2. Chapter # 05 Material Handling
Presented to Dr. Haris
Group Members
Muhammad Hassan Sarfraz 11-IE-47
Muhammad Zameer 11-IE-49
Faisal Hafeez IE-54
01/10/2014

3. Material handling Definition
“Material handling means providing the right amount of the right material, in the right condition, at the right place, in the right position, in the right sequence, for the right cost and by the right method”

4. Material handling Definition
Right amount
How much inventory needed?
Smaller load size are preferred
Right material
Manual material handling results in picking wrong material
Automatic identification is key to accurate identification and picking right material e.g. using Bar-code-based or RFID-based system
Right condition
It is the state which customer desires to receive the material
The goods must also be received without damage
Right orientation
It means positioning of material for ease of handling
The orientation should be in such a way that it reduces the handling time

5. Material handling Definition
Right place
It is desirable to directly transport material to point of use rather than store the material at some intermediate location.
Right time
It means ON-TIME delivery
The goal is to achieve a lower cycle time MH system
Right cost
It is not necessarily the lowest cost
Minimizing cost is wrong objective in material handling system design
The most appropriate goal is to design most efficient material handling system at the most reasonable cost

6. Estimating MH cost
The development of MH equipment today is much more complex task than it was in the past
MH solution are no longer a simple case of moving material through conveyors
New MH technologies have dramatically changed the amount of labor required for MH tasks
Before installation Simulation techniques are used to estimate the cost of different systems, to find an optimal MH system
From the time of installation of a MH system, one can reduce cost by continuous improvement in the system.

7. Scope of Material handling
In a typical facility, material handling accounts for;
25% of all employees
55% of all factory space
87% of all production time
15 to 70% of total product cost
Material Handling can be viewed as a mean by which total manufacturing costs are reduced through more efficient material flow control, lower inventories and improved safety.

8. Safety Considerations
Facility designers should be familiar with all the safety requirements for the type of facility they are designing.
Poor ergonomics ,which means setting the workers in the job instead of setting the job for workers, accounts for one-third of all workplace injuries.
A poor layout for the rack area is a common shortfall in the designs of pallet-rack solutions in industries.
OSHA regulations for general industry provide the basis and represent the minimum standards.

9. Material handling Principles
Planning principle (what, when, where, how, who)
Standardization Principle (Less variety, Customization)
Work Principle (volume/weight * distance)
Ergonomic Principle (working conditions according to abilities of workers)
Unit Load Principle (Single entity)
Space Utilization (cubic space)
System Principle (Collection of entities)
Automation Principle (Electro-mechanical devices)
Environmental Principle (not to waste natural resources)
Life-Cycle Cost Principle (All cash flows)

10. Designing MH system 6 steps to design Material Handling system;
Define objective and scope
Analyze the requirements for moving, storing, protecting and controlling materials
Generate alternative designs for MH system requirement
Evaluate alternative material handling system designs
Select the preferred design
Implement the preferred design
It is unrealistic to expect that the material handling system will operate perfectly the first time around.
Adopting a posture of continuous improvement will result in far more efficient operation of material handling system.

11. alternative MH system AIM CONCEPTUALIZE DESIGN INSTALL
For development of Alternatives “Ideal System Approach” is used, which consist of four phases;
AIM
Aim for theoretical Ideal System
Theoretical Ideal System has;
Zero cost
Perfect Quality
No hazards
No wasted space
CONCEPTUALIZE
Conceptualize the Ultimate ideal system
Ultimate Ideal System is a system that would be achievable in future
DESIGN
Design the technologically workable system
Technologically workable system has;
Not applicable
High cost
Not appropriate conditions
INSTALL
Install the recommended system
Recommended system is;
Cost effective
Match our requirements

12. MH system equation =

13. MH system equation What Question Where Question When Question
What are the types of material to be moved?
What are their characteristics
What are amounts moved and stored
Where Question
Where is the material coming from?
Where is the material delivered?
Where is the material stored?
Where can material handling tasks be eliminated, combined or simplified?
When Question
When should material be moved?
When is time to mechanize or automate?
MATERIALS
MOVES

14. MH system equation How Question Who Question Which Question
How is material moved or stored?
How much inventory should be maintained?
How should the material be tracked?
Who Question
What are required skills to perform MH tasks?
Who should be trained to service and maintain the MH system?
Who should be involved in designing the system?
Which Question
Which MH operations are necessary
Which types of MH equipment?
Which MH system is cost effective?
METHODS

15. MH Planning chart Material handling planning chart can be used to;
Gather information pertaining to a specific MH problem
To provide Preliminary examination of the alternative solutions
The result from analyses using this chart can be used in simulation of alternative solutions
Following figure shows a planning chart which includes;
Information on operations (O), transportations (T), storages (S) and inspection (I)
All movements, performed by operator or machine should be recorded

16. MH Planning chart This planning chart usually contains 15 columns
First eight columns provide information on the Where Question
The 9th to 12th column answer the What Question
The frequency to move is recorded In 13th column. Frequency is calculated based on estimated production volume and the capacity of unit load.
The 14th column tells about length of the move. The distance moved can only be calculated after the completion of facility layout design
The 15th column tells about the method of material handling with appropriate material handling equipment

18. Unit load design Definition:
“A single item, a number of items, or bulk material, which is arranged or restrained so that the load can be stored and picked up and moved between two locations as a single mass.”
The nature of unit load could change each time an item, or a number of items, or bulk material is moved. Variability in quantity/size per move is permissible.

19. Further Understanding
A single item moved between two locations manually constitutes one unit load.
Two tote pans with identical components moved by a dolly from one machine to the other constitute one unit load.
One pallet load of non uniform-sized cartons moved by a lift truck from packaging area to the shipping dock constitute one unit load.
Pallet
Tote pan

20. Size of Unit load Size of Unit Load can range
from a single part carried by a person to:
Each carton moved through conveyors
A number of cartons on a pallet moved by fork lift trucks
A number of containers moved by rail across states or by container ships across continents.
Two important elements in determining the size of the unit load are;
Cube (length x with x height)
Weight limit
Carton boxes, pallets, tote pans can be used according to need

21. EFFECTS OF Size of Unit load
Large Unit Loads
Require bigger & heavier equipment with higher load capacities
Increase WIP inventory
Completion time increases
Major advantage is fewer moves
Small unit loads:
Increased transportation needs
Reduce WIP Inventory
Require simple material handling (push carts and similar devices)
Decrease job completion time

23. Important conclusion: In order to achieve single unit production the material handling time must be shorter than the unit processing time.

24. Basic manners to move Unit load
Lifting under the mass
Inserting the lifting elements into the body of unit load
Squeezing the load between two lifting surfaces
Suspending the load

25. Returnable containers
Containers with good Stacking and Nesting features can provide significant reduction in material handling
Full container can be stacked on top of another full container in the same spatial orientation
Stackability
The shape of the containers permits an empty container to be inserted into another empty container
Nestability

26. This figure shows why we need stackability and nestability

27. Pallets and Pallet sizes
A common method of containing the unit load.
They come in a variety of designs and are usually dictated by the application. Common designs are;
Stringer design
Block design

28. Container & Pallet Pooling
It was widely accepted in Europe first then north American companies adopted it also.
It means, instead of buying, rent containers and pallets for a fee per day per container or pallet.
Whenever you need them, you go to the nearest depot and get as many as you need.
After use, they are returned to the nearest depot or another company in the supply chain.
The figure in next slide shows the container/pallet flow in a).Conventional
b). Pallet pooling system
c). Integrated logistics and pallet pooling system

30. Example (on efficiency of returnable containers)

31. Solution Container Space utilization:
Divide the useable cube by the exterior envelope of the container.
2. Storage space efficiency:
Ratio of useable cube and the storage of cube.
3.Container nesting ratio:
Overall container height by the nested height.

32. 4. Trailer Space Utilization:
Along the Length= containers.
Along the width= containers.
Along the height= containers.
Total= containers.
Utilization

33. 5. Retailer Return Ratio:
One stack of empty containers contain 55 containers.
The total number of empty containers per trailer;
Trailer Return Ratio.

34. Mh equipment classification
Containers and unitizing equipment
Containers (pallets, skids, tote pans)
Unitizers (Stretchwrap, Palletizers)
Material Transport Equipment
Conveyors (chute, belt, roller, wheel, slat, chain, trolley, sorting)
Industrial vehicles (walking, Riding, Automated)
Monorails, hoists &cranes
Storage and retrieval equipment
Unit Load storage and retrieval (Block stacking, Mobile rack)
Small load storage and retrieval equipment
Automatic identification and communication equipment
Automatic identification and recognition (Bar codes, radio frequency tag)
Automatic paperless communication (voice headset, smart card)

35. Estimating MH cost
The development of MH equipment today is much more complex task than it was in the past
MH solution are no longer a simple case of moving material through conveyors
New MH technologies have dramatically changed the amount of labor required for MH tasks
Before installation Simulation techniques are used to estimate the cost of different systems, to find an optimal MH system
From the time of installation of a MH system, one can reduce cost by continuous improvement in the system.

36. ?
Any Question