INDUSTRIAL PLANT ENGINEERING

Module 4. Principles of materials handling

Objectives:

1. Discuss the planning principles, standardization principle and work principle.

2. Select appropriate material handling system.
3. Identify the hazards for the equipment or products.

Contents:

4.1. Introduction:

Materials handling is the art and science involving the moving, packaging and storing of substances in any
form. Some of the other definitions are:

- Materials handling is the movement and storage of materials at the lowest possible cost through the
use of proper methods and equipment.

- Materials handling is the moving of materials or product by any means, including storage, and all
movements except processing operations and inspection.

- Materials handling is the art and science of conveying, elevating, positioning, transporting, packaging
and storing of materials.

4.2 Principles of Material Handling:

1. Planning principle: All handling activities should be planned.

2. Systems principle: Plan a system integrating as many handling activities as possible and coordinating the
full scope of operations (receiving, storage, production, inspection, packing, warehousing, supply and
transportation).
3. Space utilization principle: Make optimum use of cubic space.
4. Unit load principle: Increase quantity, size, weight of load handled.
5. Gravity principle: Utilize gravity to move a material wherever practicable.
6. Material flow principle: Plan an operation sequence and equipment arrangement to optimize material flow.
7. Simplification principle: Reduce combine or eliminate unnecessary movement and/or equipment.
8. Safety principle: Provide for safe handling methods and equipment.
9. Mechanization principle: Use mechanical or automated material handling Equipment
10. Standardization principle: Standardize method, types, size of material handling equipment.
11. Flexibility principle: Use methods and equipment that can perform a variety of task and applications
12. Equipment selection principle: Consider all aspect of material, move and method to be utilized.
13. Dead weight principle: Reduce the ratio of dead weight to pay load in mobile equipment.
14. Motion principle: Equipment designed to transport material should be kept in motion.
15. Idle time principle: Reduce idle time/unproductive time of both MH equipment and man power.
16. Maintenance principle: Plan for preventive maintenance or scheduled repair of all handling equipment.
17. Obsolescence principle: Replace obsolete handling methods/equipment when more efficient
method/equipment will improve operation.
18. Capacity principle: Use handling equipment to help achieve its full capacity.
19. Control principle: Use material handling equipment to improve production control, inventory control and
other handling.
20. Performance principle: Determine efficiency of handling performance in terms of cost per unit handled
which is the primary criterion.
OBJECTIVES OF MATERIAL HANDLING
• Minimize cost of material handling.
• Minimize delays and interruptions by making available the materials at the point of use at right quantity
and at right time.
• Increase the productive capacity of the production facilities by effective utilization of capacity and
enhancing productivity.
• Safety in material handling through improvement in working condition.
• Maximum utilization of material handling equipment.
• Prevention of damages to materials.
• Lower investment in process inventory

SELECTION OF MATERIAL HANDLING EQUIPMENTS

Selection of Material Handling equipment is an important decision as it affects both cost and efficiency of
handling system. The following factors are to be taken into account while selecting material handling
equipment.
• PROPERTIES OF THE MATERIAL
Whether it is solid, liquid or gas, and in what size, shape and weight it is to be moved, are important
considerations and can already lead to a preliminary elimination from the range of available equipment under
review. Similarly, if a material is fragile, corrosive or toxic this will imply that certain handling methods and
containers will be preferable to others.
• LAYOUT AND CHARACTERISTICS OF THE BUILDING
Another restricting factor is the availability of space for handling. Low-level ceiling may preclude the use of
hoists or cranes, and the presence of supporting columns in awkward places can limit the size of the material
handling equipment. Layout itself will indicate the type of production operation (continuous, intermittent, fixed
position or group) and can indicate some items of equipment that will be more suitable than others. Floor
capacity also helps in selecting the best material handling equipment.
• PRODUCTION FLOW
If the flow is fairly constant between two fixed positions that are not likely to change, fixed equipment such as
conveyors or chutes can be successfully used. If, on the other hand, the flow is not constant and the direction
changes occasionally from one point to another because several products are being produced simultaneously,
moving equipment such as trucks would be preferable.
• COST CONSIDERATIONS
Several cost elements need to be taken into consideration when comparisons are made between various items
of equipment that are all capable of handling the same load. Initial investment and operating and maintenance
costs are the major cost to be considered.
• NATURE OF OPERATIONS
Selection of equipment also depends on nature of operations like whether handling is temporary or permanent,
whether the flow is continuous or intermittent and material flow pattern-vertical or horizontal.
• ENGINEERING FACTORS
Selection of equipment also depends on engineering factors like door and ceiling dimensions, floor space, floor
conditions and structural strength.
• EQUIPMENT RELIABILITY
Reliability of the equipment and supplier reputation and the after sale service also plays an important role in
selecting material handling equipment.

Material handling equipment is classified into four main categories based on its function: transportation,
positioning, storage, and unit load formation. Below is an overview of the different types within each
category.

4.3 Types of Material Handling

A. Manual Material Handling (MMH)
• Involves lifting, carrying, pushing, or pulling materials by human effort.
 • Used for small-scale operations or lightweight materials.
• Risks: Fatigue, injuries (e.g., back strain).
• Solutions: Use ergonomic tools like carts, dollies, and lifting aids.
B. Mechanized Material Handling
• Uses machines and equipment to transport materials.
• Suitable for medium to large-scale operations.
• Includes forklifts, conveyors, cranes, and hoists.
C. Automated Material Handling (AMH)
• Uses technology and robotics to reduce human intervention.
• Includes Automated Guided Vehicles (AGVs), robotic arms, and conveyor systems.
• Advantages: Increased speed, accuracy, and reduced labor costs.
D. Bulk Material Handling
• Used for large volumes of raw materials (e.g., coal, sand, grains).
• Includes screw conveyors, hoppers, bucket elevators, and pneumatic systems.

Categories of Material Handling Equipment:

1. Transportation Equipment
- Used to move materials from one location to another within a facility.
A. Conveyors - are mechanical handling systems used to transport materials from one location to another
within a facility. They are widely used in manufacturing, warehousing, distribution, and mining industries. The
choice of conveyor depends on the type of material, required speed, distance, and operational environment.
• Belt Conveyors – Used for moving bulk materials or packaged goods.

• Roller Conveyors – Suitable for transporting boxes and pallets.

• Chain Conveyors – Ideal for heavy loads like automotive parts.

• Screw Conveyors – Used for bulk materials like grain or cement.

• Overhead Conveyors – Useful in assembly lines and warehouses.

• Pneumatic Conveyors - Uses air pressure to transport fine or powdered materials.

• Vibrating Conveyors - Uses vibration to move materials.

• Bucket Conveyors (Bucket Elevators) - Used for vertical lifting of bulk materials.

• Magnetic Conveyors - Used for moving ferrous (iron-based) materials.

 B. Industrial Trucks - are vehicles designed for transporting materials, goods, or equipment within a
facility, warehouse, or manufacturing plant. They enhance productivity, reduce manual labor, and improve
safety in material handling operations.
1. Hand-Operated Trucks (Manual or Non-Powered) - Used for small loads and short distances and
requires physical effort from workers.
• Hand Trucks (Dollies) - Two-wheeled carts for carrying boxes, sacks, or small items.

• Pallet Jacks (Manual Pallet Trucks) - Used to lift and transport palletized loads.

• Platform Trucks - Four-wheeled carts with a flat platform for carrying goods.

2. Powered Industrial Trucks (Motorized) - Equipped with an engine (electric, gas, diesel) for heavy-duty
tasks and used for long distances and heavier loads.
• Forklifts (Lift Trucks) - Most common industrial truck with forks for lifting pallets.
 • Electric Pallet Jacks (Walkie Pallet Trucks) - Powered version of a pallet jack with an electric motor.

• Order Pickers - Used for retrieving items from high shelves in warehouses.

• Tow Tractors (Tuggers) - Used for pulling multiple carts in a train formation.

• Automated Guided Vehicles (AGVs) - Self-driving trucks using sensors and software for navigation.

C. Cranes and Hoists - Cranes and hoists are lifting and transportation equipment used to move heavy
loads efficiently and safely within industrial, construction, and warehouse environments. They reduce manual
labor, improve productivity, and enhance workplace safety.
 A crane is a lifting device designed to move heavy materials horizontally and vertically. It consists of a hook,
wire rope, and a hoist mechanism mounted on a supporting structure.

Types of Cranes:
A. Overhead Cranes (Bridge Cranes) - Used in manufacturing plants, warehouses, and assembly lines and
mounted on overhead beams to move loads across a large area.
• Single Girder Overhead Crane
o One main beam, lighter capacity (1–20 tons)
o Cost-effective for light-duty applications

• Double Girder Overhead Crane

o Two main beams, higher load capacity (20–500 tons)
o Ideal for heavy-duty lifting (e.g., steel mills, shipyards)

• Gantry Crane
o Similar to overhead cranes but mounted on legs
o Used in outdoor applications like shipyards, container yards

• Jib Crane
o Has a rotating arm (jib) that swings loads
o Used in workstations, docks, and small assembly lines
B. Mobile Cranes - Portable and used in construction, infrastructure projects, and heavy lifting
• Truck-Mounted Crane
o Mounted on a truck chassis for easy transport
o Used in construction and logistics

• Rough Terrain Crane

o Designed for off-road applications
o Used in construction, oil and gas, and mining

• Crawler Crane
o Mounted on tracks (crawlers) for stability on rough ground
o Used in large infrastructure projects

• Tower Crane
o Tall, fixed cranes used for high-rise construction
o Capable of lifting loads to extreme heights
 C. Special Purpose Cranes
• Floating Crane – Used for marine and offshore applications.

• Aerial Crane (Helicopter Crane) – Used for transporting materials in remote areas.

Hoists
A hoist is a lifting mechanism used to raise and lower materials. It is often integrated with cranes but can
also be used independently.

Types of Hoists
A. Manual Hoists - Operated by hand or foot power and used for low-capacity lifting (up to 5 tons)
• Chain Hoist – Uses a hand chain to lift loads.

• Lever Hoist (Come-Along) – Uses a lever and ratchet mechanism.

 B. Powered Hoists - Uses electric, pneumatic, or hydraulic power for lifting and ideal for frequent and
heavy lifting operations.
• Electric Hoist – Most common; used in factories and warehouses.

• Pneumatic (Air) Hoist – Used in explosive environments (e.g., chemical plants).

• Hydraulic Hoist – Used for high-capacity, heavy-duty lifting.

2. Positioning Equipment
- is used to move, align, or adjust materials to the correct location for processing, assembly, or storage.
It helps in reducing worker fatigue, increasing precision, and improving safety.
A. Lift Tables - Scissor-like mechanisms that raise or lower materials to a desired height and used in assembly
lines, warehouses, and repair workshops.
Types:
• Hydraulic Lift Tables – Powered by hydraulic fluid.
• Electric Lift Tables – Operated by electric motors.
• Pneumatic Lift Tables – Uses air pressure.
 B. Turntables - Rotating platforms that allow materials to be turned for easy access and used in packing
stations, welding, and automotive assembly.

C. Tilt Tables - Tilts materials at different angles for easier handling and common in manufacturing and
packaging industries.

D. Manipulators - Mechanical arms that assist in lifting, rotating, and positioning objects and used in
automotive, electronics, and aerospace industries.

E. Hoists & Balancers - Hoists lift materials, while balancers provide weightless movement and common in
workstations, assembly lines, and machine shops.
F. Robotic Arms - Automated machines that handle repetitive tasks and used in automobile manufacturing,
food processing, and packaging.

3. Storage Equipment
- is used to hold, organize, and protect materials until they are needed for production, assembly, or
distribution. It helps in maximizing space, improving inventory management, and enhancing workplace
efficiency.
Types of Storage Equipment:
A. Racks and Shelving - Used to store and organize materials in warehouses and distribution centers.
1. Pallet Racks – Designed for storing palletized goods.
• Selective Pallet Racks – Most common; allows direct access to each pallet.
• Drive-In & Drive-Through Racks – High-density storage with limited access points.
• Push-Back Racks – Uses sliding carts to store multiple pallets in depth.
• Cantilever Racks – Ideal for long and bulky items (pipes, lumber, steel bars).

2. Industrial Shelving – Used for small parts, tools, and non-palletized goods.
• Boltless Shelving – Easy to assemble, commonly used in warehouses.
• Wire Shelving – Lightweight, provides air circulation (ideal for food storage).

B. Automated Storage and Retrieval Systems (AS/RS) - Computer-controlled storage systems that
automatically place and retrieve items.
• Vertical Lift Modules (VLMs) – Uses trays and lifts to optimize space.
• Carousels – Rotating storage systems (vertical or horizontal).
• Mini-Load Systems – Automated bins for small item storage.
C. Mezzanines - Raised platforms used for additional storage above the ground level.
• Freestanding Mezzanines – Independent structures that provide flexibility.
• Rack-Supported Mezzanines – Built above shelving or pallet racks.
• Building-Supported Mezzanines – Integrated with the facility structure.

D. Bins and Containers - Used for organizing and storing smaller items efficiently.
• Stackable Bins – Space-saving, can be placed on racks or shelves.
• Tote Boxes – Plastic containers used in warehouses and manufacturing.
• Bulk Containers – Heavy-duty bins for large and loose materials.
4. Unit Load Formation Equipment
- is used to combine multiple items into a single load for easier transportation, handling, and storage.
This improves efficiency, reduces damage, and lowers handling costs.
Types of Unit Load Formation Equipment:
A. Pallets - Flat platforms used to stack, store, and transport goods as a unit.
• Wooden Pallets – Most common; cost-effective but less durable.
• Plastic Pallets – Durable, lightweight, and reusable.
• Metal Pallets – Used for heavy loads and harsh environments.
• Presswood Pallets – Lightweight, nestable, and eco-friendly.

B. Skids - Similar to pallets but without bottom deckboards (easier to drag) and used for temporary storage or
heavy machinery transport.

C. Slip Sheets - Thin plastic, fiberboard, or corrugated sheets used instead of pallets and requires a push-pull
attachment on forklifts. This are used in food, beverage, and export industries.
D. Containers and Crates - Used to enclose and protect products during shipping and handling.
• Wooden Crates – Strong and reusable for fragile items.
• Plastic Totes – Used for small parts in warehouses and manufacturing.
• Metal Containers – Ideal for heavy-duty industrial applications.
• Corrugated Boxes (Cardboard) – Common for lightweight packaging.

E. Strapping and Banding - Used to secure and stabilize unit loads.

Materials:
• Steel Straps – For heavy loads (construction, metal industries).
• Plastic Straps (Polypropylene & Polyester) – Lighter, used in shipping.
• Corded & Woven Straps – Flexible and shock-resistant.

F. Shrink Wrapping and Stretch Wrapping - Plastic film used to hold unit loads together.
• Shrink Wrap – Heated to shrink tightly around the load.
• Stretch Wrap – Stretched and wrapped around the load without heat.

G. Automated Unit Load Systems - Machines that automate load formation.

• Palletizers – Automatically stacks boxes, bags, or containers onto pallets.
• Robotic Load Formers – Uses robotic arms to precisely stack and align loads.
4.4 Plant Layout and Material Handling
Plant layout and material handling are closely interrelated concepts in manufacturing and industrial
operations. An efficient plant layout ensures smooth workflow, while an effective material handling system
minimizes movement, reduces costs, and improves safety and productivity.

1. Plant Layout
Plant layout refers to the arrangement of machines, equipment, workstations, and storage areas within a
facility to ensure an efficient workflow.
Objectives of Plant Layout:
- Minimize material handling costs by reducing unnecessary movement.
- Ensure smooth production flow with minimal delays.
- Maximize space utilization for efficiency.
- Enhance worker safety and comfort by reducing hazards.
- Improve productivity with optimized workstations and logistics.
Types of Plant Layout:
1. Product Layout (Line Layout)
• Used for mass production and assembly line manufacturing.
• Machines and workstations are arranged in a sequential order based on the production process.
• Example: Automobile assembly lines.
• Advantages: High efficiency, reduced handling time, and lower production cost.
• Disadvantages: High initial setup cost and inflexible to changes.
2. Process Layout (Functional Layout)
• Machines are grouped based on their function (e.g., drilling, welding, painting).
• Suitable for job shops and batch production with customized products.
• Example: A machine shop with separate sections for milling, grinding, and assembly.
• Advantages: High flexibility and better customization.
• Disadvantages: Increased material handling and longer production time.
3. Fixed Position Layout
• The product remains stationary, and workers/machines move around it.
• Used for large, heavy, or complex products like ships, aircraft, and construction projects.
• Advantages: Minimal product movement and high customization.
• Disadvantages: Requires skilled labor and may be less efficient.
4. Cellular Layout (Group Technology Layout)
• Hybrid of process and product layouts. Machines are grouped into cells that handle similar processes.
• Used for batch production with similar products.
 • Example: A manufacturing unit producing different types of electronic components.
• Advantages: Reduced material handling time and improved flexibility.
• Disadvantages: Requires advanced planning and skilled workforce.
5. Combination Layout (Hybrid Layout)
• A mix of different layouts to optimize workflow.
• Used in large-scale manufacturing where multiple processes are required.
• Example: An automobile plant with assembly lines and machining centers.
• Advantages: Flexible and efficient for complex production.
• Disadvantages: Requires detailed planning and high setup costs.

2. Material Handling in Plant Layout

Material handling involves the movement, storage, and control of materials within the facility to minimize costs
and improve efficiency.
Principles of Material Handling in Plant Layout:
✔ Minimize Movement – Design layouts that reduce transportation distances.
✔ Automate Where Possible – Use conveyors, AGVs, and robots to reduce manual labor.
✔ Use Space Effectively – Utilize vertical storage and ergonomic workstation design.
✔ Enhance Safety – Implement proper handling techniques and safety measures.
✔ Standardize Equipment – Use common pallets, containers, and transport tools.

Material Handling Equipment Used in Plant Layout:

Category Examples Purpose

Belt conveyors, roller conveyors, overhead Transport materials efficiently between
Conveyors
conveyors workstations
Industrial Trucks Forklifts, pallet jacks, AGVs Move raw materials and finished goods
Cranes & Hoists Jib cranes, gantry cranes, chain hoists Lift and transport heavy loads
Storage
Pallet racks, AS/RS, bins Organize and store materials systematically
Equipment
Unit Load
Pallets, containers, stretch wrappers Secure materials for movement and storage
Handling

3. Integration of Plant Layout & Material Handling

An optimal plant layout and material handling system should work together to:
✔ Reduce bottlenecks in production.
✔ Enhance process efficiency by reducing unnecessary movements.
✔ Minimize handling costs with automation and standardization.
✔ Ensure worker safety and ergonomic comfort.
✔ Improve product quality with streamlined operations.

Example of an Optimized System:

- Automobile Manufacturing Plant:
• Assembly lines (Product Layout) reduce material handling time.
• AGVs and conveyors transport materials automatically.
• Robotic arms assist in assembly, reducing manual effort.
• Palletized storage improves space utilization.