MECHANICAL SYSTEM DESIGN
MATERIAL HANDLING SYSTEM
-Chaitanya Narendra Damle
PRN: 1806096
INTRODUCTION TO MATERIAL HANDLING:
 Definition:
⁻
Material handling is the movement, protection, storage and
control
of
materials
and
products
throughout
manufacturing, warehousing, distribution, consumption and
disposal.
⁻
Materials handling is the art and science of conveying,
elevating, positioning, transporting, packaging and storing
of materials.
 As
a process, material handling incorporates a wide range of
manual, semi-automated and automated equipment and systems
that support logistics and make the supply chain work.
 Any
Material handling process includes:
1.
Picking up the load
2.
Transporting the load
3.
Setting up the load
 Material
handling is to move the materials around.
 Material
handling does not add any value.
 It
adds to the cost of product; therefore it should be
eliminated or at least reduced as much as possible.
 It
applies to the movement of raw materials, parts in
process, finished goods, packing materials, and disposal
of scraps
EFFECT OF MATERIAL HANDLING ON COST:
 In
a typical factory handling accounts for
⁻
25% of all employees,
⁻
55% of all factory space, and
⁻
87% of production time.
 Material
handling is estimated to represent between 15 and 70% of
the total cost of a manufactured product.
 Material
handling is one of the first places to look for cost reduction
& quality improvements.
SYSTEM CONCEPT FOR MATERIAL HANDLING:
Any solution to the material handling problem must satisfy the following
conditions:
1. The solution to material handling problem should not transfer the
problems into other areas of the product cycle.
2. The solution should not only resolve the immediate problems, but also
take care of problems for a reasonably long period of time. It should be
able to account for future expansion or modification without unreasonable
cost.
3. The solution should not be prone to rapid obsolescence.
4. The solution should be as simple as possible and easy to
adopt.
5. The solution should be such that, the initial cost as well as
operational costs should be minimum.
6.The rate of return on investment should justify the solution.
TYPES OF LOAD HANDLED BY MATERIAL HANDLING
SYSTEM:
Load is classified into two types:
1.
Bulk Load:
 Bulk
load consists of a large number of homogenous
particles or lumps of any material.
 Examples:
coal, minerals, sand very small steel
components, etc.
2.
Unit Load:
 Unit
load is a rigid mass which is handled and transported
as one single piece.
 Examples:
machines, large boxes, containers, etc.
CONTAINERIZATION:
 The
use of containers for the handling of bulk loads and small
sized products is done for bringing convenience the material
handling.
 Depending
upon the size of the containers, one container
may be treated as a unit load or number of containers
together may be treated as a unit load.
 The
process of converting the bulk loads or small units into a
unit load by using the containers, is known as Containerization.
 Types:
wire–mesh, steel, wooden, plastic.
CONSIDERATIONS IN CONTAINERIZATION:
 Limit
the number of container sizes and shapes.
 Design
the container size and shape based on the load to be
handled.
 Size
the containers taking into account the space available
in material handling equipment.
 Design
the containers for stacking arrangement.
 Design
the containers for flexibility and maximum utilization.
 Keep
the containers painted.
 Color-code
the containers by function.
 Wire-mesh
and solid steel containers are preferred over wood or
plastic containers for the sake of cleanliness, fire protection and
long life.
 In
many applications, wire-mesh containers are preferred over solid
steel containers due to following reasons:
 Wire-mesh
containers are self-cleaning.
 When
parts are dropped into the container, the wire-mesh
containers produce less noise as compared to the solid steel
containers.
 Wire-mesh
containers are used for washing parts without
removing them from the container.
 Parts
will dry and cool faster in wire-mesh containers than in solid
steel containers.