Material Handling Class notes for 4-2 mechanical

UNIT-5
Introduction:
One of the significant events that changed the organized manufacturing
sector was the industrial revolution. The revolution started during 1790 to 1810 AD
in France and extended to the European countries. Prior to this, manufacturing was
confined to domestic sectors with low volumes of production. There was practically
no mechanization and atomization in manufacturing prior to this revolution. The
factory system evolved during this period, using the steam power and factories
were larger in size. Productivity per man hour increased substantially. In this
scenario, material handling evolved as a specialist subject. The aim was to reduce
the man power deployed on material handling activities since it did not contribute
anything to the value of the product; but added significantly to the cost of the
product up to 70% in some cases. There is a need for engineering professionals to
learn the scientific principles of material handling to curtail its cost to as minimum
as 15% of the product cost.

Scope of material handling

The scope of materials handling activity within an organization depends on the
type of product manufactured, the size of the organization, the value of the product
and the activity being performed and the relative importance of materials handling
to the enterprise.
Whenever material is moved from one place to other in a factory situation
during manufacture or when the manufactured product is distributed to the ultimate
consumer through a chain of distributing agencies, MH occurs in three layers:
Layer 1 : people handling individual parts / work piece/ unit
Layer 2: Material handled within the confines of a room or department or
plant in the factory
Layer 3:Complete material handling system. i.e. A chain of events starting
from supplier- factory- distribution network- consumer- disposal- recycle

as shown in the schematic below:

Individual parts

Departmental or part

Definition of material Handling:

Materials handling is defined as the art and science of moving, packaging
and storing of substances in any form.
Other definitions include:

Creation of time and place utility.

Movement and storage of material at the lowest possible cost through
the use of proper methods and equipment.
Lifting, shifting and placing of material which effect saving in money,
time and place.
Art and science of conveying, elevating, positioning, transporting,
packaging and storing of materials.

Objectives of material Handling:

The simplest solution to the materials handling problem- No
movement, no cost is hardly practicable for a complete manufacturing
process. It is basically a sound approach when one is attempting to improve

a complete production cycle and when the number of handlings can be

reduced. It is also a good solution in the making of heavy industrial
equipment. In the latter situation it is often more feasible to bring the tools
and workers to the product than to transport the product to the machine or
work area.
In addition to the objective of reducing the overall costs of materials
handling by reducing the number of handlings involved, the following may be
considered as objectives of the engineer in his or her approach to this
problem.
Lower the unit materials handling costs: It is obvious that if the overall
materials handling costs are reduced the unit costs will be reduced. This
approach requires the costs of handling be allocated to or identified with the
units of product, or its component parts that are moved.
Reduce the manufacturing cycle time: The total time required to make a
product from the receipt of raw materials to the finished goods can be
reduced through effective materials handling.
Contribute toward a better control of the flow of goods: A principle
way in which good materials handling practice can affect savings is by
making the control of goods easier- practically in continuous manufacturing,
where all operations are tied together by the materials handling plan.
Provide for improved working conditions and greater safety in the
movement of materials many of the provisions of the occupational safety
and health act require adherence to safe handling practices. These must be
followed. In addition, it is evident that the safe handling of materials will be
reflected in a better industrial accident record.
Provide for fewer rejects: Care in the handling of the product will
contribute to a better quality level of the goods produced. Products damaged
by inefficient handling are all too often a major cost to manufacture.
Achieve decreased storage requirement: Better movement and storage
of materials should increase the utilization of storage space.
Gain higher productivity at lower manufacturing cost: Any materials
handling system, if it is worth its investments, is design to improve
productivity. This improvement should be achieved by moving materials in
the fastest, most efficient and economical way possible.

Material Handling Systems:

The systems approach to materials handling demands that all elements of
the chain of cause and effect be analyzed so we may accomplish our
objectives.
Systematic analysis or the systems approach to materials handling demands
that our solutions to materials handling problems satisfy certain important
conditions, as follows:
1. That they resolve more problems than they create; that they do not
transfer problems into other areas; and that the amount of return on
investment adequately justifies the solution.
2. That they not only resolve the immediate problems, but that they take
care of the problems for a reasonably long period of time; and that
they readily permit expansion, modification, or necessary change
without unreasonable cost-in other words, that they will not become
obsolete too rapidly.
3. That the solutions are as simple as it is possible to make them; for, if
they are simple, acceptance on the part of management and everyone
else concerned, including the operators, is more palatable and,
therefore, more easily and more rapidly achieved.
The best solution to materials handling problems does not usually come
very easily. But, it generally comes about by systematic analysis of
pertinent factors; by examining, insofar as it is possible to do so, the total
system; and by applying the proper technique or techniques from a board
range of disciplines.
The important consideration is that the technique, or the method, should
fit the application and be commensurate in value with the scope of the
problem undergoing analysis.

With the proper perspective distilled from all the factors involved, the
least total cost of the system can be developed. And, that is the ultimate
objective of the systems approach to materials handling.

Principles of Material Handling:

A good materials handling engineer will generally have several years of
experience that can be brought to bear on the solution of materials handling
problems or the design of materials handling systems.
For many years, discussions of principles of materials handling have been
published by many experts in the field. The following list has been adapted
from CIC-MHE:
1. Eliminate wasteful methods by
Reducing to a minimum the number of handlings of materials.
Eliminating unnecessary mixing and subsequent sorting.
Using mechanical aids to eliminate the use of hand labor in
movement of materials.
Avoiding the unnecessary transfer of materials from floor to
workplace or from container to container.
Increasing the speed of handling.
Utilizing gravity as a moving force wherever practicable.
Introducing automation into the materials handling plan.
2. In laying out the plant:
Plan a system for materials flow and combine handling with
processing wherever possible.
Provide for continuous or appropriate intermittent flow of
materials.
Provide for the optimal flow of materials between operations and
with a minimum of retrograde movement.
Plan the layout of the work-station area for a minimum of
handling of the product.
Maximize the quantity and size of weight handled.
Coordinate the overall materials handling throughout the entire
plant.
Provide for safe handling and safe equipment and integrate with
the management information and control system.
Plan for adequate receiving, storage and shipping facilities.
Design adequate aisle and access areas.
3. In the selection and application of materials handling equipment:
Plan activities and analyze equipment needs before considering
the purchase of equipment.

Ensure that the existing equipment is being used effectively.

Use the simplest equipment that is adaptable to the problem:
avoid the use of complicated mechanisms and controls.
Adopt standard equipment if possible; ensure that the purchase
of special equipment is economically justified.
Select equipment that is flexible in its application.
Select equipment that will minimize the ratio of mobile
equipment deadweights to pay loads.
Determine comparative costs of equipment before purchasing.
Recognize the need for different equipment for different jobs.
Recognize the need to provide suitable building conditions for
the equipment.
Provide for alternative methods for use in emergencies.
Give consideration to the maintenance of the equipment.
Replace obsolete methods and equipment with more efficient
ones.

Classification of material handling equipment:

Tompkins and white divide materials handling equipment into five
classifications. They give following list but note that numerous
variations can exist within each category:
1. Conveyors
2. Monorails, hoists, and cranes
3. Industrial trucks
4. Containers and supports
5. Auxiliary and other equipment
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
materials handled.
Equipment factors to be taken into consideration may well include the
following:
Adaptability: The load carrying and movement characteristics of the
equipment should fit the materials handling problem.

Flexibility: Where possible the equipment should have flexibility to

handle more than one material, referring either to class or size.
Load capacity: Equipment selected should have great enough loadcarrying characteristics to do the job effectively, yet should not be too
large and result in excessive operating costs.
Power: Enough power should be available to do the job.
Speed: Rapidity of movement of material, within the limits of the
production process or plant safety, should be considered.
Space requirements: The space required to install or operate
materials handling equipment is an important factor in its selection.
Supervision required: As applied to equipment selection, this refers
to the degree of automatically designed into the equipment.
Ease of maintenance: Equipment selected should be easily
maintained at reasonable cost.
Environment: Equipment selected must conform to any environment
regulations.
Cost: The consideration of the cost of the equipment is an obvious
factor in its selection.
Relationship between Material Handling and Plant Layout:
1. The relationship between the two involves the data required for
designing each
activity, their common objectives, the effect on space, and the flow
pattern.
2. Specifically, plant layout problems require knowledge of the equipment
operating
cost in order to locate the departments in a manner that will minimize
the total
material-handling cost.
3. At the same time, in designing a material handling system the layout
should be
known in order to have the move length, move time, source and
destination of the
move.
4. Because of this dependency, the only feasible way is to start with one
problem, use
its solution for solving the other, then go back and modify the first
problem on the
basis of the new information obtained from the second, and so on until
a satisfactory
design is obtained.
5. Plant layout and material handling have the common objective of cost
minimization.
The material handling cost can be minimized by arranging closely
related
departments such that the material moves only short distances.

UNIT- 6
Basic Material Handling Systems:
1. Equipment Oriented Systems:
Industrial Truck Systems: Platform trucks and skids, fork
trucks and pallets, and tractor- trailers.
Conveyor systems.
Overhead systems: Overhead cranes, and monorails.
2. Material(Load ) Oriented systems:
Unit handling systems.
Bulk handling systems: conveyors, power shovels, scoops,
cranes, draglines, and construction equipment.

 Liquid material handling systems.

3. Method (Production) Oriented Systems:
These are described in terms of the types of production in which
they are used:
Manual system.
Mechanised or automated systems
Mass production handling systems.
Job shop handling systems.
4. Function Oriented Handling Systems:
Transportation systems: For horizontal motion.
Elevating Systems: For vertical motion over vertical or steeply
inclined routes.
Conveying systems: Horizontal, vertical or combined motions.
Transferring systems: Horizontal, inclined or declined motions
through the air.
Self loading systems: Intermittent motion with machines that
pick up, move and set down, i.e., unit load systems.
Selection and Design of Handling System:
Materials handling systems are expensive to purchase and operate.
The expenses are those of initial costs, labour cost for operating the material
handling equipments and maintenance and repair costs. The indirect
expenses are those resulting from damaged or lost materials, delays in
material deliveries and accidents. Since these expenses are quite
substantial, greater attention of management is needed to the design and
selection of materials handling systems.
Since the pattern of flow of materials in a plant definitely affects the
material handling costs, it is vital that the design and layout of buildings
must be integrated with the design of the materials handling system.
Hence, the selection and design of the materials handling system should be
done along with the development of the layout as each one affects the other.
For example, if overhead cranes are to be used, the structure of the
building must be strong enough to support the operation of these services. If
heavy loads are to be transported on trucks, floors must have adequate
support to withstand these loads. Aisles or gangways must be wide enough
to accommodate fork lift trucks that will travel through the areas carrying the
loads. Adequate floor space has to be provided in the layout for fixed
positions handling devices such as conveyors.
Steps to be followed in the selection and design of material handling
systems are:
1. Identification of the appropriate systems.
2. Review of design criteria and objectives of the handling system.
3. Collection of data regarding flow pattern and flow requirements.
4. Identification of activity relationships between departments.

5. Determination of space requirement and establishment of material flow

pattern.
6. Analysis of material and building characteristics.
7. Preliminary selection of basic handling system and generation of
alternative systems considering feasibility of mechanization and
equipment capabilities.
8. Evaluation of alternatives with respect to optimal material flow,
utilizing gravity, minimum cost, flexibility, ease of maintenance, and
capacity utilization.
9. Selection of the best suitable alternative system and checking it for
compatibility with layout.
10.
Specification of the system.
11.
Procurement of the equipment and installation of the system.

Material Handling Equipment Selection:

Given the material flow requirements for one or moves, MHS
alternatives can be determined by selecting appropriate MH equipment that,
in some way, satisfies the requirements.
An important issue is the classification level from which the MH equipment is
selected:
High Levelcategories of equipment, e.g., conveyors, cranes,
industrial trucks, positioning equipment
Intermediate Levelequipment types within categories, e.g., chute or
roller conveyors, pallet jack or pallet truck industrial trucks
Low Levelequipment models within an equipment type, e.g., an
Acme Model X diesel-powered counterbalanced lift truck with a rated
lift capacity of 5,000 lbs.

Selection Problem: Starting from a low level can result in too many
possible choices, while starting from a high level does not narrow the
number of possible choices enough; starting from the intermediate level
reduces the selection problem to choosing from 1550 possible types of MH
equipment.
The process of MH equipment selection can be decomposed into two
stages (see above Figure ):
(1)Determine Technical Feasibilityselect MH equipment types that
can satisfy the material flow requirements from a technological
perspective;
e.g., a pallet jack is not technically feasible for stacking pallets onto
storage racks
(2)Determine Economic Feasibilityfrom among the technically
feasible equipment types, select the equipment type that is most
cost effective given the material handling requirements;
e.g., while both a pallet jack and pallet truck are technically
feasible for long-distance moves, the pallet truck, while costing more
initially, would be more cost effective because it can travel faster due
the operators ability to ride on the truck

Material Handling Equipment:

1. 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.
(A)Conveyors
Chute conveyor
Wheel conveyor
Roller conveyor
Chain conveyor
Slat conveyor
Flat Belt conveyor
Magnetic Belt conveyor
Troughed Belt conveyor
Bucket conveyor
Vibrating conveyor

 Screw conveyor
Pneumatic conveyor
Vertical conveyor
Cart-on-track conveyor
Tow conveyor
Trolley conveyor
Power-and-free conveyor
Monorail
Sortation conveyor
(B) . Cranes
Jib crane
Bridge crane
Gantry Crane
Stacker Crane
(C). Industrial Trucks
Hand truck
Pallet Truck
Walkie stacker
Pallet jack
Platform Truck
Counter Balanced lift truck
Narrow-Aisle straddle truck
Narrow-Aisle reach truck
Turret truck
Order picker
Sideloader
Tractor-trailor
Personnel and burden carrier
Automatic guided vehicle
(D). No equipment
Manual
Transport equipment is used to move material from one location to
another, while positioning equipment is used to manipulate material at a
single location. The major subcategories of transport equipment are
conveyors, cranes, and industrial trucks. Material can also be transported
manually using no equipment.
The following general equipment characteristics can be used to
describe the functional differences between conveyors, cranes, and
industrial trucks :
Path:

Fixedmove between two specific points

Variablemove between a large variety of points

Area:

Restrictedmove restricted to a limited area

Unrestrictedunlimited area of movement

Move frequency:
Lowlow number of moves per period, or
intermittent moves
Highhigh number of moves per period
Adjacent move:

Yesmove is between adjacent activities

Nomove is between activities that are not adjacent

Transportation Equipment Characteristics

Path

Fixed

Variable

Area

Restricted

Frequenc
y
Adjacent

High
-

Yes

Equipme
nt
Category

Conveyo
r

Conveyo
r

Restricted

Low

High

Low

No

Industrial
truck/cra
ne

Industrial
Truck

Crane

Unrestrict
ed
-

Industrial
Truck

2. Positioning Equipment: Equipment used to handle material at a

single location (e.g., to feed and/or manipulate materials so that are
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.

Manual (no equipment)

Lift/tilt/turn table
Dock leveler
Ball transfer table
Rotary index table
Parts feeder
Air film device
Hoist
Balancer
Manipulator
Industrial robot

3.

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 selfrestraining (e.g., a single part or interlocking parts), then they can
be formed into a unit load with no equipment.
Self-restraining(no equipment)
Pallets
Skids
Slipsheets
Tote pans
Pallet/skid boxes
Bins/baskets/racks
Cartons
Bags
Bulk load containers
Crates
Intermodal containers
Strapping/tape/glue
Shrink-wrap/ stretch-wrap
Palletizers
4. 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 machines of an
AS/RS, or storage carousels). If materials are block stacked directly
on the floor, then no storage equipment is required.
Block stacking (no equipment)
Selective pallet rack
Drive-in rack
Drive-through rack
Push-back rack
Flow-through rack
Sliding rack
Cantilever rack
Stacking frame
Bin shelving
Storage drawers
Storage carousel
Vertical lift module
A-frame
Automatic storage/ retrieval system
5.

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.
Manual (no equipment)
Bar codes
Radio frequency identification tags
Voice recognition
Magnetic stripes
Machine vision
Portable data terminals

Material Category
Individual Units
Containerized
items
Bulk Materials

Material Categories
solid
Physical state
Liquid
Part,
Subassembly
Carton, Bag, Tote,
Barrel
box, pallet, bin
Sand, cement,
coal, granular
products

Liquid chemicals,
solvents, gasoline

Gas
Cylinder
Oxygen, nitrogen,
carbon dioxide

The impact of the material category listed in Table 1 on the type of MH

equipment is as follows:
Individual units and containerized items discrete material flow unit
loads unit handling equipment
Bulk materials continuous material flow bulk handling equipment

Unit load Concept:

A unit load is either a single unit of an item, or multiple units so

arranged or restricted that they can be handled as a single unit and
maintain their integrity.
Advantages of unit loads:
1. More items can be handled at the same time, thereby reducing
the number of
trips required and, potentially, reducing
handling costs, loading and unloading times, and product
damage.
2. Enables the use of standardized material handling equipment.

Unit vs. bulk handling of

material.

Disadvantages of unit loads:

1. Time spent forming and breaking down the unit load.
2. Cost of containers/pallets and other load restraining materials used in
the unit load

3. Empty containers/pallets may need to be returned to their point of

origin.
Basic ways of restraining a unit load:
self-restrainingone or more units that can maintain their integrity
when handled as a single item (e.g., a single part or interlocking parts
Platformspallets (paper, wood, plastic, metal), skids (metal, plastic)
Sheetsslip sheets (plastic, cardboard, plywood)
Reusable containerstote pans, pallet boxes, skid boxes, bins,
baskets, bulk containers (e.g., barrels), intermodal containers
Disposable containerscartons, bags, crates
Racksracks
Load stabilizationstrapping, shrink-wrapping, stretch-wrapping,
glue, tape, wire, rubber bands
Basic ways of moving a unit load:
Use of a lifting device under the mass of the load (e.g., a pallet and
fork truck)
Inserting a lifting element into the body of the load (e.g., a coil of steel)
Squeezing the load between two lifting surfaces (e.g., lifting a light
carton between your hands, or the use of carton clamps on a lift truck)
Suspending the load (e.g., hoist and crane)
Function Oriented Systems:

UNIT-7
Methods to minimize the cost of material Handling:
The primary method of material handling is to reduce overall unit costs
of production.
The following subordinate methods are a good check-list for cost reduction:
1. Maintain or improve product quality, reduce damage, and provide for
protection of materials,
2. Promote safety and improve working conditions,
3. Promote productivity through;
o Material should flow in a straight line,
o Material should move as short a distance as possible,
o Use gravity! It is free power,
o Move more material at one time,
o Mechanize material handling,

o Automate material handling,

o Maintain or improve material handling/production ratios,
o Increase throughput by using automatic material handling
equipment,
4. Promote increased use of facilities by;
Promote the use of the building cube,
Purchase versatile equipment,
Standardize material handling equipment,
Maximize production equipment utilization using material
handling feeders,
Maintain, and replace as needed, all equipment and develop a
preventive maintenance
program,
Integrate all material handling equipment into a system,
5. Reduce tare (dead) weight,
6. Control inventory.
OR models have been applied to the design and operations of material
handling
Systems, involving use of mathematical programming, simulation, queuing
theory, and network models.
Examples of applications: Conveyor systems, pallet design and loading,
equipment selection, dock design, equipment routing, packaging, and
storage
system design.
The selection of material handling equipment and its assignment to
departmental material-handling tasks: after an initial screening has
been
performed by the designer to determine the most promising candidates, the
final selection is to be made analytically.
Each move can be performed by most or all of the candidate
equipment, thus for each
move, there are different values for the operating cost and time based
on the equipment
used.
The problem requires selection of equipment among the candidate
set and assigning them
to the moves such that a move is not made by more than one item of
equipment unless
they are of the same type (that is, each move is assigned to only one
equipment type) and
all moves assigned to a piece of equipment can be performed in the
available time on the
equipment.
The primary objective of the problem is cost (operating and initial)
minimization. There

are also some secondary objectives such as maximum utilization of

equipment and
minimum variation in the selected types, but they are most often
compatible with the
primary objective.
Parameters to be used:
q = total number of moves to be assigned,
p = number of candidate equipment types,
aij = {0/1} binary parameter; 1 if equipment type i can perform move j, or
0 otherwise,
Wij = total operating cost of performing move j by equipment type i in the
predetermined
time period,
Ki = capital cost of one unit of equipment type i in the pre-determined time
period,
hij = total operating time required by equipment type i to perform move j,
Hi = available operating time of one unit of equipment type i in the predetermined
time period,
i =index to be used for equipment types, i = 1, .. , p,
j =index to be used for moves, j = 1, .. , q,
Decision variables:
i = number of units of equipment of a selected equipment type i that are
required,
Xij = {0/1} binary decision variable; 1 if equipment type i is assigned to
move j, or
0 otherwise,
Minimizing z =

Safety in Handling:
Since about two thirds of the general causes of accidents are directly
related to materials handling, safety in materials handling is a major concern
of production managers and safety engineers. The considerations for safe
handling of materials are as follows:
(1)Installation of adequate guards and safety devices on handling
equipment.
(2)Keep handling equipments in good operating conditions.
(3)Replace manual handling by mechanized handling for difficult,
hazardous handling activities.
(4)Do not permit the handling equipments to be overloaded or operated
beyond rated capacity.
(5)Keep aisles clear and uncluttered.
(6)Avoid conjestion of materials.
(7)Maintain adequate lighting.
(8)Maintain floors in good condition.
(9)Provide good housekeeping.

10.
11.
12.

Stack materials carefully.

Train operators in properly operating the handling equipments.
Highlight handling hazard or danger zones.

UNIT 8
Ergonomics:
It is the scientific discipline concerned with the understanding of
interactions among humans and other elements of a system, and the
profession that applies theory, principles, data and methods to design
in order to optimize human well-being and overall system
performance.

Ergonomics of Material Handling Equipment:

Consider the use of mechanical aids whenever possible to assist

employees in
their materials-handling needs. Examples include:
Pallet jack;
Lift table;
Two-wheeled hand truck;
Lift and tilt table;
Four-wheeled cart;
Winch;
Motorized hand truck;
Manipulator;
Hoist;
Positioner;
Crane;
Upender;
Conveyor;
Dumper;
Chute;
Powered industrial vehicle.
Try to incorporate concepts that fit the job to the worker. Consider
maintenance

and setup needs when planning, designing, purchasing and installing

equipment.
Build equipment around materials handling requirements.
The person who specifies a materials handling device should understand and
clearly define usage expectations and desired outcomes.
This includes, but is not limited to, identifying:
What will be carried (assessing size, weight, and other pertinent
parameters)
Overall weight and size capacity demands (using worst case load
weight
and size estimates)
The terrain and anticipated travel path (identifying the presence of
ramps,
severe floor irregularities, steps, or other obstacles)
Pertinent environmental conditions (extremes in temperature, water,
or
chemical exposures, etc.)
How frequently the unit will be used (infrequently to constantly)
Information pertaining to the people who will use the device (user
population characteristics versus load and device characteristics), as
necessary and appropriate
Such detailed information will help ensure that the specified device will
fit the task
requirements, reduce ergonomic risk factors, and reduce the human burden.
Improperly designed or specified material handling aids have the potential to
slow down work, lead the user to abandon the unit, or, worse, result in injury
to
the handler and perhaps to others. Choosing the right equipment can make
work
less physically taxing, reduce material handling risk factors, and make
performing
the task more acceptable to a wider range of people.
There is a host of material handling technologies available, including
cranes,
hoists, and monorails for lifting, lowering, and transporting; manipulators for
picking and orienting; and work positioners and lift tables for lifting, lowering,
and
rotating objects. Carts, dollies, and trucks are used for transporting loads,
and a
wide variety of tools and equipment, intended to reduce physical stressors
associated with manual handling tasks, are available. Examples include

conveyors, totes, flow racks, and ball transfers. Often teaming a combination
of
handling devices to work in concert as a system is desirable and should be
considered. An example of this would be the use of a lift table used in
conjunction with a conveyor and ball transfer to move materials from a
receiving
department through an incoming inspection process area.
Work scheduling
Bring only enough material to complete the job in the immediate work
area. Extra
material will either need additional handling to get it back to storage or will
create
congestion. Likewise, too little will require extra handling.
Consider the following, whenever possible, in jobs with considerable manual
materials handling:
Rotate employees from less strenuous jobs;
Split work among two or more employees;
Institute appropriate work/rest schedules.
Provide the worker with specific training in the following areas:
Using mechanical handling aids. Employees may avoid mechanical
aids
because they simply do not know how to use them;
Recognizing materials handling problems in the workplace;
Identifying procedures that can prevent excessive manual materials
handling;
Proper body mechanics.
Remember that requiring employees to use particular lifting techniques
like
the squat lift has not been shown to be of any significant value. It is not
recommended. However, training on manual handling techniques should be
part
of a comprehensive back injury reduction program (even though lifting
training
alone is not effective in reducing back injuries).
Environment
Review work areas for proper illumination levels. Poor lighting can
contribute to
accidents and injuries, and diminish quality of products.
Make allowances for weather conditions including the following:
Issue appropriate clothing, including gloves;
Take measures to prevent cold and heat stress;
Maintain aisles;
Shield storage areas from mud and snow.

Evaluate noise levels to ensure that workers can hear and heed mechanical
handling warning signals. Be sure air-contaminant levels are not excessive.
This
can be achieved through routine monitoring programs in high-exposure
areas.
Recommend, review and implement changes
Once workers, staff and line personnel have identified problems, they
must be
acted upon. At this point, deficiencies have been identified with possible
solutions
in mind. The process is broken down into the following stages:
Prioritize Priorities are categorized by the degree of hazard and
risk
associated with materials handling. These are determined as part of
the
initial management analysis of the materials handling process,
essentially
a historical approach. Risk is based on the frequency of worker
exposure
to the hazards of any given task and the number of workers routinely
exposed;
Review Establish as company policy the review of materials
handling
safety as part of the planning procedure for any proposed process. This
review should be ongoing since new materials handling equipment is
on
the market, and the state of the art in ergonomics is rapidly changing.
The
most effective review is conducted in an atmosphere of participatory
management. There should be strong involvement and representation
from all groups of employees. This can be accomplished generally
through
established committees or quality circles.
Two key elements of the review process are determining the impact proposed
changes will have on other jobs, and what new problems will arise as a
consequence of the changes made. Failure to consider these elements can
result in a loss of credibility for the newly emphasized materials handling
process.

Miscellaneous Handling Equipment:

(1)Pipe lines which are closed tubes that transport liquids by means of
pumps or gravity.
(2)Automatic transfer devices which automatically grasp materials,
hold them firmly while operations are being performed and move
them to other locations.

(3)Automated guided vehicle(AGV) systems These devices do not

require operators and provide a great deal of flexibility in the paths
they travel and the functions they
perform. The AGVS are
controlled by signals sent through wires embedded in the floor or
inductive tape on the floor surface. A remote control computer is
needed to control the movement of AGVs.
(4)Industrial robots A robot is a mechanism which has a movable arm
like projection with a gripper on the end that can perform a variety
of repetitive tasks. Robots usually have a built in control that can
be reprogrammed and hence they are very versatile.
The process design and the principles and the principles of efficient
materials handling provide the framework for selecting specific
materials handling devices and the core of the materials handling
system. Each of the handling devices discussed above has its own
unique characteristics, and advantages and disadvantages.