1. Material handling systems Prepared By:- Siju Prakash Asst. Professor Department of Pharmaceutics Veerayatan Institute of Pharmacy

2. Content Definition Objective Importance Advantages Disadvantages Store design in pharmaceutical industries Material handling principles MH equipment types

3. Definition of material handling Materials handling refers to the process of moving, controlling, protecting as well as storing materials such as goods, items, etc. for manufacture, disposal, and distribution or even for consumption OR Materials handling is the art and science of moving, packing and storing of substances in any form.

4. Why Material Handling? improves efficiency Improves productivity Maximize profits Competitive edge

5. Where MHE is utilized Warehouses Manufacturing Plants Ports Airports

6. Objective of material handling  To increase efficiency of material flow by ensuring availability of materials when & where they needed  To reduce MH cost  To improve facilities utilization  To improve safety & working conditions  To facilitate mfg processes  To increase productivity

7. Importance of material handling  It helps productivity and thereby increases profitability of an industry.  Improve efficiency of a production.  Reduce damage of materials during storage and movement.  Maximize space utilization.  Reduce overall cost by improving materials handling.

8. Cont..  Improve customer services.  Reduced physical strain on workers.  Saving time.  Greater degree of safety.  Improvement in plant layout.

9. Advantages of material handling  To Lowers unit materials handling cost  To reduce manufacturing cycle time  To provide better control of the flow of materials  To provide better working conditions  To provide Contribution for better quality by avoiding damages to products  To Increase storage capacity  To provide higher productivity at lower manufacturing costs

10. Disadvantages 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 additional maintenance facilities and costs required.

11. Cont.. If not operated well there are chances of accidents and damages. Inventory carrying cost is high in some cases Installation and operation cost is high Skilled labor or operator is required to operate almost all material handling system. More pollution Increase unemployment

12. Store design in pharmaceutical industries

13. Store design in pharmaceutical industries Store design in pharmaceutical industries Objective Ensuring Maximum utilization of space Maintaining a balance between Service and Operating Cost Minimizing movement Planning and controlling movement and location Providing Safe, Secure and Environmentally sound conditions

14. Store design in pharmaceutical industries

15. MATERIAL HANDLING PRINCIPLES

16. All materials to be handled mechanically from the inbound raw materials stage to the outgoing finished goods stage

17. Heavy loads must be handled mechanically

18. Avoid mixing materials which require future sorting

19. Transfer of material from one container to another should be done mechanically

20. Hot and hazardous materials must be handled mechanically

21. Materials are to be moved in a straight line to the extent possible. Minimum number of changes in the direction while moving materials is preferable.

22. Avoiding floor contact of materials is preferable. Pallets [A flat transport structure that supports goods in a stable fashion. Most pallets are wooden, pallets also are made of plastic, metal, and paper] can be used for this purpose.

23. Gravity feed must be taken into advantage wherever feasible.

24. Pick and place of materials within operations and in transit should be infrequent.

25. PRINCIPLES OF MH (Cont..) 8/04/2013lec # 21 & 2225 1. Planning: Plan all MH & Storage activities to obtain maximum overall operating efficiency 2. System Flow: Integrate as many handling activities as is practical into a coordinated system of operations covering vendor, receiving, storage, production, inspection, packaging, warehousing, shipping, transportation, & customer

26. PRINCIPLES OF MH (Cont..) 3. Material Flow: Provide an operation sequence & equipment layout optimizing material flow 4. Simplification: Simplify handling by reducing, eliminating, or combining unnecessary movements &/or equipment 5. Gravity: Use gravity to material handling whenever practical 8/04/2013lec # 21 & 2226

27. Cont… 6. Space Utilization: Make optimum utilization of the building cube 7. Unit Size: Increase the quantity, size or weight of unit loads or flow rate 8. Mechanization: Mechanize handling operations

28. PRINCIPLES OF MH (Cont..) 9. Automation: Provide automation to include production, handling & storage functions 10. Equipment Selection: In selecting handling equipment, consider all aspects of the material handled, the movement, & the method to be used 11. Standardization: Standardize handling methods as well as type & sizes of handling equipment 8/04/2013lec # 21 & 2228

29. Cont.. 12. Adaptability:Use methods & equipment that can best perform a variety of tasks & applications when special- purpose equipment is not justified 13. Dead Weight:Reduce the ratio of dead weight of mobile handling equipment to load carried 14. Utilization: Plan for optimum utilization of handling equipment & manpower

30. PRINCIPLES OF MH (Cont..) 15. Maintenance: Plan for preventive maintenance & schedule repairs of all handling equipments 16. Obsolescence: Replace obsolete handling methods & equipment when more efficient methods of equipment will improve operations 17. Control: Use material Handling activities to improve control of production, inventory & order handling 8/04/2013lec # 21 & 2230

31. 18. Capacity: Use handling equipment to help achieve the desired production capacity 19. Performance: Determine the effectiveness of handling performance in terms of expense per unit handled 20. Safety: Provide suitable methods & equipment for safe handling

32. MH EQUIPMENT TYPES All Equipments in MH are classified in three main types, i.e 1. Conveyors: Conveyors are used for moving materials continuously over a fixed path. Examples of different conveyors are; roller, belt conveyors 8/04/2013lec # 21 & 2232

33. Conveyers Equipment used to move materials over a fixed path between specific points

34. Large conveyer

35. Types of Conveyers Mainly there are about 20 types of conveyers  Belt conveyers  Wheel conveyers  Roller conveyers  Chain conveyers  Slat conveyers  Flat belt conveyers  Magnetic belt conveyers  Vertical conveyers

36. Belt Conveyor -Motor driven belt usually made of metal fabric

37. Chain Conveyor-Motor driven chain that drags material along a metal side base.

38. Roller Conveyor- Boxes, large parts or units loads roll on top of a series of rollers mounted on a rigid frame.

39. Pneumatic Conveyor- High volume of air flows through a tube carrying materials along with air flow.

40. conveyers are used When material is to be moved frequently between specific points To move materials over a fixed path When there is a sufficient flow volume to justify the fixed conveyor investment

41. MH EQUIPMENT TYPES (Cont..) 1.Conveyors: Advantage 1. Permits high capacity for moving large number of items 2. Their speed is adjustable 3. Handling combined with other activities such as processing & inspection is possible 4. They are versatile & can be on floor or overhead 8/04/2013lec # 21 & 2241

42. Cont…. 5. Temporary storage of loads b/w work station is possible (particularly overhead conveyors) 6. Load transfer is automatic & does not require the assistance of many operators 7. Straight line paths or aisles are not required 8. Utilization of the cube is feasible through the use of overhead conveyors

43. MH EQUIPMENT TYPES (Cont..) 1.Conveyors: Disadvantages: 1. They allow a fixed path, serving only limited areas 2. Bottlenecks can develop in the system 3. A breakdown in any part of the conveyor stops the entire line 4. Since conveyors are fixed in position, they hinder the movement of mobile equipment on the floor 8/04/2013lec # 21 & 2243

44. MH EQUIPMENT TYPES (Cont..) Elevators 2. Cranes, Elevators & Hoists Cranes & Hoists are items of overhead equipment for moving loads intermittently within a limited area. Bridge cranes, monorail cranes, & hoists are examples of this basic equipment type 8/04/2013lec # 21 & 2244

45. Cranes – Devices mounted on overheard rail or ground wheels or rails.They lift, swing and transport large and heavy materials

46. Elevators – Types of cranes that lift materials – usually between floors or buildings Elevators – Types of cranes that lift materials – usually between floors or buildings

47. Hoists- Move vertically or horizontally. May be air hoist, electric hoist, chain hoist

48. MH EQUIPMENT TYPES (Cont..) 2. Cranes & Hoist s: Bridge Crane 8/04/2013lec # 21 & 2248

49. MH EQUIPMENT TYPES (Cont..) 2. Cranes & Hoists: Jib Cranes 8/04/2013lec # 21 & 2249

50. MH EQUIPMENT TYPES (Cont..) 2. Cranes & Hoists: Monorail Cranes & Hoists 8/04/2013lec # 21 & 2250

51. MH EQUIPMENT TYPES (Cont..) 2.Cranes & Hoists Advantages: 1. Lifting as well as transferring of material is possible 2. Interference with the work on the floor is minimized 3. Valuable floor space is saved for truck rather than being utilized for installation of handling equipment 4. Such equipment is capable of handling heavy loads 5. Such equipment can be used for loading & unloading of materials 8/04/2013lec # 21 & 2251

52. MH EQUIPMENT TYPES (Cont..) 2.Cranes & Hoists Disadvantages: 1. They require heavy investment (especially bridge cranes) 2. They serve a limited area 3. Some cranes move only in straight line & thus can not make turns 4. Utilization may not be as high as desirable since cranes are used only for a short time during daily work 5. An operator has to be available for operating some types, such as bridge cranes Applications: Shipyards & heavy equipment production facilities 8/04/2013lec # 21 & 2252

53. MH EQUIPMENT TYPES (Cont..) 3. Trucks Hand or Powered Trucks move loads over varying paths Examples of such Trucks include Lift Trucks, Fork Trucks, Trailer Trains, & Automated Guided Vehicles 8/04/2013lec # 21 & 2253

54. MH EQUIPMENT TYPES (Cont..) 3. Trucks Lift Trucks: 8/04/2013lec # 21 & 2254

55. MH EQUIPMENT TYPES (Cont..) 3. Trucks Hand Trucks: 8/04/2013lec # 21 & 2255

56. MH EQUIPMENT TYPES (Cont..) 3. Trucks Fork Trucks: 8/04/2013lec # 21 & 2256 Pallet truck

57. MH EQUIPMENT TYPES (Cont..) 3. Trucks Trailer Trains: 8/04/2013lec # 21 & 2257

58. MH EQUIPMENT TYPES (Cont..) 3. Trucks AGVs: 8/04/2013lec # 21 & 2258

59. MH EQUIPMENT TYPES (Cont..) 3. Trucks Advantages: They are not require to follow a fixed path of movement & therefore can be used any where on the floor where space permits They are capable of loading, unloading, & lifting, in addition to transferring material Because of their unrestricted mobility, which allows them to serve different areas, trucks can achieve high utilization 8/04/2013lec # 21 & 2259

60. MH EQUIPMENT TYPES (Cont..) 3. Trucks Disadvantages: They cannot handle heavy loads They limited capacity per trip Aisles are require; other wise the trucks will interfere with the work on the floor Most trucks have to be driven by an operator Trucks do not allow handling to be combined with processing & inspection, as other type of eqpt do 8/04/2013lec # 21 & 2260

61. Auxiliary Equipments - Devices or attachments used with handling equipments to make their use more effective and versatile

62. Skid boxes

63. Expendable pallet