Material Handling System Design and Decision

Material handling system design and decision
MATERIAL HANDLING
Material handling is the movement, storage, control and protection of materials, goods, and
products throughout the process of manufacturing, distribution, consumption and disposal. The
focus is on the methods, mechanical equipment, systems and related controls used to achieve
these functions. Material handling systems range from simple pallet rack and shelving projects to
complex conveyor belt and Automated storage and Retrieval systems (AS/RS). Material
handling can also consist of sorting and picking as well as automatic guided vehicles.
The main objectives of material handling are as follows:
 It should be able determine appropriate distance to be covered.

 Facilitate the reduction in material damage as to improve quality.
 Reducing overall manufacturing time by designing efficient material movement
 Improve material flow control
 Creation and encouragement of safe and hazard-free work condition
 Improve productivity and efficiency
 Better utilization of time and equipment
 Cost reduction
 Increasing warehouse capacity
When designing a material handling system, it is important to refer to best practices to ensure
that all the equipment and processes—including manual, semi-automated and automated—in a
facility work together as a unified, system. By analyzing the goals of the material handling
process and aligning them to guidelines, such as the 10 Principles of Material Handling, a
properly designed system will improve customer service, reduce inventory, shorten delivery
time, and lower overall handling costs in manufacturing, distribution and transportation. These
principles include:
Planning: Define the needs, strategic performance objectives and functional specification of the
proposed system and supporting technologies at the outset of the design. The plan should be
developed in a team approach, with input from consultants, suppliers and end users, as well as
from management, engineering, information systems, finance and operations.
Standardization: All material handling methods, equipment, controls and software should be
standardized and able to perform a range of tasks in a variety of operating conditions.
Work: Material handling processes should be simplified by reducing, combining, shortening or
eliminating unnecessary movement that will impede productivity. Examples include using
gravity to assist in material movement, and employing straight-line movement as much as
possible.
Ergonomics: Work and working conditions should be adapted to support the abilities of a
worker, reduce repetitive and strenuous manual labor, and emphasize safety.
Unit load: Because less effort and work is required to move several individual items together as
a single load (as opposed to moving many items one at a time), unit loads—such as pallets,
containers or totes of items—should be used.
Space utilization: To maximize efficient use of space within a facility, it is important to keep
work areas organized and free of clutter, to maximize density in storage areas (without
compromising accessibility and flexibility), and to utilize overhead space.
System: Material movement and storage should be coordinated throughout all processes, from
receiving, inspection, storage, production, assembly, packaging, unitizing and order selection, to
shipping, transportation and the handling of returns.
Environment: Energy use and potential environmental impact should be considered when
designing the system, with reusability and recycling processes implemented when possible, as
well as safe practices established for handling hazardous materials.
Automation: To improve operational efficiency, responsiveness, consistency and predictability,
automated material handling technologies should be deployed when possible and where they
make sense to do so.
Life cycle cost: For all equipment specified for the system, an analysis of life cycle costs should
be conducted. Areas of consideration should include capital investment, installation, setup,
programming, training, system testing, operation, maintenance and repair, reuse value and
ultimate disposal
CONSIDERATIONS IN MATERIAL HANDLING SYSTEM DESIGN
1. Material characteristics
2. Flow Rate
3. Plant Layout

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Material handling system design and decision

The main objectives of material handling are as follows:

 It should be able determine appropriate distance to be covered.

CONSIDERATIONS IN MATERIAL HANDLING SYSTEM DESIGN

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