Institute of Aeronautical Engineering

(Autonomous)
Dundigal, Hyderabad – 500 043

PLANT LYOUT AND MATERIAL HANDLING

B.Tech VIII SEM (JNTUH – R15)

Prepared by :
Dr. Paidi Raghavulu,
Professor
 UNIT-I
SYLLABUS

• Classification of layout.
• Advantages of Layout & limitations of different layouts.
• Layout design procedure.
• Over view of the Plant layout
 Plant Layout- Introduction

• The term Plant layout is mainly used to represent the physical arrangement of a
plant and different parts of a plant. The arrangement of machines, equipments
and other industrial facilities like receiving and shipping departments, tool
rooms, maintenance rooms and employee amenities which helps in attaining
rapid and interrupted flow of production activities at minimum cost is usually
referred to as plant layout.
• The layout decisions mainly deals with the location on & arrangement of the
production, support, customer service and other industrial facilities.
 Definition of Plant Layout
According to ‘Knowels & Thomson’ Plant layout deals with
• Planning and arranging manufacturing machinery, equipment and services for the
first time in completely new plants.
• The improvements in layouts already in use in order to introduce new methods
and improvements in manufacturing procedure.
 SCOPE OF PLANT LAYOUT

• Plant layout has broad scope of operations as it not only deals with the
primary decisions of machines and other facilities, but also concerned with
all the improvements that have to be made to the existing layout based on
the subsequent developments in the production methods.
• In simple terms, a plant layout is a floor plan which is meant for
determining and arranging the machinery and equipment of a plant at the
most suitable place such that both the materials flow and handling can be
obtained at low cost.
 PRINCIPLES OF PLANT LAYOUT

1. The principle of Minimum Travel: Operations manager must design layout in

such a way that the distance between operations is minimum which intern
helps in avoiding the labor & time wastages there by reducing the cost of
material handling.

2. The Principle of Sequence: The machines & operations must be arranged

sequentially. This principle is effectively attained in product/ line layout.
3. The Principle of Usage: The available space needs to be optimally utilized.
This principle has wide acceptance in towns and cities where a piece of land
is very much expensive
4.The Principle of compactness: All the significant factors need to be fully
integrated and related, producing a well integrated and final layout.
5. The Principle of Safety & Satisfaction : The layout must have provisions for
safety of workers. It must be planned, based on the comfort and convenience of
the workers for making them feel satisfied.
6. Principle of Flexibility: The layout must allow improvements with less difficulty
and at minimum cos.
7. The Principle of Minimum Investment: The ideal layout must provide savings in
fixed capital investment not by ignoring the installation of required facilities but
by efficiently and optimally using the available facilities (economies of scale).
 OBJECTIVES OF A GOOD LAYOUT

The main objective of a plant layout is to optimally arrange all the factors of
production in such a way that it facilitates
-low production cost and
-Increased returs to scale.
For attaining this objective , the plant engineer should consider following
secondary objectives while developing a plant layout.
1. By minimizing and controlling the material handling & Transportation costs.
2. To eliminate the hurdles and points of overloading by making use of
appropriate line balancing techniques.
3. To provide adequate space and to establish proper locations for both production
centers and service centers.
4. To minimize the waiting time of semi finished goods.
5. To provide safe and adequate working conditions there by minimizing accidents.
6. To ensure that the space available is utilized optimally.
7. To make provisions for adequate flexibility in the designed layouts so that the
minute changes in product design or changes in material specification can be
accommodated easily.
8. To make the plant maintenance simple & easy.
9.To design and locate the workstations adequately to facilitate uninterrupted flow
of material and movement of men.
10. To encourage the effective utilization4. Cellular manufacturing layout/ group
technology layout
11. To maintain high turnover of work in progress.
12. To effectively design the layout for improving productivity and quality of
product.
 Factors Influencing the Plant layout

The various factors influencing the plant layout decisions are :

1. Materials : some arrangement must be done for purpose of storing and
moving the raw materials into plant until they get converted into finished
products. The nature, type & form of raw material (ie liquid /solid,
seasonal , market conditions,/ Material specification.
2. Product: The nature of product(Size, demand) influences the type of layout
required. Production of ship-building, the product is fixed where as the
production resources such as men & machinery needs to be brought
towards the product. The demand of product also affects the layout(Storage,
handling)
3. Machinery: The size and type of machinery which dictated by the product
type, quantity of production , management policies.
4. Type of Industry: Plant layout decisions also influenced by the type of industry.
-Synthetic Industries: In these type several elements undergo production
process to form finished product.
Ex: Chemical , paper industry
- Analytical Industries: In these type, conversion of raw material into different
elements.
ex: sugar mill produces sugar bagasse, molasses, jaggery apart from sugar
crystals.
- Extractive Industries: Such industries extract one element from the group of
elements . ex: extraction of a metal from ore
6: Location: The location of the plant also affects plant layout in different.
a: type of building is decided by the terrain and size of the site.
b: location : influences the plant layout decisions in following ways.
- Size & Topography:decides the type of building to be constructed.
- Mode of transportation:
-Fuel requirementss of the firm:
-Future expansion of the firm: if village site is selected , the expansion of
the concern my be influenced by the addtion of one or more wings to the present
construction. When the urban is selected, expansion is influenced by addition of
several stories to the present construction. Based on no. of story , thev material
handling requirements can be determined wich influences the plant layout.
7. Managerial Policies: Layout is influenced by managerial policies which are as
follows.
a: The production volume & scope for expansion.
b: The level of automation required.
c: Production or purchase of equipment.
d: Desire for rapid delivery of goods to customers, policy of purchasing.
e: Personnel policies.
 TYPES/CLASSIFICATION OF PLANT LAYOUTS

• A plant layout mainly deals with the arrangement and grouping of machines which
are used for producing goods. Mostly grouping is employed on different product
lines. The selection of a particular layout relies on many factors.
1. Process layout/ Functional layout/ Job-shop layout.
2. Product Layout/ Line processing layout/ flow line layout
3. Fixed position Layout / Static Layout.
4. Cellular manufacturing Layout/ Group Technology Layout
5. Combination Layout/ Hybrid Layout.
 PROCESS/FUNCTIONAL/JOB SHOP LAYOUT
Process Layout : is a type of layout which is characterized by the presence of
similar machines or similar operations at specified location. It is known by
different names. It is also called as functional layout or Job shop layout or bath
production layout.
In Process layout: The machines are grouped on the basis of their operational
characteristics. Ie machines that are performing the same operation are installed
at a specific location.
All drilling m/cs are installed in drilling dpt. All lathe machines are installed in
Turning dpt. All welding m/cs are installed in welding dept.
2. PRODUCT /LINE PROCESS / LINE/FLOW LINE
LAYOUT

• Product Layout: refers to the sequential or orderly arrangement of machines

in one line based on sequencing rules.
It is also called as Straight line Layout
or
Layout for serialized manufacture
In this layout , there exists several machines such that the partly processed
products (WIP) of machine becomes an input for the other machine.
3. FIXED POSITION /STATIONARY / STATIC LAYOUT
Fixed Position Layout: In this type of layout, material remain at a fixed place
and the complete job is done at a fixed station with materials.
-men and machines are moved to the place of materials for the necessary
operations.

• This type of layout is suitable for

• hydraulic turbines, ship building, Locomotive Industry.
 4. CELLULAR MANUFACTURING LAYOUT/
GROUP TECHNOLOGY LAYOUT

• Similar shape operations are made as a group or cellular and respective are
installed as a group
 5. COMBINATION/ HYBRID LAYOUT

• This layout contains a mix of process and Product layout .

• This layout is considered for special production line.

 ADVANTAGES OF PROCESS LAYOUT
1. Process layout provides greater flexibility in Production
2. A special machinery is used for performing specific job, efficient
supervision can be made/achieved.
3. A low investment on machines and equipment as general purpose
machines are used.
4. It provides greater scope for expansion as the production capabilities can be
increased easily.
5. It helps in optimum utilization of production recourses such as men and
machine equipments.
6. The breakdown of the equipment can be handled in process layout by
allotting the work to other machines or other work station.
7. Process layout motivates the individual worker by offering increased
incentives based on his performance.
DISADVANTAGES OF PROCESS LAYOUT

1. It is very much difficult to transfer the materials in process layout as

mechanical devices are not able to efficiently handle the materials.
2. More space is required for its functioning.
3. It is very much difficult to control the various activities.
4. It is associates with high cycle time as the WIP needs to move to different
work stations for their processing.
5. If more number of WIP units get accumulated near single m/c , it results in
congestion problems.
ADVANTAGES OF PRODUCT LAYOUT
1. Mechanical devices are used for handling materials, which helps in bringing
down the cost of material handling.
2. Helps in avoiding the obstructions in production.
3. Highly economical as it requires less time for processing.
4. It motivates the group of workers by providing higher incentives to increase
their performance level.
5. Offers better production control.
6. It requires small floor area for producing a single unit of product.
7. It reduces WIP and minimizes the investment.
8. Both mistakes and the defective items can be easily detected.
DISADVANTAGES OF PRODUCT LAYOUT

1. Lack of flexibility in production operations

2. It is not possible to supervise the operations.
3. Has less scope for expansion.
4. It is very expensive.
5. A Single breakdown of equipment along a production line can interrupt
the whole system.
LAYOUT PLANNING

• The engineering or planning department is responsible for designing and

installing a layout.
• In the manufacturing and service organizations, the layout planning deals
with the arrangement of resources so that the performance of the operating
system could be improved.
• A set of tools and techniques can be provided by the layout planning which
helps the operations manager to locate resources and also for assessment of
alternatives for locating the resources.
 LAYOUT PLANNING TOOLS & TECHNIQUES
The different techniques that are available and useful for layout planning are
1. Templates
2. Operations Sequence Analysis.
3. Line balancing.
1.Template: It is a two dimensional technique which is the most commonly used.
Templates are the design patterns which consists of a thin plate, made up of
wood or metal and which serve as a gate for performing mechanical
activities.
- It constitutes the scaled representation of the physical object of the
layout.
-Templates are fixed for preparing plans, for drawing several possible
layouts. The best possible option can be explored by eliminating the
unnecessary handling and backtracking of materials.
- It is usually employed for re-designing the existing department/building
- For verifying the layout design configuration decided by other layout
technique.
2. Operations Sequence Analysis: It is an early approach to process type layout.
It develops a good plan for arranging the departments graphically so that the
layout problem get an optimal solution. Through the operations sequence
analysis, the relative locations of operating department with respect to one
another can be predicted.
3. Line Balancing: it is an important activity of an assembly line operation,
which is mainly used for the equitable distribution of work among the
employees so that total number of employees can be greatly reduced. Line
balancing is not an easy task because there are different alternative methods
that can be far more easily applied than line balancing for the decision of
work. Some of the methods used by operation researchers to study line
balancing problems include linear programming, dynamic programming
and other optimal methods.
Steps followed in designing a layout
1. Statement showing the objectives, scope and factors that need to be
considered
2. Gather the primary data on sales forecasts, production volumes, production
schedules, part lists, operations and their sequences.
3. Development of flow process charts, flow diagram, string diagram, templates
and so on.
4. 4. establishment and the design of the production process.
5. Material flow pattern is planned and complete material handling plan is
developed.
6. Computation of the requirements of work centres and equipments.
7. Planning is done for individual work centres.
8. Selection of proper material handling equipments.
9. Identifying the storage requirements
10. Planning for the auxiliary and service facilities.
11. Identification of routing, service department, employee facilities and
requirement of space for each work station
12. Outlining the specification of building so that the requirement s of the layout
can be fixed.
13. Development of floor plan for representing the location of doors, windows,
stair case, lifts other infrastructural facilities.
14. Preparation of tentative or drafts layout plans.
15. Preparation of a comprehensive layout drawing which can be even accepted by
top management.
16. Preparation and design of work schedules for layout installations.
 CLASSIFICATION OF LAYOUT DESIGN PROCEDURES/
EVALUATING METHODS.
The design procedure s for layout are broadly classified into two type. They are,
1. manual methods
2. computerized methods
1. The manual methods are conventional type and are sub-divided as follows.
1a) travel chart method
1b)systematic layout planning
1c) local-distance analysis method

2.Computerized methods are constructive type and improvement type algorithms

and they are classified as follows.
2a) Automated layout design program (ALDEP)
2b)Computerized Relation ship Layout planning (CORELAP)
2c)Computerized Relative Allocation of Facilities Technique. (CRAFT)
2d)Computerized Plant Layout and Evaluation Technique. (PLANET).
2e)Computerized Facilities Design (COFAD)
 MANUAL LAYOUT DESIGN PROCEDURE
• Travel chart method 1a)isTravel chart method:
a technique used for determining the overall flow of
materials. The travel chart is used to identify the most active departments
when materials move from one department to the other.
• In this method, the optimal solution can be reached by considering the trial
and error method wherein the active departments are located centrally so as
to minimize the non-adjacent flows.
• The travel chart is drawn by using circles for representing the work stations
and lines for the transportation of loads across the work centres and
departments.
Procedure:
1. identify the departments which maintain the adjustment links with the
other departments.
2. in facility outline, the most active departments must be located at the
central position.
3. By trial and error method, other departments must be located in such a
way that the non-adjacent flows could be minimized to a great extent.
4. By eliminating all the non-adjacent moves, the optimal solution is said to
 Manual layout design procedure
1b) systematic layout planning method
• Some production systems like service systems, make use of systematic
layout planning wherein the amount of material that flows between the
departments may not be critical for the development of an appropriate
facility layout.
• In this method, a chart is prepared in which ratings are given for
representing the relative importance of locating one department close to
another department and is termed as “Relation ship chart or Richard
Mutrher’s half matrix”. The important ratings are expressed with code
letters a,e,I,o,u,x which are called as “nearness codes”. A;long with
nearness code, a reason code is also used which is indicated by a number
that depends on a variety of reasons for locating any two departments,
adjacent to each other.
• When the problem is formulated in systematic layout planning (SLP)
method, based on the sequential steps in general design, the process starts as
shown in below flow chart.
 UNIT-II
Syllabus:
• Heuristics for plant layout, ALDEP, CORELAP, CRAFT
• Group Layout, Fixed position layout
• Quadratic assignment model, Branch and bound method
 HEURISTICS FOR PLANT LAYOUT
• When there is no method which guarantees an optimal solution with
reduced computational effort, in such situation we aim at a solution which
is not necessarily optimal but which is near optimal. The method to get
such a solution is known as heuristic method. Here an attempt is made to
strike a compromise between the computational effort and the quality of
the solution.
 HEURISTICS TO SOLVE THE LAYOUT PROBLEMS
• Computerized Relative Allocation of Facilities Technique (CRAFT)
• Automated design layout design program (ALDEP)
• Computerized Relationship Layout Planning
• ( CORELAP)
• Plant Layout Evaluation Technique (PLANET)
• Plant Layout Evaluation Technique (PLANET)
 CLASSIFICATION OF COMPUTER PROGRAMS OF PLANT LAYOUT:

a)Construction of Algorithms : Computer programs

help in constructing the algorithms. A construction
algorithm includes the proper selection and
placement of activities (dpts), thus helps in
obtaining successive design layout.
b)Improvement of Algorithms: This perception of
computer program provides an idea about
improvement in the quality of layout problem. In
order to improve the quality design layout, the
activities (departments) are interchanged from the
initial existing layout.
 PROGRAMS ARE MOST COMMONLY USED IN DESIGNING A
PLANT LAYOUT.
1. Computerized Relative Allocation of Facilities
Technique (CRAFT)
2. Automated design layout design program (ALDEP)
3. Computerized Relationship Layout Planning (
CORELAP)
4. Computerized Facilities and Design (COFAD)
5. Plant Layout Evaluation Technique (PLANET)
Model 2, 3 are construction algorithm which generate
layout by successive addition of facilities to locations.
Model 1 is an improvement algorithm which takes ,
an input and improves to optimal solution in a number
of iterations.
 COMPUTERIZED RELATIVE ALLOCATION OF FACILITIES
TECHNIQUE (CRAFT) :
• CRAFT is the first improvement algorithm which is most widely used in plant
layout design. This algorithm minimizes the material handling cost between the
departments. CRAFT not only helps in designing layout by considering material
handling cost, but also provide advancement in designing layout by considering
the interpretation not material flow. Initially CRAFT performs the evaluation
of given layout, hence considers the effects on design layout by interchanging
the departments. A pair wise exchange criteria gives an optimum results, to
minimize the transportation cost between the departments. The interchanging
of the departments continues to extreme limit, where no further improvements
can be made. In this locations are exchanged w.r.t similar are or with common
border. It allows some departments to be fixed in position so that there is no
chance of exchanging the locations.
 INPUT REQUIREMENTS OF CRAFT

• Total number of Departments

• Number of interchangeable departments
• Number of fixed departments with their location.
• Location of those departments.
• Area of each department.
• Initial Layout
• Flow data (matrix which shows no of unit loads moving between all
departments
• Cost per unit distance ( cost matrix )
 STEPS INVOLVED IN CRAFT:
Step-1: note the input requirements.
Step-2: compute centroids of all the departments in the present layout.
Step-3: Form the distance matrix by using centroids.
Step-4:. Given data on flow, distance and cost, compute the total handling cost
of the present layout.
Step-5: Find all the possible pair wise interchanges of departments based on
concept of common border or equal area.
Step-6: for each possibility, interchange the corresponding centroids and
compute approximate costs.
Step-7: Find the pair of departments corresponding to minimum handling cost
from among all the possible pair of interchanges.
Step-8: Is the cost in the previous is less than the total cost of the present
layout?. If yes, go to step-8. If not go to step-11.
Step-8: Inter change the selected pair of departments. Call this as the NEW-LAYOUT.
Comput centrods, distance matrix and total cost.

Step-9: is the cost of new layout is less than the cost of the present layout?
If yes go to step-10. If not go to step-11.

Step-10: The new layout is here after considered as the present layout. The data on
centroids, layout matrix and the total cost is retained. Go to step-5.

Step-11: Print the present layout as the FINAL LAYOUT.

Step-12: stop the process.

The above algorithm is schematically represented with help of flow chart.

 ADVANTAGES OF CRAFT :
• Possibility of changing the input shapes
• CRAFT allows fixing of special locations.
• Computation speed of RAFT is fast and economical in operations.
• It can perform Mathematical operations easily.
• It is possible o check earlier interactions to run the program.
• It can be used for office layouts.
•
DISADVANTAGES OF CRAFT :
Due to the need of initial layout, the program is strictly applied only to modify the
already existing layout or to plan the new layout where borders (outline) are known.
• Distance between the departments is represented as a straight line.
• It requires manual adjustments.
• It does not provide the assurance of having lowest possible cost layout.
• It is difficult to improve the program produced by heuristic and sub-optimal
procedure (CRAFT)
• While feeding the input data in a program, it requires an attentive construction.
• It requires better adaptation for resettlements.
• The solution obtained from CRAFT program mainly depends on the path
• It considers the unpleasant relationships.
• CRAFT is restricted to 40 departments.
2 AUTOMATED LAYOUT DESIGN PROGRAM
(ALDEP)
• ALDEP belongs to the construction type program, which builds the
layout with out using the existing layout. It also considered as an
improvement program due to the evaluation process of accepting or
rejecting the given layout. It builds the layout by placing the most
related departments, size required and based on the closeness rating (ie,
A or E ) of A, E, I, O, U, X. it adds continuously the other departments
till the placement of all activities has been completed. This process is
continued till all the departments are placed in he layout and no
department should be available for placing with high closeness rating. At
this stage , score is computed for layout in terms of numerical values.
This procedure is repeated for several times and evaluates the best
layout with maximum layout score.
 INPUT REQUIREMENTS OF ALDEP:

• The number of departments in the layout.

• Area of each department.
• Length and width of layout
• The values of closeness for the pairs of department based on Relationship chart.
• Minimum Department Preference (MDP) value
• Sweep width.
• The least possible score for an acceptable layout.
• Total number of layouts to be generated.
• Building outline and scale of layout printout.
• The location and size of each prohibited area ( if present)
 STEP BY STEP PROCEDURE OF ALDEP ALGORITM
STEP BY STEP PROCEEDURE OF ALDEP
STEP-1: Give the input in following manner.
• The number of departments in the layout.
• Area of each department.
• Length and width of layout
• The values of closeness for the pairs of department based on Relationship chart.
• Minimum Department Preference (MDP) value
• Sweep width.
• Number of iterations to be carried out (N)
• Current iteration number (I)
• Location and sie of fixed department (if present)
• Score of the current layout.
• The least possible score for an acceptable layout.
• Total number of layouts to be generated.
• Building outline and scale of layout printout.
• The location and size of each prohibited area if present
STEP-4: check for the availability of non selected department in catgory –B
If it is non empty, then choose a non selected department in category –B itself
corresponding to maximum REL value and place that dept in the layout.
If it is empty, then select a department randomly from category –A, and place it in
the layout.
STEP-5: check for e placement of all departments n the layout. If an department is
found to be unplaced, follow the STEP-3, otherwise determine the score for the
layout.
STEP-6: check whether the computed score of the layout is higher than the
current best layout
If yes, call the new layout as the current best layout and save corresponding
score.
If no , cancel the new layout.
STEP-7: check for the current iteration number ie I=N. I yes , print the current
best layout as final layout and its corresponding score as a final score.
If no, increase the iteration number as (I=I+1) and follow step
 ADVANTAGES OF ALDEP:

• It can affix the particular locations which are available under certain
limits.
• The solution or result obtained from ALDEP is available with in t definite
area.
• The possibility of developing several replacements in order to obtain the
optimum solution of layout.
• The possibility to have majority of inter-relationships.
• The capacity of degenerating multiple level of layouts
 DISADVANTAGES OF ALDEP:

• It does not calculate the movement cost.

• Honor can not be given to unpleasant relationships.
• The method of determining score is suspicious or undefined.
• The process of evaluating production is complicated.
• It does not consider the mandatory space configuration.
• Restricted to only upto 63 departments.
 COMPUTERIZED RELATION SHIP LAYOUT PLANNING
( CORELAP)

• Computerized Relationship Layout Planning algorithm is a

chart for construction of layout. The layout in CORELAP can
be generated by locating the rectangular shaped departments, if
departmental area and layout scale allows their representation
in a rectangular form. CRELAP has the capacity to manage
upto 70 number of departments.
 INPUT REQUIREMENTS OF CORELAP

• The number of departments in the layout.

• Area of each department.
• Length and width of layout.
• The closeness Relationship value based on Relationship chart. (REL chart)
• Scale of output
• Building length to width ratio
• Department pre-assignment.
 STEP-BY-STEP PROCEDURE OF CORELAP

STEP-1 : Provide basic input data in the following manner.

• The number of departments in the layout.
• Area of each department.
• Length and width of layout.
• The closeness Relationship values based on Relationship chart. (REL
chart)
• Scale of output
• Building length to width ratio
• Department pre-assignment
• STEP-2: Consider scale as 1 square = 600 sq.m
Compute no. of square units for all the departments.
no of squares = dept. area /Area per square in layout

STEP-3: By using R EL- chart, ompute totl closeness rating for all the departments

STEP-4:Select department with highest TCR value. The selected department occupy 1 square and it is
placed in the centre of layout matrix.

STEP-5. Check the closeness relationship of first selected dept with other departments. And note the
corresponding closeness value . now select maximum REL value dept.

Select that department which has maximum REL Value as 3rd seleced dept.
STEP-6: Repeat the above procedure with unassigned departments
Apply above procedure till all the departments are selected.
Select 1st priority dept as a first in placement order
Select 2nd priority dept as a second in placement order
Select 3rd priority department as a third in placement order
Select 4th priority dept. as a fourth in placement order.
Select 5th priority dept as a fifth in placement order
•
•
•
•
•
•
 GROUP TECHNOLOGY (CELLULAR ) LAYOUT

• Group Technology (Cellular) layout: is a type of

layout where the machined are arranged in the
form of cells. Each cell may function either as a
product layout within large shop or a process
layout. The cells in a cellular layout are engaged in
producing single parts of same machine having
same features and those requiring the same
production setting. The figure shown below
shows a cellular manufacturing layout.
 SUITABILITY OF GROUP TECHNOLOGY (CELLULAR)
LAYOUT:
• Group Technology layout or cellular layout helps in producing products
having different parts
• This layout can be applied in the work centres having easily movable machine
tools.
• This layout can be used when the production of a product is independent of its
capacity
OBJECTIVES OF GROUP TECHNOLOGY (CELLULAR)
LAYOUT
• To increase the rate of production.
• Improves operator’s experience, due to repletion of
operations.
• Reduces material handling and work in process inventory
• To improve human relations as a group (cell) consists of few
operators, which form as small unit team.
• Reduces product cost there by it makes economical.
 ADVANTAGES OF (GROUP TECHNOLOGY) CELLULAR
MANUFACTURING LAYOUT
• Increases reliability of components.,
• Increases effective machine operation.ncreases
Productivity.
• High costing accuracy.
• Increased customer service.
• Increased order potential.
• Reduced planning effort.
• Reduced paper work.
• requires low setting time.
• low machine down time.
• low work in progress.
• low work movement.
• Reduced over all production time.
• Reduced over all cost
 DISADVANTAGES OF CELLULAR MANUFACTURING
(GROUP TECHNOLOGY) LAYOUT
• It involves less manufacturing flexibility.
• Increases the machine down time as machines are grouped as cells which
may not be functional throughout the production process.
• this group technology layout may not be feasible for all situations.
• if the product mix is completely dissimilar, then we may not have
meaningful information.
STEPS INVOLVED IN GROUP TECHNOLOGY (CELLULAR)
LAYOUT
Step-1. Grouping of parts : The parts are grouped into families depending
upon the operations to be performed,
Step-2. Path allocation: The flow path will be allocated depending upon the
part families, Product type and sequential order of eperations..
Step-3. Processing of Parts: the parts are processed into respective cells.
 THE METHODS EMPLOYED FOR DEVELOPMENT OF
GROUP TECHNOLOGY LAYOUT :
i) Empirical Methods ii) Analytical Methods
• Empirical Methods: In this method, the job/components/parts to be
processed are made as families and machines/ facilities are divided into
groups. This method is used for simple cases and can be performed without
any managerial aid. This method can be illustrated in detail by considering
an example.
• Example: Manufacturing of 80 parts in a plant. The parts are made into
families bade on their process operations as follows.

parameters Familiy-A Family-B

Number of parts 50 30
Opertionso be carried out Milling, drilling, grinding & Turning, welding, finishing
finishing and painting
• It can be observed that the Machines/Facilities can be made into groups as
follows.
• Group-1: Milling (M), Drilling (D), Grinding (G)
• Group-2: Turning (T), Welding (W)
• Group-3: Finishing F), Painting (P)
• Therefore
• , by trial and hit method, layout can be developed as shown in figure below.
 Analytical Methods:
This method is carried out in two steps.
Step-1: Codind/ classification
Step-2: Production flow analysis
• Coding/classification : A code number is provided to each part depending
upon its type and operation. Codes will be alphabets or variables to describe
the parts. This system can be specific to type (unstandard) or standard type.
Computerized/EDP coding/ classification system is usually employed in many
industries.
• Example:
“BRISCH” is a coding / classification system and consists of 9-digits. Every
individual digit represents a specific parameter as shown below

Digit Representation

I Material

II Shape

III Size-dimension

iV Priority of operation

V - IX Path of operations in ascending order

b): Production Flow Analysis:

• In production flow analysis, the flow path of parts will be analyzed.

The sequential steps to obtain an optimum path is as follows.
• Identification of initial operation for all parts.
• Grouping of machines / facilities according to first operation.
• Analyzing of second operation for all parts.
• Grouping of machines / facilities according to second operation.
• The above steps are repeated to enhance the complete job work
through every machine / facility.
• In this process no backtracking is allowed throughout the process.
 FIXED POSITION / STATIONARY LAYOUT:
• In this type of layout, material remains at a fixed place and
the complete job is done at a fixed station with materials.
• It involves the movement of men and machines to the
product which remains stationary for the necessary
operations. In this layout, major component remains in a
fixed location and tools machinery and men as well as
other pieces of material are brought to this location.
• The movement of men and machines to the product is
advisable because the cost of moving them would be less
than the cost of moving the product which is very bulky.
• This type of layout is followed in the manufacture of bulky
and heavy products such as
• Hydraulic turbines, ship building, Locomotive Industry.
Construction of building requires fixed location layout
because men, cement, sand, bricks, steel, wood and others
are taken to the site of construction.
 ADVANTAGES OF FIXED POSITION LAYOUT:
i. capital investment is minimum
ii. continuity of operation is ensured.
iii. Less total production cost.
iv. Less material movement.

DISADVANTAGES OF FIXED POSITION LAYOUT

i. machine and tools etc. take more time to reach at the work place.
ii. highly skilled workers are required.
iii. complicated jigs and fixtures may be required in fixing jobs and tools
etc.
 ADVANTAGES OF CELLULAR MANUFACTURING
LAYOUT.
i. Increases reliability of components.,
ii. Increases effective machine operation.
iii. Increases productivity.
iv. High costing accuracy.
v. Increased customer service.
vi. Increased order potential.
vii. Reduced planning effort.
viii. Reduced paper work.
ix. Requires low setting time.
x. Low machine down time.
xi. Low work in progress.
xii. Low work movement.
xiii. Reduced over all production time.
xiv. Reduced over all cost
 COMPARISION BETWEEN
GROUP LAYOUT & FIXED POSITION LAYOUT:

Group Layout Fixed position layout

• In his layout the machines are grouped • In this layout primary the product is
into families depending on the sequential very heavy and is kept in fixed
order of the job operations location. The tool, machinery , men an
other materials will be transferred to
• This layout is also called as cellular layout fixed location
• This layout helps to produce products • This layout is also called as static
having different parts. layout.
• Used when the production of product is • Find its application in manufacturing
heavy products like locomotives, ship,
independent of its capacity. boilers, air crafts and generators.
• Cost of handling material is very less • When the cost of transferring the bulk
• Semi skilled operators are needed to volume of material is very high.
perform work • Highly skilled workers are needed to
perform work
• Easy customer service. • It is very difficult to position the
• reduced planning effort. material, object or machines.
• low machine down time. • More planning effort is required
• Increased over all cost
• . reduced over all cost
 QUADRATIC ASSIGNMENT PROBLEM

• Quadratic Assignment Problem (QAP) is a technique of evaluating the

prime solution for ‘n’ number of departments to ‘n’ number of locations.
• The term “Quadratics” means the product of two decision variables and it is
a second order function. The term ‘assignment’ means matching each of the
department with specific location. Thus QAP is modeled to facilitate layout
for each department with specific location. QAP is a second degree
function of variables and constraints are linear functions of variables.
 QUADRATIC ASSIGNMENT PROGRAMMING
Assumptions made:
METHOD.
• Net income/revenue from operating plant is equal to the difference of gross
revenue and cost of primary input excluding handling cost between plants.
• Flow of material is independent of plant location.
• Transporting cost of unit material is independent pf plant and its location.
• Number of departments/ facilities will be equal to number of locations.
 Evaluation of optimum Solution with QAP for plan layout.

• Notations used in this technique are ;

• ‘ a ij ‘ is net income/ revenue from operating plant ‘i’ at location ‘j’
• ‘fik’ is material flow from plant ‘I ’ to plant ‘k’
• ‘cjl’ is transporting cost of unit material fro location ‘f’ t location ‘l’
• ‘n’ total number of plants/locations.
• ‘xij =1 represent plant ‘I’ is at location ‘j’
• For this condition, QAP can be formulated as

• aij. Xij --- . Fik . cij . xij . xkl -------- ( 1)

• Subjective constraints

• . Xij =1, I =1,2,3,4…………n

• . Xij =1, j =1,2,3,4…………n

• Xij € { 0, 1}, I, j = 1,2,3,4……….n

• If ‘aij’ is locating and operational cost of plant ‘I’ at location ‘j’ then equation (1) becomes

• aij. Xij + -. fik . cij . xij . xkl -------- ( 2

• Subjective to constrains as same mentioned above
For Facility Layout Problem:
.
Notations used in this technique are ;
‘ a ij ‘ is fixed cost of locating facilities ‘i’ at location ‘j’
‘fik’ is material flow between facilities ‘ i’ and ‘k’
‘cjl’ is cost per unit flow of material between locations ‘j’ t location ‘l’
For this condition, Lawler introduced a new decision variable
Ie., bijkl = { fik . cjl + aij if i =k and j=l
{ fik . cjl if I # k and j #l
Therefore the objective function of QAP is given as

Xij + -. bijkl . xij . xkl -------- ( 3)

(constraints are similar as mentioned above)

Subjective constraints
. Xij =1, I =1,2,3,4…………n

. Xij =1, j =1,2,3,4…………n

Xij € { 0, 1}, I, j = 1,2,3,4……….n

 BRANCH AND BOUND METHOD

• Branch and bounding method: This method is used for arriving at an

optimal solution to the problem of Quadratic assignment is Branch and
Bounding.
• Procedure is explained wit example of assigning of four machines in
available four locations.
• The Wij be the flow of material f movement between machines ‘I’ and ‘j’
and is shown in below table .
• ‘dij ‘ be the distance between locations ‘ i’ and ‘j’ , and is given distance
matrix.
.

Location 1 2 3 4 Location 1 2 3 4
Machine
Location

1 0 3 0 1 1 0 1 2 6
2 0 3 0 2 0 3 5
3 0 2 3 0 4
4 0 4 0
Distance matrix
Flow matrix
Our problem to the machines are assigned to available
locations so as to minimize the total cost of material handling.
Solution:
Step-1 : compute the lower-bound to the problem.
The total cost will contain the sum of six elements. Each element being the product of product of
one of the element of the flow matrix W and distance matrix.
Arrange the elements of flow matrix in descending order.
The array can be written as A = { 5. 3, 2, 1, 0, 0)
Similarly, the elements of distance matrix are arranged in ascending oder.
The array can written as B = { 1, 2, 3, 4, 5, 6}
The dot product of A and B = 5*1 +3*2 + 2*3 + 1*4 + o*5 + )*6 } = 5+6+6+4= 21
The cost for optimal layout will be 21 or more.
Hence the Lower-bound to the problem = 21
 Solution :
• Step-2: perform Branching from the starting node.
Suppose machine-1 is assigned to location-1, for this condition compute
the cost of material handling.
The elements of the flow matrix which represent material movement
associated with machine-1 are
• W12, W13, W14 (5, 0, 1) . let these be is designated by set P1 = ( 5, 0.1 )
• Distances from m/c -1 to other available locations are d12 , d13, d14 (1, 2,
6) . Let these be designated by set Q1 = ( 1, 2, 6 )
• When m/c -1 is assigned to location-1, the other machines 2, 3, and 4 can
be assigned to locations 2,3 and 4.ed with these machines designated as
set R = { W23, W24 W34 } = { 3, 0, 2 }
• The distance associated with locations 2, 3 and 4 designated as set S = {
d23 , d24, d34 } = { 3,5, 4}
• The cost of the layout will consists of six elements with following steps.
 .
• Crete vectors by arranging set P1 in descending order and set Q1 in ascending order find their dot product . call this C1=
P1 . Q1 = (5, 1, 0 ) . (1, 2, 6) = 5*1 + 1*2 + 0*6 ) = 8
• Cerate vectors by arranging set R in descending order and set S in ascending order .find their dot product. Call this as
C2
• Find the lower bound by adding C1 and C2 , LB = C1 + C2

• For present case , the lower-bound =LB= { P1 descending . Q1 ascending + R descending . S in ass }
= { ( 5, 1, 0). (1,2,6) + ( 3, 2, 0). ( 3,4, 5) } =
= { 5 + 2 + 0 } + { 9 + 8 + 0} = 7 + 17 = 24

• Similarly , the lower-bound , when facility-1 is assigned to locaction-2, location-3 and location-4 can be evaluated and
results are shown in following table.

Table: Lower-bounds when facility-1 is assigned to locations 1,2,3 and 4

Facility-1 is assigned to Lower-bound

Location-1 24
Location-2 22
Location-3 26
Location-4 32
Facilitiy-1 can be assigned in four feasible ways. Therefore , the
options can be pictorially represents as in figure: 9.4
 UNIT-III

• INTRODUCTION TO MATERIAL HANDLING SYSTEMS

• MATERIAL HANDLING PRINCIPLES
• CLASSIFICATION OF MATERIAL HANDLING EQUIPMENT
• RELATIONSHIP OF MATERIAL HANDLING TO PLNAT LAYOUT
 MATERIAL HANDLING- definition
• Material handling is defined as movement of material of any form ( raw
material, finished, packaged, solid, liquid, gas,, light and heavy) from one
location to another location, either in a restricted path by manual or mechanical
aids. The movement may be either horizontal, vertical or may be combination
of both.
• Material handling involves all those activities that are responsible for efficient
movement of goods either with in a plant or a warehouse or between a plant
and a transportation agency.
 IMPORTANCE OF MATERIAL HANDLING:
Importance of material handling can be studied under following aspects.
• Movement: It is associated with the transfer of goods into and out of storage
facilities or within these facilities. Efficiency of material handling can be
achieved by efficient transfer of goods to, from and within the storage
facility.
• Time: Aspect of time can be studied from production and customer's
perspectives. In case of production, it refers to the time required for bringing
the raw materials to the production site. Efficiency is said to have been
achieved, if it has to encounter problems of work stoppage, higher
inventories and increased space of storage.
• Quantity: Quantity refers to the amount of raw materials/finished goods
transferred from/to an organization. It accurate estimation results in
delivering right product to the right customer at the right time in right
quantity.
• Space: Space refers to the warehouse/plant capacity used by the material
handling equipment. Such space will be fixed. However, efficiency of
operations can be achieved by efficiently utilizing this space.
 OBJECTIVES OF MATERIAL HANDLING:
1. Increased usage capacity: It is mainly focused to increase the effective
usage capacity of a warehouse. Both horizontal and vertical capacities of a
warehouse needs to be utilized in an efficient manner, such that the firm
must achieve both economies of scale and scope.
2. To minimize Aisle Space: 'Aisle space' refers to a passage present between
the rows of shelves. If materials are handled with care, this can be reduced
to a great extent so as to accommodate more quantity of materials than
they have been used to do it before.
3. Reduces Handling Frequency: In case of logistics management, materials
initially move from the source to the warehouse, then they can be
transferred to an order selection areas where they can be picked up and
made into orders and then finally, to their shipment areas where they are
ready for final consumption by the customers. During all these stages,
several unnecessary movements of goods can be practiced by a firm which
has to be avoided in order to enhance the operational efficiency of ware-
house. Thus, firms should design material handling system
4. Develops Effective Working Conditions:
It focuses mainly on the development of secure and safe working
environment where employees develop s sense of safety while working in
an organization.
5)Automated Movement: Automated material handling system reduces the Burdon
of manual labor by combining them with automated systems, because there are
certain areas where operations cannot be performed with out making use
manual labors. The best example might be the activities associated with the
order picking area. Hence, an organization needs to develop an environment in
such a way that it would stimulate people to perform the job efficiently.
6 )Improved Logistics Service: It helps in improving the efficiency of logistics
system by effectively fulfilling the customer requirements. It is responsible for
the conveyance of goods to customers on time and in proper quantities. Due to
efficient movement of goods into warehouse or properly locating the stock or
by accurately filling the orders and also by properly preparing orders for
shipment to customers, material handling forms a crucial component of an
outbound logistics. This objective is greatly emphasized by the logistics
manager which makes him to strive hard to ensure that the customer's orders
and the production requirements are responded and met quickly and efficiently.
7) Eliminating short-distance warehouse movements
8) Minimizes Cost: By incorporating flexible material handling within the customer
service programs.
 FUNCTIONS OF MATERIAL HANDLING
1. It selects the type of machine, equipment and plant layout, so that the
material handling requirements can be minimized.
2. It includes the choice of convenient, effective and protected material
handling equipment.
3. It helps in reducing the material handling cost by considering the
following..
4. minimum movement of semi finished products during the manufacturing.
5. Planning of movement of number of parts under one unit
6. Minimizing the travelling distance between the departments.
7. By increasing operational speed of handling through mechanization.
8. Removing backtracking and duplicate handling.
9. use of gravity for material handling.
 JOBS OF MATERIAL HANDLING
Material handling performs the following operations.
(i) It receives the incoming raw material and delivers (ie shipping) the
outgoing products.
(ii) It transports the materials to its processing area by handling in work place
or in line or in interdepartmental or in intercompany .
(iii) It carries and stores the products at a suitable place.
(iv) In addition to the above operations, it can help in transport arrangement,
products delivery etc., depending upon the requirement
 CHARSCTERISTICS /FEATURES OF MATERIAL
HANDLING EQUIPMENT:

• A) Materials
(i) Bulk ( in huge quantity)
(ii) Packaged
• B) Movement of materials
(i) In horizontal direction
(ii) In vertical direction
(iii) Both horizontal & vertical direction
• C) Supervision required for an equipment
(I). More
(ii) Less
(iii) Automatic or semi-automatic type
• D) Path to be followed for materials
(I) Variable
(ii) Flexible
(iii) Fixed area
• E) Mode of speed
(i). Variable
(ii) Fixed
(iii) Fixed or variable
• F) Source of power for the operation of an equipment.
(I) Electric. Power
(ii). Power from. I.C engine
(iii) Manual power
(iv) Gravity power
 MERITS/ADVANTAGES OF MATERIAL HANDLING
SYSTEMS
• It reduces the time required for handling the materials
• Reduction in material handling & indirect labor cost.
• Improvement on productivity
• Better usage of floor space & facility
• Least fatigue to the worker
• Improved work environment
• Reduction in bottle necks
• Greater flexibility
• Improvement in safety & reduction in accidents.
• Improved material flow ( Less back tracking
• It promotes a protected and clean material handling without any difficulty.
• it eliminates the idle time of workers and machines.
• Increases the flow rate of materials from one workstation to another..
• material handling is a secured process.
• Compact and better stocking of materials in good location available in plant.

**** END OF MID-I *****

 MID-II
PRINCIPLES OF MATERIAL HANDLING

Several principles of material handling are employed for better utilization,

safer operating conditions, lower costs and better performance of material
handling
• 1. planning principle: The material handling systems should have well planned
methods which consisted of objectives of performance, needs and characteristics of
the product.
• 2. Standardization Principle: To achieve the objectives of performance of
handling system, standardize the material handling method, equipment, control
without influencing flexibility, modularity and the amount of material moving
through the system.
• 3.Work principle: Minimize the material handling work without affecting the level
of service required at the operations and productivity.
• 4. Ergonomic principle: To ensure safe and effective operations for the human
worker, the capabilities and limitations should be adapted, designed at the time of
material handling task and equipment.
• 5. Unit load principle: Unit load should be sized and arranged in a manner, which
completes the objectives of material flow and inventory at each stage of supply
chain.
 PRINCIPLES OF MATERIAL HANDLING contd..
6. Space utilization principle: The overall space available should be used
efficiently and effectively.
7. System principle: For the formulation of coordinated and operational
system, the material movement and storage activities should be fully
integrated.
8. Automation principle: The material handling system should be automated
or mechanized to improve operational efficiency, reduce manual labour and
operating cost.
9.Environmental principle: The designing and selection of equipment and
material handling system depends on the criteria of environmental Impact
and energy consumption.
10.Life cycle cost principle: The system should have thorough economic
analysis for entire life cycle of the material handling system and
equipments.
VARIOUS TYPES OF MATERIAL HANDLING EQUIPMENTS

The material handling equipments are broadly classified into various types
based on four categories.
1.) Design features
2) Nature and type of work
3)Working area
4)movement or motion of materials
 VARIOUS TYPES OF MATERIAL HANDLING
EQUIPMENTS
1. Design features: According to design they are classified as
1.1. Hoisting equipment
1.2 conveying equipment
1.3 surface and overhead equipment.
2. Nature and type of work: Equipments used for the movement and storage of materials at site are classified as
2.1 transporting equipments such as industrial trucks, cranes, conveyors.
2.2. Positioning equipments such as hoists, lifts, parts feeder, levelers etc.
2.3. Unit load formation equipments such as pallets, bags, crates, tote pans, cartoons etc.
2.4 storage equipments such as storage carousel, sliding racks, pallet racks, mezzanine etc.
2.5Identification and control equipments such as magnetic stripe, bar codes, radio frequency tag, machine vision etc.
3. Working area: In this category, equipments are classified as
3.1. Unrestricted Area: equipments such as trucks, tractors, carts etc.., which are restricted to move in any direction.
3.2 Restricted Area: Equipments such as gantry cranes, overhead travelling cranes and stacker cranes, which are confined to
working area.
3.3 Line Restricted: Equipments such as lifts and elevators, conveyors, AGV's etc .. Which follows a continuous specified path for
transportation of materials.
3.4 Position Restricted: Equipments such as job cranes and other industrial robots which are fixed units and works in specified
areas from its position.
3.5 Auxiliary Equipments: Equipments used to improve the effectiveness of handling such as unit load carriers, dispatch
Equipments, assembling and securing Equipments.
4.Movement or Motion of Materials: According to path of move the equipments are classified as,
4.1 Vertical motion (for lifting and lowering)
4.2 Horizontal motion (for transportation)
4.3 combined horizontal and vertical motion
 CONVEYORS:

1.0 Roller conveyors: Roller conveyors contain a series of rollers or tubes along their path. Position
of rollers is perpendicular to the direction of motion of conveyor.
1.1) Power Roller conveyors:
1.2)Non-powered Roller Conveyors:
1.3) Skate wheel conveyors:
2. Belt conveyors: Belt conveyors use a belt made of rubber, which is a reinforced elastomer. The
operation of belt conveyors is carried out in a continuous loop. Half length of belt is used to
carry and deliver the items or materials where as other half length id is for return path
2.1) Flat belt: These are used for individual parts or pallets
2.2) Troughed Belts: These are used for Bulk materials like gravel, coal, grain
3.Power and Free Overhead Trolley Conveyor:
4 Elevator: Elevator is a group of Equipments used in material handling to transfer the bulk
quantity of materials from lower heights to upper heights. There are four types of elevates and
are as follows.
• 4.1)Bucket elevators
• 4.2)Fright elevators
• 4.3) hoist elevators
• 4.4) lifts
 1.0 Roller conveyors:
• Roller conveyors contain a series of rollers or tubes along their path.
Position of rollers is perpendicular to the direction of motion of
conveyor. The rollers are placed in a fixed frame which elevates the
conveyor path above the floor level from several inches to several
feet.'s.
• For this purpose tote pans or pallets or cartons are employed. When the
rollers rotate the unit loads carried by flat pallets or tote pans moves
forward.
• Roller conveyors are two types
• 1.1) Power Roller conveyors: These are driven by means of chain or
belts.
• 1.2)Non-powered Roller Conveyors: These are driven by gravity.
Hence the path has sufficient downward slope to overcome the rolling
friction.
• To deliver the loads from storage compartment in between
manufacturing operations, roller conveyors are employed. It can also
be used in sorting/merging operations.
• 1.3) Skate wheel conveyors: Skate. Sheet conveyors contain skate
wheels rotating on shafts which are connected to a frame to roll tote
pans, pallets and other containers located along their path. This the
design and operation of these conveyors is same as that of roller
conveyors with a difference that these conveyors use skate wheels in
place of services of rollers.
• The weight of skate wheel conveyors is very low compared to the
roller conveyors. Therefore the loads should be light in weight as the
contacts between the loads and conveyors are highly concentrated.
 2.0 BELT CONVEYORS:

• Belt conveyors use a belt made of rubber,

which is a reinforced elastomer. The
operation of belt conveyors is carried out in a
continuous loop. Half length of belt is used to
carry and deliver the items or materials where
as other half length id is for return path.
• A frame containing support sliders or
rollers along its forward loop is used to
support the conveyor belt. A drive roller is
provided at one end of the conveyor to power
the belt.
• Belt Conyers are two types
• 1. Flat belt: These are used for individual
parts or pallets
• 2. Troughed Belts: These are used for Bulk
materials like gravel, coal, grain
 3.POWER AND FREE OVERHEAD TROLLEY
CONVEYOR:
• This type of conveyor equipment consists of a
wheeled carriage fixed with trolleys engaged on
the tracks or beam. The track includes upper
and lower track. The lower track carries from
trolleys spaced along a fixed track. While the
upper track carries continuously moving
endless chain. When the driving chain is
connected to the trolley from upper track, the
load travels from one path to another path.
When the driving chain is disconnected then the
trolley becomes idle. This conveyor is
applicable in factories to move parts and
assemblies in the production system. This
conveyor is used for storage and delivery of
materials or parts
 4 ELEVATOR:
• Elevator is a group of Equipments used in material handling to transfer the
bulk quantity of materials from lower heights to upper heights. There are
four types of elevatos and are as follows.
• (i)Bucket elevators
• (ii)Fright elevators
• (iii) hoist elevators
• (iv) lifts
• 4.1) Bucket elevators: It is a simple ,reliable and powered equipment used
for lifting bulk materials from lower heights to upper heights. It is driven
by chain or belt drives on which, metallic buckets are attached. The buckets
move in uni-direction and lifts the materials from lower surface by
scooping and delivers to the upper surface by centrifugal action.
 Bucket elevators- Components
The function of each equipment is as follows.
• .Belt chain: A bucket elevator has endless chain driven or belt driven pulling system used to pull
the buckets. Belts/chains are provided for carrying the buckets.
• Buckets: Sheet metal buckets are used for handling bulk materials. Buckets are fastened to
chain/belt by means of screw and nuts, rivets etc.
• Casing: Casings are provided for converging the entire elevator. There are three casings provided
for bucket elevator ie., upper casing, lower casing and intermediate casing.
• Drive unit: Drive units are provided for driving the pulleys using belt drives. These units are
situated at the upper end casings and are driven using the electric motors.
• Brakes: Brakes are attached to pulley/shaft for preventing the backward motion of the elevator
when it is not in use.
• Hoppers: Hoppers are used for filling the bulk material into metal buckets.
• Guides: Guides/Guide sprockets are provided for preventing misalignment of belts and chain in
bucket elevators.
• Discharge Spouts: These are provided at the upper portion of casing for discharging the bulk
material from the metallic buckets.
• Manholes: These are located at the lower casing for checking the operation of an elevator.
• Hence, the bucket elevators are used for delivering the bulk materials such as coke, coal, carbon,
ash, aluminium. Ore, pulverized chalk etc., from lower heights to upper height in vertical or
inclined direction.
 4.1.1 CLASSIFICATION OF BUCKET ELEVATORS
Based on the method of unloading (discharging) and bucket spacing, bucket
elevators are categorized into three types

• TYPE-I or centrifugal discharge elevators

• TYPE-II or Continuous discharge elevators
• TYPE-III or positive discharge elevators1.TYPE-I or centrifugal discharge
elevators
1)TYPE-I or centrifugal discharge elevators
• In type-1 elevators , the buckets are
positioned at an uniform pitch to avoid
interface during the loading and
unloading. This elevators uses both
belt or chain drives to drive pulley's.
The loading and unloading is carried
out by scooping and centrifugal action
respectively. This type of elevators
are basically used for vertical
structures and. For practical
appositions, which includes all kinds
of free flowing and small lump
materials such as grains, coal,
• Sand, clay, sugar, dry chemicals etc.
The speed of this elevator ranges from
2 1.1 to2 mpm.
 2)TYPE-II or continuous Discharge Elevator:
• The construction of type-III elevator is
similar to type -I elevator, except that
buckets are side mounted on two strands
of chain. The buckets are equally spaced
on chain to avoid interference. To inver
the buckets for complete unloading,
buckets are provided with a pair of Snub
Sprockets incorporated under head
Sprockets. The loading is carried out by
scooping or digging action of bucket and
unloading is through centrifugal action.
The speed of this elevator ranges from
o.6 to o.67 mpm. An inclined type-III
elevator especifically suitable for
perfect gravity discharge applications.
Light weight materials, fluffy sluggish
and slightly sticky materials are more
suitable for this elevator.
 3).TYPE-III or positive Discharge Elevators
• The construction of type-III elevator is
similar to type -I elevator, except that
buckets are side mounted on two strands of
chain. The buckets are equally spaced on
chain to avoid interference. To invert the
buckets for complete unloading, buckets are
provided with a pair of Snub Sprockets
incorporated under head Sprockets. The
loading is carried out by scooping or digging
action of bucket and unloading is through
centrifugal action. The speed of this elevator
ranges from o.6 to o.67 mpm. An inclined
type-III elevator specifically suitable for
perfect gravity discharge applications. Light
weight materials, fluffy sluggish and
slightly sticky materials are more suitable
for this elevator.
•
 HOW MATERIAL HANDLING IS RELATED TO PLANT
LAYOUT
It has been observed that plant layout is closely interrelated to material
handling system, as good layout provides the minimum rate of material
handling and eliminate re-handling. The material handling parameters to
be considered in designing plant layout are
1. Excess movement of materials: Can cause damage to materials and effects the valuable time of
workers in shifting the materials. Hence a well planned plant layout reduces the material handling
2.Time Utilization: Saving the worker's productive time by providing a good plant layout, enhances an
effective production. Plant layout should have minimum workman travel and clearly identified well-
named functional areas, distinct areas for raw materials, tools, work-in-process, inspection of
finished goods, et .
3. Economical use of Space: An important perception in plant layout is space. All the machines and
equipments have to be arranged in sequential and well-planned manner such that , no empty space
should be wasted. There should be a possibility of optimum choice of expansion in future.
4.Use of Miscellaneous Tools: The effective utilization of bins, trolleys, racks, trays, conventional
packing techniques, conveyors, chutes, inclined planes and gravity feed-bins reduce material
backtracking and unnecessary movement of workers. Thus effectiveness in manufacturing can be
obtained.
Therefore, a good plant layout provides an effective material handling. System which ensures
minimum material handling.
 DIFFERENT TYPES MATERIAL HANDLING
EQUIPMENT ASSOCIATED WITH DIFFERENT PLANT
LAYOUTS
• The different types of material handling equipment associated with different plant layouts are
• 1. Cranes, hoists,
• Industrial truck  Fixed position layout
•
• 2. Hand trucks, forklift,
• trucks. Automated trucks  Process Layout
• AGV's.
•
• 3. Conveyors.  Product layout
• 1.1.Cranes and Hoists: Cranes are used lowering, lifting and transporting heavy loads in a factory.
Provided with one or more hoists which can be used as a load lifting component with the help of pulley
wrapped with ropes or chains or cables. A hook is attached at the end of rope or chain or cables.
• 1.2 Powered industrial trucks are also used for transferring palletized loads, palletized container in a
factory.
• 2.1 Hand and Forklift Trucks: Hand trucks and forklift trucks are used for moving pallet loads or parts in
a factory.
• 2.2 AGV's: Automated guided vehicles are widely used for moving work-in-process materials along the
specified path in low and medium quantity production.
• 3 Conveyors: Mono-rails and other rail guided vehicles are used for moving single assemblies, products
or pallet loads along defined routes in a factory and also for moving large quanties of products over a
fixed routes.
 UNIT – IV

• BASIC MATERIAL HANDLING SYSTEMS:

CLASSIFICATION OF BASIC MATERIAL HANDLING
SYSTEMS:
1. EQUIPMENT ORIENTED SYSTEM:
• Over head system
• Conveyor system
• Tractor trailer system
• Fork lift truck and pallet system.
• Industrial truck system
• Under ground system.
2.0 MATERIAL ORIENTED SYSTEM:
• Unit material handling system.
• Bulk handling system.
• Liquid handling system.
 METHOD ORIENTED SYSTEM

• Manual system
• Mechanized or Automated system.
• Job shop handling
• Mass production handling system.
4. FUNCTION ORIENTED SYSTEM
• Transportation devices, Trucks
• Conveying systems
• Transferring system
• Elevating system.
5a: FIXED PATH ORIENTED SYSTEM
• Conveyor
• Hoists
• Lift
• Crane
• Pallets
5b: VARIABLE PATH ORIENTED SYSTEM.
• Tractors
• Trucks
• Railways
• Aircraft
• Water
 FACTORS TO BE CONSIDERED WHILE SELECTING
MATERIAL HANDLING EQUIPMENT.

• The plant lay out (product and process layout)

• The type of process (either continuous or intermittent flow process )
• The sequence of operations to be performed for product.
• Type of process ( is it batch or JIT process)
• The plant building construction details
• The existing material handling equipments.
• The final cost of product.
• The physical & chemical properties of the material to be handled.
• The flexibility, reliability, speed and efficiency of material handling
equipment.
• The noise of machines and exhaust gases of material handling equipment.
• The future costs of handling equipments maintenance & running costs.
• The depreciation rate of equipment.
• The safety of employees during the material handling.
MANUAL METHOD OF MATERIAL HANDLING

In industries, manual handling of materials is the major part of unskilled

labour. In this method, the worker has to lift and move the heavy loads by
activities such as lowering, pushing, pulling etc. This method includes
stacking/un stacking loads on pallets, stacking shelves, lifting and lowering
loads, moving trolleys and packing stock. when the worker performs these
kind of activities due to improper handling or excessive loads, it may result
in either physical risk or injury to the worker (s). Therefore, safety
measures have to be taken into consideration during manual material
handling.
MECHANICAL MATERIAL HANDLING
• This method of material handling arises when the materials are to be
handled beyond the physical capacity of the workers. In this method,
different equipments are used to move, store, motion control and
protect the materials. The different equipments that are most
commonly used are cranes, elevators, conveyors, platform trucks,
forklift trucks, electric hoists, etc.
FORK LIFT
FLAT FORM TRUCK
 FUNCTION ORIENTED MATERIAL HANDLING SYSTEM

TRANSPORTATION SYSTEM OR EQUIPMENT

• hand truck .
• Narrow gauge rail road
• Industrial tractors and trailers.
• walkie trucks
• Skids
• Dollies
ii) CONVEYING SYSTEMS or EQUIPMENTS:
• Belt conveyors
• Chain Conveyors
• Roller Conveyors
• Screw conveyors
• Bucket conveyors
• Elevating conveyors
iii. TRANSFERRING SYSTEM OR EQUIPMENT
• Cranes: These are the material handling Equipments used for lifting or
lowering the material or load. The cranes are power driven or operated
manually.
• Jib cranes:
• Overhead cranes:
• Gantry cranes:
• wharf cranes:
iv) ELEVATING SYSTEMS OR EQUIPMENT.
• Drum type elevators
• Traction type elevators
• Bucket elevators
 PATH ORIENTED MATERIAL HANDLING SYSTEM
OR
EQUIPMENT
i. The path followed: The path followed for material handling is tabulated as
follows.
ii. The course followed
iii. THE TYPE OF MOTION FOLLOWED:
The different types of motions followed are represented by figure which is as
follows.
 UNIT – V

1 ASPECTS OF ANALYSIS:
Cost analysis is performed to reduce the cost of material handling system. For
different plants cost of material handling will be different. The aspects of
cost analysis are as follows.
• cost of handling division.
• Handling process as part of the operation.
• Individual costs related to handling
• Total factory cost of handling
i. Cost of handling Division: The cost of handling division is related to
functions within a accountable frame work, which includes tool rooms,
receiving shipment, packing, crating, internal transport, storage of raw
material, in process and finished goods.
ii. Handling Process as part of the operation: Handling process is an
integral part of the operation and it deals with handling, machining, setting
or positioning time of the component. Internal handling cost is given by.
• Internal handling cost: Labour cost of dept* handling time/ total time.
iii. Individual costs related to handling: Individual costs related to material
handling system includes, equipment cost, maintenance cost remuneration
to the operators, handlers, fitters, checkers, etc.
iv. Total Factory cost of Handling: The cost of handling in a factory is the
sum of cost of handling divisions, handling process as part of the operation
and individual costs related to handling.
VARIOUS COST CONSIDERATIONS IN MATERIAL HANDLING

i. Initial cost of equipment

ii. Installation cost
iii. Operating cost
iv. Cost of suppliers, repairs, maintenance etc.
v. Depreciation cost.
vi. Taxes and insurance cost
vii. Obsolescence cost.
vii. Auxiliary equipment cost.
ix. License cost
x. interest on investment cost.
xi. Rental of space
xii. Probable salvage cost
i. Initial cost of Equipment: The cost of equipment to be
purchased varies from model to model depending upon the
operations to be performed. The firm has to bear this cost to
meet the requirement according to its standard.
ii. Installation cost: Generally, the initial cost is done by the
manufacturer. In some cases while installing, the equipment
has to be rearranged or if any kind of alteration required has to
be done according to the building structure. This cost has to
bear by the installer.
iii. Operating cost: The cost of operation includes power cost, labour cost,
supervision cost, running cost, etc. These cost has to be minimized in order
to enhance the productivity.
iv. Cost of supplies, Repairs, Maintenance etc: The industry has to bear any
failure of the component, repairs or general maintenance cost of the
equipment. The maintenance can be carried out by either industry
personnel or agency experts. If the maintenance is carried out by industry
personnel then, they have to carry inventories and must train the persons
who are involved in this job. Thus, the cost of maintenance will be
increased. If the maintenance is carried by agency experts then, the cost of
maintenance will be reduced.
v. Depreciation cost: The cost starts when the equipment is installed and
operating at full swing. It mainly deals with replacing the old equipment
with a new one. It should be kept as low as possible.
vi. Taxes and insurance cost: The local taxes and the insurance cost has to be
borne by the firm according to state or central government acts.
vii. Obsolescence cost: This cost is similar to that of depreciation cost. It deals
with replacing the equipment with a new equipment which is
technologically superior to the older one. This cost also should be
minimum as possible.
viii. Auxiliary equipment cost: It is an optical operating cost such as charging
of truck batteries, etc. This is required for efficient working of the system
and to improve the productivity. It also increases the life of equipment.
ix. License cost: The equipment which is to be provided by license such as
,heavy trucks, etc. The licensing cost has to be borne by the firm to operate
the trucks.
x. Interest on investment cost: When a firm is not in a position to purchase the
equipment then, it has to be taken on a loan. In such cases the interest has
to be borne by the firm.
xi. Rent of space: The cost of space rented or if equipment is hired for rent
comes under this category. Example: Rent of garage space for parking.
xii. Probable salvage cost: This cost arises when the equipment is break down
and is to be scrapped. This scrapping value should be as high as possible.
HOW COST OF MATERIAL HANDLING DECREASES BY
IMPROVING THE MATERIAL HANDLING TECHNIQUES:
i. Better utilization of space.
ii. Reducing material handling labour
iii. Minimizing the damage of material during material handling.
iv. Material handling should not be handled by skilled or semi-skilled
labour.
v. Reduction in process storage
vi Indirect labour expenses should be minimized on activities such as
quality control, storage inspection, shipping, tool room, repairing,
etc.
vii. Increasing the rate of production.
viii. Decreasing the inventory.
ix. Minimizing the cost on packing and other protective devices.
i. Load utilization: In load unitization, material handling must consider a
fundamental principle which states that the economy (earnings) of material
handling is directly influenced by the size of load handled. Put simply, it is
directly proportional to the number of trips ie., as the number of trips
increases, more number of labour is required to unload it which in turn
increases the cost of stacking. Hence, an entire process can be made
economical by reducing the number of trips for materials handling one of
the best method is by consolidating the small packages to form a single
load which is termed as load unitization. pelletization and containerization
are used for the accomplishment of a unit load.
• Pelletization: A pallet or a skid is a wooden platform usually
used for stacking goods during transportation and storage. It is
highly economically to keep the manufactured goods in the
form of stocks until the order fulfillment requires bulk
breaking . pelletization is also useful in optimal utilization of
space optimal utilization space and load unitization.
• Containerization: Basically, containers are used for consistent
handling of materials and load unitization. Containers are
secured and waterproofed large boxes, in which goods are
safely placed for transportations and storage. This ability of
containers facilities the forms to storage goods even in open
yard without making use of ordinary warehouse
• Space layout: As the cost of warehouse is mainly influenced
by the location of stocks in warehouses, firm need to maintain
a proper balanced between the two, while designing the
internal arrangement of warehouses.
• . Layout for storage: While designing a warehouse 'configuration' plays a
vital role. If goods are available in large amount for storage, extensive care
needs to be taken for their arrangement which is time consuming step. In a
warehouse where turnover is low, wide and deep storage are suitable where
stocking may be as high as ceiling height with narrow aisles. However, this
layout may not be suitable in case of increased turnover which requires
wide aisles and decreased altitude of stocks.
• TRAINING PROGRAMME FOR SAFETY OF MATERIAL
HANDLING EMPLOYEES
• Proper material lifting techniques for manual handling.
• The employees must be aware of different equipments available for
material handling.
• Proper terminology of different equipments.
• The various operating procedures for different types of material handling
equipments.
• Listing of different codes with respect to the corresponding equipment.
• Different rules and regulation pertaining to specific types of material
handling equipment.
• Inspection of the equipment at regular interval.
• Proper work practice for handling and the use of safety devices.
• Use of appropriate material handling equipment for its suitable task.
• General maintenance procedures and requirements
• DIFFERENT ACCIDENTS ENCOUNTERED BY FORK LIFT
TRUCK
• i. Loads being dropped/pushed onto employees.
• ii. Overturning of trucks.
• iii. Collision with static elements or knocking them on other employees.
• iv. Employees being hit by the FLT
• v. Trapping injuries.
• Causes of Accidents by Forklift Truck
• Operators fault.
• Instability of load caused by shift in the centre of gravity.
• Using trucks for unsuitable premises.
• Lack of clear visibility.
• Due to insufficient skills of drivers and other employees working in the
regions where FLT is being used.
• Due to poor communication among employees working in that area.
• Due to improper layout and markings on the premises.
• Inadequate ventilation and battery charging.
• Lack of maintenance of FLT
• using FLT for unsuited tasks.
• Due to over speed of trucks with heavy loads.
ERGONOMICS OF MATERIAL HANDLING EQUIPMENTS
• Ergonomics: Ergonomics is defined as the science
which deals with the study of work. It is also
concerned with the design of working systems.
Ergonomics relates or involves the man, machine
and environment in order to increase the efficiency
and productivity of the system.
PRINCIPLES INVOLVED IN ERGONOMICS FOR
DESIGNING WORK SYSTEM.
• work task
• work equipment
• work process
• work space
• work environment
• work stress
• work strain
• Work fatigue.