MHSE Part 01

MATERIAL HANDLING SYSTEM
ENGINEERING (MHSE)
(Logistics Engineering)
Course Code : GCE

Thiagarajar College of Engineering
2013-2014
TVSM / PED / MSE / MHSE Slide 1
Course Objectives:
1. Understand and map process and material flow.
2. Access the potential failure modes in material storage and handling between
POM/POS to POC.
3. Design material storage and handling system to prevent potential failure

modes.
4. Verify produced part quality is delivered to the point of consumption
5. Apply "OR" (Operation Research) and REBA/RULA tools and techniques in

storage and material handling system design.
6. Develop standardized storage and handling work procedures.

Course Contents:
1 - INTRODUCTION TO MATERIAL HANDLING SYSTEM
Need, scope, definitions and terminologies, types, elements, Organization for logistics
management and control. Introduction Types of Material Handling Equipments (AGVs,
Fork lift, prime movers, stackers, lifts etc), selection criteria for MHES Process flow
charting/mapping techniques
2 - DESIGNING OF MATERIAL HANDLING FACILITIES
Design considerations for MHF, selection of materials. Estimation of number of facilities

required; cost estimation and control. Introduction to thermoforming/injection molded
crate design and manufacturing for kitting of the parts.
3 – ERGONOMICS IN MATERIAL HANDLING FACILITIES DESIGN
Application of RULA & REBA in MHF design, MHF design considerations for plastic
parts, painted Parts, machined parts, fragile parts, c class parts, inter-plant material
movement, and in-direct areas.

4 - MEASURES OF MATERIAL HANDLING SYSTEM
Reliability, maintainability, serviceability, availability factors, Supply supports, TPM for

MHF, manufacturing consideration: processes, methods and tools, assembly and
dismantling of MHF, system feasibility analysis, system operational requirements,
Supportability analysis, functional analysis, MTBF and MTTR for MHFs, flexibility in
MHFs, traceability of MHFs and MHEs, salvaging of MHFs and MHEs
5 - STORAGE SYSTEM
Creation of modern stores and storage systems: concept of stores, types of stores,
storage facilities, considerations for creation of stores, estimation of docks, truck turn-
around time, truck window time, inventory and types, WIP, material retention point,
model store concept.
6 – ANALYSIS OF MATERIAL HANDLING SYSTEMS

Analysis of Vehicle based system- determination of number of vehicles in AGVs and
determination of delivery distance. Conveyor analysis – single direction, continuous
loop and re-circulating conveyors

References:
1. Blanchard and Benjamin S, “Logistics Engineering and Management”, 6th
International Edition, Prentice Hall Inc, 2004.
2. Christopher M, “Logistics and Supply Chain Management - Creating Value
Adding Networks”, Prentice Hall, 2005.
3. James M. Apple, “Plant Layout and Material Handling” John Wiley, 3rd Edition,
1977.
4. Mikel P.Groover, “Automation, Production Systems, and Computer-Integrated
Manufacturing”, PHI Publishers, 3rd Edition 2008.
5. Prauss L, “The Green Multiplier - a Study of Environmental Protection and
Supply Chain”, Antonn Rauss Limited, Palgrave Macmillan, 2005.
6. Taylor G.D, “Logistics Engineering handbook”, CRC Press, 2008.
7. TVSM Material Handling Facilities Design Guidelines and Manuals

What is Logistics ?
The movement of goods through the supply chain
“the art and science of obtaining, producing, and

distributing material and product in the proper place
and in proper quantities”

Perspective of Logistics Industry
Global logistics industry is estimated to be worth USD 300 billion

The annual logistics in any country varies between 9% to 20% of their GDP
Ref: Logistics industry

analysis by market
research.com
The annual logistics cost in India is estimated to be 14% of GDP whereas

automotive sector contributes to 7 to 8% of GDP.
Out of the total cost 99% is accounted by the unorganized sector
Evolution of Logistics Industry
Carried loads manually Used animals
Used animal carts Used animal carts



Ref: Logistics industry analysis by market research.com

Supply Chain Management
Inbound Inhouse Outbound

Logistics Logistics Logistics
Dealership
Area warehouse
SUPPLIERS
TVSM
☺
Custome
Slide no. 12
TVSM / Operating Plan / Board / 21-Apr-2009
Material flow
Information flow
Cash flow
PD Rollout /PED
Inbound /Apr-13–
Logistics Supplier Slide 12
Training
Inbound Logistics
Web
Weekly
TVS-M release SCHEDULES Frequenc
y: 90% of
value
daily
JIT Call
(2Bin/Kanban)
Assembly line SUPPLIERS

Point of
consumption MILKRUN PACKING
Stores
Milk run Containerisation:
Slide no. 13
Web
2Bin/ Advance
Kanban shipping
notification
2Bin/Kanban
Information flow
Material flow
Barcoded invoice
PD Rollout /PED
Inbound /Apr-13–
Logistics Supplier Slide 13
Training
Outbound Logistics
Outbound Logistics Overview
Web
Orders -
MOS
Mfg. Plant Area warehouse Dealership
Secondary
Primary distribution distribution
TVSM
Slide no. 14
Schedules
Transporters
Information flow
Material flow
PD Rollout /PED /Apr-13 Slide 14

In-house Logistics
Manufacturing Plant Layout
VU stores
2Bin stores
Testing &
Kitting area
Booking
Vehicle
assembly-
Mainline
Engine Vehicle Vehicle

storage assembly- assembly-
Painting
Pre-line Sub assy
stores

In-house Logistics
Schematic of vehicle assembly with supporting units
2Bin stores Vehicle unit stores Warehouse

booking
Vehicle main line

Vehicle pre-
Engine line Testing
assembly Vehicle main line
Vehicle pre-
line
Vehicle sub assy
Painted parts storage – Painted parts storage –

DP Stores
Metal parts Plastic parts

Material Handling System Engineering
In-house Logistics is also Referred as

“Material handling System Engineering”
Material Handling System Engineering Consists of
• Handling – Material Handling Facilities
• Transfer – Material Handling Equipment
• Storage – Material Storage Systems

Video

What is Material Handling ?

Material Handling System in Home
Kitchen equipment stand Kitchen equipment stand
Cell phone stand

Material Handling System
Material Handling System - Definition
• Material handling system is the art and science of moving, storing, protecting
and controlling the materials.
• Materials handling system is the movement and storage of materials at the

lowest possible cost through the use of proper methods and equipment.
• Material handling system is the function of moving the right material to the
right place in the right time, in the right amount, in sequence, and in the right
condition to minimize production cost.
• The movement of raw material, semi-finished goods and finished articles

through various stages of production and warehousing.

Material handling
- Moving: Transfer of the material at the right time and the right place.
- Storing: Provides a buffer between operations, facilitates the efficient use of people and
machines.

Material handling
- Protecting: Includes the packaging, packing against damage and theft.
- Controlling: Physical orientation, sequence and space between material.
Ratio counter Scanner

Material Handling Facilities
3W material handling facilities – with modular concept and flexibility to accommodate future
models
Chassis Wind sheld trolley
trolley
Engine trolley Shock absorber trolley
Slide no. 24
PD Rollout /PED /Apr-13 Slide 24

Material Storage Facilities
Storage pallets Flow Rack System

Storage Bins
Heavy Duty Racking System

Lean Lifts Over head Conveyor
Material Transfer Equipment
Hand pallet truck Battery pallet truck Loading/Unloading Conveyor
Stacker Reach Truck Fork Lift

Importance of Material Handling System
• Material Handling accounts for:

– 25% of all employees,
– 55% of all factory space,
– 87% of production time
– 15-70% of the total cost of a manufactured product
• 3-5% of all material handled becomes damaged

– “Totally eliminate”
– However, handling less is not the answer.

Importance of material handling
The primary objective of a material handling system is to reduce the unit cost of
production.
• Reduce manufacturing cycle time

• Reduce delays, and damage
• Promote safety and improve working conditions
• Maintain or improve product quality
• Improve productivity
• Improve the utilization of facilities
• Reduce tare weight
• Control inventory

Requirements of Material Handling System
The essential requirements of a good materials handling system:
(i) Efficient and safe movement of materials to the desired place.
(ii) Timely movement of the materials when needed.
(iii) Supply of materials at the desired rate.
(iv) Storing of materials utilizing minimum space.
(v) Lowest cost solution to the materials handling activities.

Scope of Material Handling System
Scope of material handling
Bulk materials as well as unit materials handing. Bulk handling is particularly relevant
in the processing, mining and construction industries.

Scope of Material Handling System
Scope of material handling

Industrial packaging of in-process materials, semi finished or finished goods, primarily
from the point of view of ease and safety of handling, storage and transportation.
Handling of materials for storage or warehousing from raw materials to finished

product stage.

Material Handling System Equation
Material handling system equation
Why?
What? Where? When? How? Who? Which?
Preferred
Material + Moves + Methods + system
Material handling systems alternatives

The What Question
• What are the types of material to be moved?
• What are their characteristics?
• What are the amounts moved and stored?

The Where Question
• Where is the material coming from? Where should it come from?
• Where is the material delivered? Where should it be delivered?
• Where is the material stored? Where should it be stored?
• Where can material handling tasks be eliminated, combined or simplified?
• Where can you apply mechanization or automation?

The When Question
• When is material needed? When should it be moved?
• When is it time to mechanize or automate?
• When should we conduct a material handling performance audit?

The How Question
• How is the material moved or stored? How should material be moved or
stored? What are the alternative ways of moving or storing the material?
• How much inventory should be maintained?
• How is the material tracked? How should the material be tracked?
• How should the problem be analyzed?

The Who Question
• Who should be handling material? What are the required skills to perform the
material handling tasks?
• Who should be trained to service and maintain the material handling system?
• Who should be involved in designing the system?

The Which Question
• Which material handling operations are necessary?
• Which type of material handling equipment, if any, should be considered?
• Which material handling system is cost effective?
• Which alternative is preferred?

Characteristic and Classification of Materials
Characteristic and Classification of materials
• Method to be adopted and choice of equipment for a materials handling system

primarily depends on the type of materials to be handled.
• Basic classification of material is made on the basis of forms, which are
(i) Gases,
(ii) Liquids,
(iii) Semi liquids,
(iv) Solids.

Gases Handling
• Gases are generally handled in tight and where required, pressure resisting
containers. However, most common method of handling of large volume of gas is
through pipes by the help of compressor, blower etc. This process is known as
pneumatic conveying.
LPG gas pipelines Natural gas pipelines

Liquid Handling
• Liquids and semi-liquids can be handled in tight or open containers which may be
fitted with facilities like insulation, heating, cooling, agitating etc.
• Large quantity of stable liquids/semi-liquids are generally conveyed through pipes

using suitable pumps, which is commonly known as hydraulic conveying.
Water pipelines Oil pipelines

Solids Handling
• Solids form the majority of materials which are handled in industrial situation.
Solids are classified into two main groups:
- Bulk load
- Unit load.
Bulk load Unit load

Bulk load
- Bulk material handling is an engineering field that is centered around the design
of equipment used for the handling of dry materials such as ores, coal, cereals,
wood chips, sand.
- The purpose of a bulk material handling facility may be to transport material from
one to several locations

Unit load
- “Picked up and moved between two locations as a single mass”.
- These materials are counted by number of pieces like machine parts,
packed boxes, fabricated items.
• Example:
1. A single item picked up and moved manually between two locations
2. Two tote pans with identical components picked up moved by a dolly from one
machine to another
3. One pallet load of nonuniform-size cartons with different products picked up and
moved by a lift truck from the packaging area to the shipping dock
4. One full load of products delivered by a truck trailer from a warehouse to a

customer store If the trailer is half full, it is still one unit load.
Unit load - Advantages & Disadvantages
Advantages:
• Standardized handling equipment
• Standardized storage equipment

• Reduced information and control burden
• Efficient space utilization
Disadvantages:
• Cost of assembly and disassembly
• Cost of container and wrappings
• Cost of empty container handling and disposal

Classification of unit load
a) Shape of unit loads - Basic geometric forms like rectangular, cylindrical,
pyramidal/conical
b) Position of C.G. (stability) of load.
c) Mass of unit load in 10 steps from 0-2.5 kg to more than 5000 kg.
d) Volume per unit in 10 steps from 0-10 cm3 to more than 10 m3.
e) Type of material in contact with conveying system like metal, wood, paper/cardboard,
textile, rubber / plastics, glass and other materials.
f) Geometrical shape (flat, concave, convex, irregular/uneven, ribbed etc.) and physical
properties (smooth, slippery, rough, hard, elastic etc.) of base surface of unit load.

Classification of unit load
g) Specific physical and chemical properties of unit loads like abrasive, corrosive, dust
emitting, damp, greasy/oily, hot, cold, fragile, having sharp edges, inflammable, explosive,
hygroscopic, sticky, toxic, obnoxious, radioactive etc.
h) Loads sensitive to pressure, shock, vibration, turning/tilting, acceleration/deceleration,
cold, heat, light, radiation, damp etc.

Material Handling System Principles
MH Principles
1. Planning
18. Capacity
19. Performance
2. Systems
17. Control
20. Safety 3. Material flow
16. Obsolescence
4. Simplification
15. Maintenance
MH
5. Gravity
14. Utilization
13. Dead weight 6. Space utilization
10. Equipment
12. Adaptability 7. Unit size
selection
11. Standardization 9. Automation 8. Mechanization

1. Planning :
Plan all material handling and storage activities to obtain maximum overall
operating efficiency.
2. System :
Integrate as many handling activities as is practical into a coordinated
system of operations, covering vendor, receiving, storage, production,
inspection, packaging, warehousing, shipping, transportation and customer.
3. Material flow :
Provide an operation sequence and equipment layout optimizing material
flow.

4. Simplification :
Simplify handling by reducing, eliminating or combining unnecessary
movements and/or equipment.
5. Gravity :
Utilize gravity to move material wherever practical.
6. Space utilization :
Make optimum utilization of building cube.

7. Unit size :
Increase the quantity, size or weight of unit loads or
flow rate.
8. Mechanization :
Mechanize handling operations.
9. Automation :
Provide automation to include both production,
handling and storage functions.

10. Equipment selection :

In selecting handling equipment consider all aspects of the material
handled , the movement and the method to be used.
11. Standardization :
Standardize handling methods, as well as types and sizes of handling
equipment.
12. Adaptability :
Use methods and equipment that can best perform a variety of tasks and
applications where special purpose equipment is not justified.

13. Dead weight :

Reduce ratio of dead weight of mobile handling equipment to load carried.
14. Utilization :
Plan for optimum utilization of handling equipment and manpower.
15. Maintenance :
Plan for preventive maintenance and scheduled repairs of all handling
equipment's.

16. Obsolescence :
Replace obsolete handling methods and equipment with more efficient
methods or equipment will improve operations.
17. Control :
Use material handling activities to improve control of production, inventory
and order handling.
18. Capacity :
Use handling equipment to help achieve desired production capacity.
19. Performance :
Determine effectiveness of handling performance in terms of expense per
unit handled.
20. Safety :
Provide suitable methods and equipment for safe handling.

Conditions for improvements
Conditions for improvement
System not capable Idle production

No pre-kitting of of change or equipment due to
work expansion material shortage
Material piled
Automatic data
directly on floor
collection system
not used
MH
Backtracking of In-plant containers
material not standardized
Operators travel
Misdirected material excessively for
materials and
Excessive
supplies
demurrage

Organization for MHFS
Organization for MHFS :
• Good organization of the materials handling system operation is essential for good
results.
• Roles of Material handling operations organization:
To move the right material to the right destination on time.
To minimize production downtime due to materials handling breakdowns.
To minimize costs.
To minimize damage and accidents.
To supervise personnel and training effectively.
To report production, movement and inventory data.
To advise management.
To plan.

Roles of MHS Organization
Roles of the Material handling organization:
To move the material.
To staff the materials handling system.
To train materials handling personnel.
To supervise the system.
To report on the system’s functioning.
To report production, movement and inventory data.
To advise management.
To plan.

Roles of the Material handling organization:
These functions closely follow the objectives listed in the previous section.
These functions may differ from company to company owing to the nature of the
industry, union contracts, industry custom or other causes.
However, these functions are necessary in every company, the organizational
location may vary.

To move material
The major function and objective of the materials handling organization is
to deliver the right material to the right destination at the right time. This is
the reason for material handling. Other objectives and functions are
secondary.
To minimize downtime
In today’s highly automated mass production, downtime in any part of the

system will shut the whole system down. The resulting loss of production
will be very costly to the company.

To minimize damage and accidents
Not only are accidents to material and personnel expensive, they interrupt
operations and may cause a shutdown. Since materials handling accounts
for a substantial proportion of all industrial accidents, the materials
handling supervisor should strive to keep these to a minimum.
To minimize costs
Materials handling operations should be carried out at minimum cost.

To supervise personnel and training effectively
A major part of the materials handling manager’s time will be spent

supervising and training workers. Achieving this objective leads to
achieving the major objective of moving the material.

To submit prompt and accurate reports
Prompt and accurate reports are essential to management control and

to efficient operation of the whole production system.

To advise management
The head of the materials handling department should be the person to

advise management on the materials handling function. He should keep
track of new technology that could improve the system.

To plan
Planning requires coordination with the plans and prospects of other

divisions of the company regarding future product lines, product
changes, volume changes, and relocations.

To report on the system’s functioning
The system manager reports on the system’s functioning in which only

deviations from the planned norms are reported. These include
breakdowns, personnel problems beyond the authority of the system
manager, and recommended replacements and improvements.

Material Handling Equipment

Material handling equipment's
Material Handling Equipments
• Material handling equipment is used to increase output, control costs, and

maximize productivity.
WHY ???
- To reduce manual efforts

Types of Material handling equipment's
Types of material equipment's
3. Storage and Retrieval Equipment
• Unit Load Storage and Retrieval
• Unit Load Storage Equipment
• Unit Load Retrieval Equipment
• Small Load Storage and Retrieval
4. Automatic Data Collection and Communication Equipment
• Automatic Identification and Recognition
• Automatic Paperless Communication

Types of Material handling equipment's
Types of material equipment's
1. Containers and Unitizing Equipment
• Containers
• Unitizers
2. Material Transport Equipment
• Conveyors
• Industrial Vehicles
• Monorails, Hoists, and Cranes

Selection of Material handling equipment's
Factors Affecting the selection of Materials Handling Equipment
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.

Factors affecting the selection of Material Handling Equipment
10. Cost
9. Environment 1. Adaptability
8. Ease of
2. Flexibility
maintenance
MH
7. Supervision
3. Load capacity
required
6. Space
4. Power
requirement 5. Speed

Equipment factors to be taken into consideration may well include the following:
1. Adaptability: the load carrying and movement characteristics of the equipment

should fit the materials handling problem.
2. Flexibility: Where possible the equipment should have flexibility to handle more than
one material, referring either to class or size.
3. Load capacity: Equipment selected should have great enough load-carrying

characteristics to do the job effectively, yet should not be too large and result in
excessive operating costs.
4. Power: Enough power should be available to do the job.
5. Speed: Rapidity of movement of material, within the limits of the production process
or plant safety, should be considered.

Equipment factors to be taken into consideration may well include the following:
6. Space requirements: The space required to install or operate materials handling

equipment is an important factor in its selection.
7. Supervision required: As applied to equipment selection, this refers to the degree of

automaticity designed into the equipment.
8. Ease of maintenance: Equipment selected should be easily maintained at

reasonable cost.
9. Environment: Equipment selected must conform to any environment regulations.
10. Cost: The consideration of the cost of the equipment is an obvious factor in its
selection.

Selection method of equipment for Material movements
Quantity of
material
moved
Conveyors,
High Conveyors AGV train
Low Manual handling Powered trucks,

Hand trucks Unit load AGV
Short Long Move Distance

Material handling equipment's – Palletizer
Unitizers: Palletizer
Palletization is the task of taking cases and stacking them in layers on pallets for
storage and/or transportation.
Manual Palletizing is the most basic and also the most widely used method.
Typically, workers remove cases from a conveyor line or an existing pallet load
and stack them onto a pallet.
Semi-Automatic Palletizing is used when case weight is a factor and workers
are subject to back strain injuries, often resulting from manual palletizing. With a
semi-automatic system, a conveyor delivers product to an operator who arranges
the cases in layers on a variable height lift table.
Automatic Palletizing provides the fastest, most efficient and most ergonomical
method of palletizing.
Manual palletizing Semi-automatic palletizer Automatic palletizer

Material handling equipment's – Stretch wrapper
Unitizers: Stretchwrapper
Stretch wrapping is the most cost-effective way to keep loads secured on a pallet.
Manual stretch wrapping.
Semi-Automatic stretch wrapping.
Automatic stretch wrapping.
Manual stretch
Semi-automatic Automatic stretch wrapper
wrapping
stretch wrapper

Material handling equipment's – Conveyors
Conveyors
A conveyor system is a common piece of mechanical handling equipment that moves
materials from one location to another.
Conveyors are especially useful in applications involving the transportation of heavy or
bulky materials.
Conveyor systems allow quick and efficient transportation for a wide variety of
materials, which make them very popular in the material handling and packaging
industries.
Various conveyor systems,
Chain conveyors
Belt conveyors
Slot conveyors
Roller conveyors
Belt conveyor Chain conveyor Roller conveyor Slot conveyor

Material handling equipment's – AGV
Automated guided vehicles
An automated guided vehicle or automatic guided vehicle (AGV) is a mobile robot that
follows markers or wires in the floor, or uses vision or lasers. They are most often
used in industrial applications to move materials around a manufacturing facility or a
warehouse.
AGV with floor marking AGV AGV with load unit

Material handling equipment's – Industrial vehicles
Industrial Vehicles
Industrial trucks refer to the different kinds of transportation items and vehicles used
to move materials and products in materials handling. These transportation devices
can include small hand-operated trucks, pallet-jacks, and various kinds of forklifts.
These trucks have a variety of characteristics to make them suitable for different
operations. Some trucks have forks, as in a forklift, or a flat surface with which to lift
items, while some trucks require a separate piece of equipment for loading.
Trucks can also be manual or powered lift and operation can be walk or ride, requiring
a user to manually push them or to ride along on the truck.
Tractor truck
Fork lift Stacker Hand pallet truck (Towing truck)

Material handling equipment's – Monorails
Monorails
A monorail is a rail-based transportation system based on a single rail, which acts as

its sole support and its guide way. The term is also used variously to describe the
beam of the system, or the vehicles traveling on such a beam or track.
Types of monorail systems are,
1. Pipe rail system
2. Flat-bar monorail system
3. Structural rail system
Monorail system Monorail system Monorail system

Material handling equipment's – Hoists
Hoists
A hoist is a device used for lifting or lowering a load by means of a drum or lift-wheel
around which rope or chain wraps. It may be manually operated, electrically or
pneumatically driven and may use chain, fiber or wire rope as its lifting medium. The
load is attached to the hoist by means of a lifting hook.
Its various types are,
1. Chain hand hoists
- Lever operated hoists
- Portable hand chain hoists
- Differential hoists
- Screw or Worm geared hoists
Chain hand hoists
- Spur geared hoists
2. Powered hoists
- Electric hoists
- Pneumatic hoists
Electric hoist Pneumatic hoist

Material handling equipment's – Cranes
Cranes
Cranes are a combination of separate hoisting mechanisms with a frame for lifting or a
combination of lifting and moving loads which can be truly suspended on or secured to
them.
Generally it will be used in a factory, for repair and maintenance work and for
intermittent lifting jobs.
An important advantage of a crane equipped with a rotating boom is the high degree
of flexibility provided in picking up and placing loads.
The cranes are classified as,
- Revolving or rotary cranes
- Trackless cranes
- Mobile cranes
- Bridge cranes
- Floating cranes
- Helicopter cranes
Rotary crane Mobile crane Bridge crane

Material handling equipment's – Storage
Storage and Retrieval

Storage and retrieval system provide the combined
function of handling and storage the material. Function can
be done by automated or semi-automated.
Examples are unit load automated storage and retrieval

systems (AS/RS) which store and retrieve whole pallets,
mini load systems with storage drawers, micro load
systems with storages totes and carousels with extractors.
In hi-rack system, storage and retrieval will be done by

manual with the help of handling equipment's.

Material Storage Systems
Containers: Tote pans

A tote pan or crate is a large shipping container, often made of plastic, steel and
wood, typically used to transport large, heavy or awkward items.
Plain crates Plain crates with lid
Perforated crates Foldable crates

Containers: Pallets
• A pallet is a flat transport structure that supports goods in a stable fashion while
being lifted by a forklift, pallet jack, front loader, work saver or other jacking
device.
• A pallet is the structural foundation of a unit load which allows handling and
storage efficiencies. Its also called as a skid.
Plastic pallets Wooden pallets
Steel pallets

Storage and Retrieval
Unit load AS/RS Person-aboard Vertical Carousel Systems

system AS/RS system
Hi-rack systems (Using hand stacker) Drive-in-rack systems

New generation material handling system

The new-generation material handling system are highly automated system based on
latest technologies, provided with flexibility capable of changing its own structure or
function in response to changes from manufacturing systems, and autonomous
functions to enhance system reliability. Such system is defined as “MMHS -
Metamorphic Material Handling System”.

MMHS project perform research and development activities focusing on the following four
Points,
1. Life cycle optimization

2. Environmentally conscious manufacturing
3. User-friendliness
4. Contribution to global industry productivity.

Subjects and objectives of MMHS

Subjects and objectives of MMHS project conceived from this viewpoint were as follows.,
1. Responsive: Responsive to changes that may take place in manufacturing

technology and environment, type of product or material to be handled, work
schedule and load.
2. Flexible: Capable of transforming itself and altering its function to meet any
change in handling requirements.
3. Autonomous: Able to make decisions on its own (to enhance system availability).
4. Highly automatic: Incorporated with next-generation automation technology.
5. Multi-functional: Having such functions as assembling, packaging and disassembling,

besides transporting.

6. Modularized: Composed of various modules, each with a distinct function; e.g.
planning module, basic module, tool-setting module, communication module, capable
of associating or dissociating one another to organize themselves into a configuration
as required.
7. Multi-level: Designed into multi-level sub-systems so as to be capable of cooperating

other independent material-handling equipment including AGVs and mobile robots.
8. Compatible: Capable of adapting itself to other existing material-handling systems.

Material Flow Analysis

Material flow
Material flow
- Material flow is defined as an organized movement of materials (raw

materials, basic and auxiliary materials, semi products, tools, and finished
products, packages and waste) in the production process or circulation.
- Material flow draws the routes, outputs, travel distances, times and
costs.
Material flow diagram

Material flow
Web
Weekly
TVS-M release SCHEDULES Frequenc
y: 90% of
value
daily
JIT Call
(2Bin/Kanban)
Assembly line SUPPLIERS

Point of
consumption MILKRUN PACKING
Stores
Milk run Containerisation:
Web
2Bin/ Advance
Kanban shipping
notification
2Bin/Kanban
Information flow
Material flow
Barcoded invoice

Material flow
Material flow in one module
Material flow in warehouse

Material flow parameters
Material flow
This movement is expressed by following parameters :
Frequency - number of transportations per time unit,

Intensity - the amount transported per time unit,
Length - the distance the material pass from the starting point to the end point,
Performance - the product of the intensity and length of material flow,
Direction - from - to,
Manipulation factor - the number of manipulation operations carried out.

Material flow parameters
The quantifiable parameters are,
Quantity of material [Q] - which can be expressed in units of mass or volume in

case of the bulk materials or in manipulation units in case of materials in pieces.
Path [s] - which is expressed in length of track or route of material movement in

the area between the source (supplier) and consumer (customer).
Time [t] - is expressed by the duration of any work activity (operation process) or
term when to start an activity or finish (time of submission the vehicle for loading,
delivery time inventory).
Retention Points -

Material retention
Retention:
The point which is holding the inventory before/after process and

re-handling in the material flow, it is called as retention point.
Material
receipt 2 Storage 4 Painting
3
1
5
Vehicle Vehicle Sub

testing 4 assembly 3 assembly

Material flow Benefits
Material flow benefits,

A controlled material flow would result the following,
Lower overhead costs

Minimization of machinery usage
Increased accuracy in monitoring materials flow
Smoother processing of materials
Increased profits
Reduced waste
A culture of continuous improvement

Material flow analysis
“Material flow analysis (MFA) is a systematic assessment of the flows and

stocks of materials within a system defined in space and time.”
Objectives :
• Define system of material flows and stocks
• Reduce no. of retention
• Reduce system complexity while maintaining basis for decision-making
• Assess relevant flows and stocks quantitatively, checking mass balance,
sensitivities, and uncertainties
• Present system results in reproducible, understandable, transparent
fashion
• Use results as a basis for managing resources, the environment, and
wastes

7 Steps of Material flow analysis
Material flow analysis techniques
A complete material flow analysis comprises seven steps.
1. Define the objective of the material flow analysis and the parameters to
be monitored
2. Define the balance scope
3. Define the balance period
4. Identify and define process steps
5. Draw the flowchart: material flows – qualitative approach
6. Draw up balances: material flows – quantitative approach
7. Interpret the results and draw conclusions.

Factors affecting Material flow analysis
Nature of materials Storage concept No. of nodes
Track or path Human work factor
Level of flow control Output
Material flow
Time analysis Handling units
Types of Transportation
warehouses machines
Technical solution of Space and size of the

warehouses area
No. of components and No. of operations on

Parameters of material components of materials
types of materials
flows b/w objects

The following types of charts can be used for the graphical representation
of a material flow analysis:
1. Flow charts:
- A flowchart is a graphic representation of how a process works, showing the
sequence of steps.
- It includes multiple steps, how the process "flows" through from start to finish.
- It is used to describe process that are to be improved.

Material Flow Analysis – Case study
Case study - Flow analysis for crank case

2. Pie charts & Histograms:
- A bar graph of a frequency distribution in which the widths of the bars are
proportional to the classes into which the variable has been divided and the
heights of the bars are proportional to the class frequencies.
Pie chart Histogram chart

Time travel diagram
3. Time–travel diagrams:

Sankey diagram
4. Sankey diagram:
- Sankey diagrams are a specific type of flow diagram, in which the
width of the arrows is shown proportionally to the flow quantity.
- They are typically used to visualize energy or material or cost
transfers between processes.

Material Handling Safety

Safety
Safety
- Safety is the state of being "safe" , the condition of being protected against
physical, emotional, occupational, or other types or consequences of failure,
damage, accidents, or any other event which could be considered non-
desirable.
- Safety can also be defined to be the control of recognized hazards to achieve

an acceptable level of risk

Industrial safety
Industrial Safety
- In a factory, handling and storing of materials provide a continuous flow

of parts and assemblies through the workplace and ensure that materials
are available when needed.
- Unfortunately, the improper handling and storing of materials often result

in costly injuries.

Mechanical Hazards
Mechanical Hazards
Hazard Risk
Rotating shafts, pullies, sprockets and gears Entanglement
Hard surfaces moving together Crushing
Scissor or shear action Severing
Sharp edge – moving or stationary Cutting or puncturing
Cable or hose connections Slips, trips and falls (e.g. oil leaks)

Non-Mechanical Hazards
Non-Mechanical Hazards
Hazard Risk
Dust Mist (vapours or fumes)
Explosive or flammable atmospheres Noise
Heat (radiated or conducted) Ignition sources (flame or spark)
High intensity light (laser, ultra-violet) Molten materials
Heavy metals (lead, cadmium, mercury) Chemicals
Steam Pressurised fluids and gases
Ionising radiation (x-rays, microwaves) Electrical

Health and Safety Hazards
Health and Safety Hazards:
• Physical hazards; lighting.
• Ergonomic hazards; force (lifting and pushing/pulling) and posture (bending,
reaching and twisting).
• Energy hazards; gravity (falling objects).
• Materials handling hazards; lifting, pushing/pulling and hazardous substances.
• Work practice hazards; following established safe work

Safe work procedures
Safe Work Procedure:

1. Wear appropriate personal protective equipment.
2. Warm up your muscles (do some light stretching) for a few minutes
before you start lifting.

3. Know the approximate weight of the item before you attempt to lift it.
Use a mechanical lifting device (e.g. dolly, hand truck, cart, etc.) to move a
heavy or bulky load wherever possible.
4. Do not attempt to lift a load that is too heavy or too bulky for you. Ask
for assistance.

5. Lifting guidelines:
i. Look and plan ahead. Make sure your path is free of obstructions,
debris and slip and fall hazards such as grease, oil, water, etc.
ii. Ensure that you can lift the load without over-exertion.
iii. Ensure that the load is “free” to move.
iv. Check that you can get a good grip of the load.
v. Stand over the object.
vi. Place your feet so you are balanced.
vii. Bend your knees (not beyond 90 degrees) and keep your back
comfortably upright.
viii. Grip the object with your two whole hands (not just the fingers) so
you can hold it securely. Avoid grasping the ends of long items.
ix. Tighten your abdominal muscles.
x. Tuck your chin into your chest.

5. Lifting guidelines:
xi. Lift by straightening your legs. Use your legs to lift.
xii. Lift smoothly without jerking.
xiii. Hold the load close to your body.
xiv. Move your feet if you must turn while lifting. Do not twist your body.
xv. When walking with a load, short steps are best. Keep the load at a
reasonable height. Watch where you are going. Watch for tripping
hazards.

6. Lowering guidelines (putting a load down):

i. Take a wide stance with one foot in front of the other.
ii. Keep the load close to your body.
iii. Keep your back straight. Do not bend over when setting a load down
iv. Bend your hips and knees.
v. Set the load down. Keep the load tilted so you do not squat your
fingers. Avoid a jerky release.
vi. Stand up smoothly, easing your muscles.

Thank you

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MATERIAL HANDLING SYSTEM

Course Code : GCE

1. Understand and map process and material flow.

3. Design material storage and handling system to prevent potential failure

4. Verify produced part quality is delivered to the point of consumption

5. Apply "OR" (Operation Research) and REBA/RULA tools and techniques in

6. Develop standardized storage and handling work procedures.

TVSM / PED / MSE / MHSE Slide 2

1 - INTRODUCTION TO MATERIAL HANDLING SYSTEM

Design considerations for MHF, selection of materials. Estimation of number of facilities

3 – ERGONOMICS IN MATERIAL HANDLING FACILITIES DESIGN

TVSM / PED / MSE / MHSE Slide 3

Reliability, maintainability, serviceability, availability factors, Supply supports, TPM for

6 – ANALYSIS OF MATERIAL HANDLING SYSTEMS

TVSM / PED / MSE / MHSE Slide 4

TVSM / PED / MSE / MHSE Slide 5

The movement of goods through the supply chain

“the art and science of obtaining, producing, and

TVSM / PED / MSE / MHSE Slide 6

Global logistics industry is estimated to be worth USD 300 billion

Ref: Logistics industry

The annual logistics cost in India is estimated to be 14% of GDP whereas

Carried loads manually Used animals

Used animal carts Used animal carts

TVSM / PED / MSE / MHSE Slide 8

TVSM / PED / MSE / MHSE Slide 9

TVSM / PED / MSE / MHSE Slide 10

Ref: Logistics industry analysis by market research.com

Inbound Inhouse Outbound

Assembly line SUPPLIERS

Outbound Logistics Overview

PD Rollout /PED /Apr-13 Slide 14

Manufacturing Plant Layout

Engine Vehicle Vehicle

TVSM / PED / MSE / MHSE Slide 15

Schematic of vehicle assembly with supporting units

2Bin stores Vehicle unit stores Warehouse

Vehicle main line

Vehicle sub assy

Painted parts storage – Painted parts storage –

TVSM / PED / MSE / MHSE Slide 16

In-house Logistics is also Referred as

Material Handling System Engineering Consists of

• Handling – Material Handling Facilities

• Transfer – Material Handling Equipment

• Storage – Material Storage Systems

TVSM / PED / MSE / MHSE Slide 17

TVSM / PED / MSE / MHSE Slide 18

TVSM / PED / MSE / MHSE Slide 19

Kitchen equipment stand Kitchen equipment stand

Cell phone stand

TVSM / PED / MSE / MHSE Slide 20

Material Handling System - Definition

• Materials handling system is the movement and storage of materials at the

• The movement of raw material, semi-finished goods and finished articles

TVSM / PED / MSE / MHSE Slide 21

TVSM / PED / MSE / MHSE Slide 22

- Controlling: Physical orientation, sequence and space between material.

Ratio counter Scanner

TVSM / PED / MSE / MHSE Slide 23

Engine trolley Shock absorber trolley

PD Rollout /PED /Apr-13 Slide 24

Storage pallets Flow Rack System

Heavy Duty Racking System