus if material handling is necessary, then material transfer methods and equipment will be advised accordingly - When? & Where? - How? – By whom?

MH Classification • MH classification by equipment type • MH classification by method

MH Classification by Equipment Type

Overview of material handling equipment - Transport Equipment • Equipment used to move material from one location to another (e.g., between workplaces, between a loading dock and a storage area, etc.). The major subcategories of transport equipment are conveyors, cranes and industrial trucks. Material can also be transported manually using no equipment - Positioning Equipment • Equipment used to handle material at a single location so that it is in the correct position for subsequent handling, machining, transport, or storage. Unlike transport equipment, positioning equipment is usually used for handling at a single workplace. Material can also be positioned manually using no equipment.

Transport equipment

Positioning equipment

Overview of material handling equipment - Unit Load Formation Equipment • Equipment used to restrict materials so that they maintain their integrity when handled a single load during transport and for storage. If materials are self-restraining (e.g., a single part or interlocking parts), then they can be formed into a unit load with no equipment. - Storage Equipment • Equipment used for holding or buffering materials over a period of time. Some storage equipment may include the transport of materials (e.g., the S/R (storage and retrieval) machines of an AS/RS (automated storage, retrieval system), or storage carousels). If materials are block stacked directly on the floor, then no storage equipment is required.

Unit load formation equipment - pallets

Storage equipment

Tire Carousel Carpet Carousel Storage equipment

Overview of material handling equipment - Identification and Control Equipment • Equipment used to collect and communicate the information that is used to coordinate the flow of materials within a facility and between a facility and its suppliers and customers. The identification of materials and associated control can be performed manually with no specialized equipment

Handheld Portable Data Terminals Identification and control equipment

MH Classification by Equipment Type MH classification based on equipment type can also be categorized as AGV: Automated guided vehicle

MH Classification by Method • MH can be of the following types: - Manual - Mechanized - Automated

Manual Material Handling involves the use of the human body to lift, lower, fill, empty,or carry loads • The load can be animate (i.e., living thing e.g., a person or animal) or inanimate (e.g., an object) • Most manufacturing or distribution systems require some manual handling tasks

Manual Material Handling

Mechanized Material Handling • In this case, manual labor is replaced by equipments • This type of material handling consists of equipment and process controllers that handle materials in a proven, systematic and mechanized manner - Cranes - Lifters - Trucks • These systems improve speed, efficiency and safety • Mechanized material handling also requires full or partial involvement of manual help

Mechanized Material Handling

Automated Material Handling • Automated materials handling (AMH) refers to any automation that reduces or eliminates the need for humans to load, unload, sort material or transfer material • Automated Material Handling System Ensures Reliability and Repeatable • In AMH systems, somewhere in the process there may be a scanner to read the bar code or a reader to read the radio frequency ID (RFID) tag (or both) - RFID is non-contact use of radio-frequency electromagnetic fields to transfer data, for the purposes of automatically identifying and tracking tags attached to objects

Automated Material Handling Think of robots

MH Classification by Method • Capabilities(power or ability to do something) of MH method can be understand using the following table:

MH Methods Characteristics Different characteristics can be judged for the type of MH methods e.g., Manual method can handle less weight Mechanized and automated can handle higher weights

Factors affecting MH • The selection of materials handling equipment requires the attaining of proper balance between - the production problem, - the capabilities of the equipment available, and - the human element involved • The ultimate aim is to arrive at the lowest cost per unit of material handled • Selection of material handling equipment is an important decision as it affects both the cost and efficiency of handling system

Factors affecting MH • The following factors are to be taken into account while selecting the material handling equipment - Properties of the Material • i.e., Whether the material is solid, liquid or gas, and in what size, shape and weight it is to be moved, are important decisions and can be lead to a preliminary elimination from the range of available equipment under review • Similarly, if the material is fragile, corrosive or toxic this will imply that certain handling method and containers will be preferable to others

Factors affecting MH - Layout and Characteristic of the building • A restricting factor is availability of space for handling • Low-level ceiling many prevent the use of hoist or cranes, and the presence of supporting columns in awkward places can limit the size of material handling equipment - Production Flow • If the flow is fairly constant between two fixed position that are not likely to be changed, fixed equipments such as conveyors or channels can be successfully used

Factors affecting MH - Cost Considerations - Nature of operations • This is the most important consideration • Initial investment and operating and maintenance cost are the major costs to be considered • By calculating and comparing the total cost of each items of equipment under consideration, a more rational decision can be reached on the most appropriate choice - Nature of operations • Selection of equipment also depends on the nature of operations like whether handling is temporary or permanent, whether the flow is continuous or intermittent and material flow pattern-horizontal or vertical

Factors affecting MH - Engineering Factors - Equipment reliability • Engineering factors such as door, ceiling dimensions, floor space, floor conditions and structural strengths are also taken in consideration in the selection of equipment - Equipment reliability • Reliability (The probability that an item will perform a required function without failure under stated conditions for a stated period of time ) of the equipment and supplier reputation and the after sale services plays an important role in selecting the equipment

MHE Marketing Any commercial product passes through the following scheme: Marketing is one of the important step to deliver a product from the manufacturing set ups to the customers

MHE Marketing • Marketing is the process of communicating the value of a product or service to customers, for selling that product or service • Marketing is the link between a society’s material requirements and its economic patterns of response • MHE marketing means to emphasis the customers about the need of MHE

• An effective marketing plan will answer such questions as: - What products will sell and in what volumes? - At what prices? - At what promotional costs? - When and by what selling method?

MHE Marketing • The main objective is to highlight the usefulness of MHEquipments • Old conventional techniques may be dangerous to human and equipment safety • MHE can efficiently and easily perform all the tasks of material transfer and storage economically and within minimum time frame.

MHE Marketing marketing concepts and methodologies • It is important that the MHE marketing group/ company must be able to understand the industrial and marketing goals • This can be done with providing new marketing concepts and methodologies • This may include - Good presentation of MHE through leaflets and internet web designing - Organizing meetings with the users and equipment manufacturers - Convey prototype models Provide surety about the performance of the equipment - Provide surety about after sales service