12/8/2018 Materials Handling: Functions, Objectives and Principles

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Materials Handling:
Functions,
Objectives and
Principles
Article shared by :

After reading this article you will learn

about:- 1. Definition of Materials
Handling 2. Objectives of Materials
Handling 3. Functions 4. Costs Included
5. Systems Concept 6. Steps in Analysing
Materials Handling Problems 7. Activity
Areas 8. Relationship with Other
Departments 9. Basic Materials Handling
Systems 10. Principles 11. Limitations.

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Contents:

1. Definition of Materials Handling

2. Objectives of Materials Handling
3. Functions of Materials Handling
4. Costs Included in Materials Handling
5. Systems Concept of Materials
Handling
6. Steps in Analysing Materials
Handling Problems
7. Activity Areas of Materials Handling
8. Relationship of Materials Handling
with Other Departments
9. Basic Materials Handling Systems
10. Principles of Materials Handling
11. Limitations of Materials Handling

1. Definition of Materials
Handling:

There is no hard and fast definition of

materials handling, however attempts
have been made to define this term.
Materials handling is the science and art
both involving the moving, packing and
storing of substance in any form, and
includes the preparation, placing and
positioning the material to facilitate their
movement or storage.

Materials handling occurs whenever a

material is moved may be in a
manufacturing, distribution (warehouse),
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or office environment. Materials handling

also occur during preparation for
shipment, transportation may be by sea,
air or land, and moving material in and
out of carriers.
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Society has defined the Materials
Handling as “Materials handling is an art
and science involving the movements,
packaging and storing of substances in
any form”.

2. Objectives of Materials
Handling:

As we know that with the rise of factory

system, men continued to develop
handling equipment to perform jobs
where human or animal muscles were
insufficient in either capacity or speed.
Later on it becomes important to reduce

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materials handling labour in order to

reduce production cost.

Therefore main objective of materials

handling engineer is to reduce product
cost the one overall goal. Materials
handling equipment is not production
machinery, but is auxiliary equipment
that improves the flow of material which
in turn reduces stoppages in production
machines and thus increases their
production.

Objectives of a proper materials

handling system are:

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1. Reduced costs,

2. Increased capacity,

3. Improved working conditions,

4. Improved customer service, and

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ADVERTISEMENTS:

5. Improved productivity.

1. Reduction in Cost:

Reduction in total cost of production can

be achieved by either reducing materials
handling or by improved handling
procedure or both.

The objective of reduction in cost of

production through improved
materials handling can be achieved
by:

(a) Reducing material handling labour.

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(b) Material handling work should not be

assigned to skilled or semi-skilled labour.

(c) Reducing indirect labour expenses on

activities connected with storage,

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inspection, quality control, repair, tool

room, shipping etc.

(d) Reducing damage of materials during

handling.

(e) Better utilisation of space.

(f) Reducing in process storage.

(g) Increasing productivity.

(h) Reducing expenditure on packaging

and other protective devices.

(i) Decreasing inventory.

2. Increase in Capacity:

Improved materials handling system

results in increase of capacity by better
utilisation of space.

Improved handling system can

increase the capacity in the
following ways:

(a) By better utilisation of space:

Racks or containers that stacks item upon

each other making full use of air space
should be preferred. From this point of
view use of overhead cranes, conveyors,
lift trucks etc., are very suitable.

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(b) By reducing travel space or

excessive wastage of space:

For this purpose a study of flow of

materials between operations should be
done considering the flow paths, volume
of material, timing etc. This study may
help in reducing travel time and space
requirements.

(c) By improving equipment

utilisation:

This can be achieved by ensuring regular

supply and distribution of material. This
will reduce the idling of machine.

(d) By faster loading or unloading:

This can be achieved by employing

conveyor system, cranes, loaders, rail
road cars, tipping trucks etc.

3. Improvement in Working
Conditions:

(a) Safety aspects:

Safety of men, material and associated

equipment not only prevents loss of
money but also enhances the moral of
workers.

(b) Easy working:

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By using proper handling equipment

heavy jobs can be handled with ease,
faster speed and at a constant rate
throughout the period of production. This
enables high morale and lower workers
turnover.

(c) Foolproof operation:

Due to absence of manual handling, there

are no chances of confusion resulting in
placing of material at wrong location or
disruption of production.

4. Improved Customer Service:

Customer’s service will be improved by

following proper and improved materials
handling system which will enable regular
and timely market supply by avoiding
disruption in production schedule. These
are the main sources of good customer
service.

3. Functions of Materials
Handling:

The basic function of material handling-

the movement of material- is as old as
man, but the need of materials handling
developed from the development of
factory system, which started from the
industrial revolution which took place in

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late eighteenth and early nineteenth

centuries.

The industries, supermarket, offices,

construction projects and the banks—all
are engaged in moving things. In early
days man was physically handling the
material, however over a period of years
he has started applying mechanical
principles like lever, wheel, pulley etc.

The material handling, though does not

add value to a product, it generally adds
significant element of cost. Material
handling generally costs between 20 to
35% of the cost of the product, with
certain exceptions. Earlier, it was a
general belief that most of this cost is
inevitable and cannot be easily avoided,
but now-a-days need for reduction in
materials handling costs through systems
approach is being realised.

Not only cost, majority of production time

is also consumed in handling materials
before, during and after the manufacture.
The materials handling time and cost can
be reduced by proper selection, operation,
maintenance and layout of these handling
devices.

The materials handling problem must be

studied at the time of planning of various
machines and tools to be required and
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before the erection of factory building.

Materials handling is a prime
consideration in designing new plants,
and existing plants can also be modify by
the application of modern materials
handling devices. These devices increase
output, improve quality, speed up the
deliveries and therefore, reduces the
production cost.

4. Costs Included in Material

Handling :

Materials handling includes

following costs:

Materials handling cost = cost of handling

+ cost of transportation + cost of pack-
aging + cost of space + cost of handling
equipment including operation,
maintenance and depreciation etc.

In any industry materials handling

is of following 3 types:

1. Handling of individual part or unit by

men,

2. Handling in room, department, or plant

3. Handling of materials during the entire

process of production and distribution,
starting from raw material source, going
through the factory and distribution

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network to the ultimate customer and

beyond, to waste disposal and recycling.

This can be shown as below:

Raw material → Supplier →

Transportation → Receiving → Storing →
Issue → Manufacturing or fabrication →
Packaging → Shipping → Dealer or
Distributors warehouse → Retailers →
Customer → Disposal → Recycling.

Since materials handling is

concerned with the movement of
materials, every movement has
following elements:

1. Picking up the load,

2. Transporting the load, and

3. Setting the load down.

5. Systems Concept for Materials

Handling:

Systems concept for materials handling

means, adopting a materials handling
system from overall optimisation point of
view. This means that it is not necessary
to buy the latest materials handling
equipment, materials handling engineer
must put all the elements of the system
together to see whether it is profitable for
the enterprise.
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He must analyse to ensure the objective of

least total cost of handling. Materials
handling engineer must have basic
criteria for selecting a handling system of
adequate monetary pay back, if all other
things are equal.

Systems approach for materials handling

demands that all elements of problem, its
cause and effect be analysed so as to
accomplish to desired objectives.

Systematic analysis should lead to

solutions which satisfy the
following important conditions:

1. There should not be any other problem

created by the new system proposed to be
implemented.

2. Amount of return on investment must

justify the proposed handling system.

3. The system must take care for

reasonably long period of time, and that it
must permit expansion or modification
without much cost and difficulty.

4. The new system must be simple to

implement so that it is easily acceptable
by management as well as by operators.

In short the new handling system must

have technique and method which can
easily fit the existing system and has least
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total cost of the system and meets the

ultimate objective of the materials
handling.

By following the systems approach,

materials handling engineer must
achieve the following:

1. Increase the production effectiveness by

having right quantity of material, at right
places at the right time, by avoiding
delays and following the orderly flow of
material or item. This helps in improving
the productivity.

2. Minimise unnecessary labour and make

the enterprise more profitable.

3. Reduce damage due to materials

handling and thus saves expenditure due
to scrap and rework. This can be achieved
only if we have sufficient data related to
the damages e.g., identification of product
or item, whether in transportation,
storing, picking or setting down,
packaging material or method, type of
container etc.

4. Reduce accident rates.

5. Effective utilisation of space by proper

layout planning.

6. Steps in Analysing Materials

Handling Problems:
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Following factors should be studied

to analyse the materials handling
problems:

1. Establish the scope of the study.

2. Pinpoint the areas of plant layout to be

covered by the study.

3. Determine volume expected to be

handled per unit time by the new system.

4. Nature and type of the materials to be

handled.

5. Determine the handling cost of the

items being handled by the present
system.

6. Determine details of distance to be

moved, with details of curves, slopes etc.

7. Determine, how to move the material

i.e., in tray, bundles, pallets etc.

8. Determine the details of the equipment

used viz., capacity, speed, flexibility etc.

9. Determine the time taken for the

movement.

10. A thorough survey should then be

made considering the systems approach.

11. Alternative systems should then be

evaluated from all angles including
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financial, physical, safety, acceptance by

the management and operators, and its
effects on working, safety and overall
environment.

7. Activity Areas of Materials

Handling:

For effective materials handling,

materials handling engineer must
look after handling work in
different areas, some of them are:

1. Packaging and packing of raw material

for the industry.

2. Loading and transportation to the

plant.

3. Unloading activities.

4. Receiving, storage and issue of material

for production.

5. In-process handling.

6. In-process storage.

7. Work-place handling.

8. Infra-departmental handling.

9. Inter-departmental handling.

10. Intra plant handling.

11. Packaging.
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12. Warehousing.

13. Packing.

14. Loading and transportation to

customers/distributors/dealers place.

8. Relationship of Materials
Handling with Other
Departments:

In the past materials handling was

neglected and due importance was not
given to this function in the industries.
This was simply due to lack of awareness
on the part of management. But now a
day this aspect is being given its due
importance and materials handling
engineers play a vital role in the
industries.

In order to carry out the functions

of materials handling, the
personnel of this department work
in close association with other
departments of the enterprise, such
as with the following:

1. Purchasing Department:

To facilitate in deciding the size of order,

packaging, packing and transportation
system from suppliers place to the plant.

2. Stores Department:

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Handling and storage of materials and

supplies is determined by the
characteristics of the items and the nature
of storage methods.

3. Production Control Department:

Handling department must

cooperate with production control
department in following fields:

(a) Directing path of material movement.

(b) Moving material in lots or containers

of predetermined sizes.

(c) Making optimum use of mechanical

handling in picking, accumulation and
loading.

(d) Meeting production requirement with

the handling equipment.

(e) Materials handling system itself must

incorporate features of production
control, inventory control and accounting.

(f) Moving materials as per schedule and

to avoid rush deliveries, partial loads or
duplicate moves.

4. Industrial Engineering
Department:

Since materials handling function is a

division of the broad field of industrial
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engineering, materials handling engineer

has to work in close cooperation with
other industrial engineers dealing
different functions, e.g.;

(a) With the process engineering in

designing the manufacturing process to
establish line balancing, in-process
handling, and storage operations.

(b) With the methods engineering in

designing the individual work places, the
methods used in performing the
operations.

(c) With the work standards personnel in

establishing work standards for materials
handling operations for using as the basis
of incentive schemes for material
handlers.

(d) With plant layout personnel in

developing the overall flow pattern and
the arrangement of the facilities in the
plant.

Relation between Plant Layout and

Materials Handling:

There exists a very close relation between

plant layout and materials handling. The
method of handling materials definitely
influences the plant layout and the plant
building. If all the devices required for a

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particular set of operations are

determined but fail to arrange them
properly then it is said that layout is not a
good one. Effective layout means
minimum handling operations.

In the plant:

(i) If materials are to be moved by hand

operated or power trucks, passages are
provided for their operation.

(ii) If materials are to be moved by

overhead cranes, passages are almost
missing but the overhead space is
unobstructed.

(iii) If materials are to be moved by pipe

lines, ducts such as paint in automobile
body building plants and saw dust as in
wood working plants, arrangement should
be made for their methods of handling.

(iv) If the building is multi-storeyed,

elevators, and conveyors of different types
may be utilized. Gravity conveyor may be
utilized in moving material in a multi-
storeyed building or one built on a sloping
grade.

Modern materials handling technique

makes possible a continuous flow of
materials and work in process between
building and from one floor to another,

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thus removing restrictions of space and

building construction, which was
handicapped in the past. Today in
advanced plants handling devices
operated by electronic controls are used.

Position of Plant Layout and

Materials Handling Departments in
an Organisation:

Position of plant layout department and

materials handling department vary from
organisation to organisation and depends
upon its size and type of product
manufactured.

The functions of these departments

are generally assigned to:

1. Plant engineer/manager

2. Plan layout engineer/manager

3. Industrial engineer/manager

4. Production engineer/manager

5. Process engineer

6. Materials handling engineer.

It has generally been observed that

most of the organisations assigned
the job of plant layout and materials
handling to either ‘Plant
Engineering’ departments or
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‘Industrial Engineering’ along with

other functions as illustrated
hereunder:

1. Plant Engineering:

(a) Plant construction,

(b) House keeping,

(c) Repair and maintenance,

(d) Safety and security,

(e) Facility design, and

(f) Utilities.

2. Industrial Engineering:

(a) Cost and economy studies,

(b) Work-study,

(c) Operation research,

(d) Systems engineering, and

(e) Facilities designing.

9. Basic Materials Handling

Systems:

1. Equipment Oriented Systems:

(a) Industrial Truck Systems: Platform

trucks and skids, fork trucks and pallets,
and tractor-trailers.
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(b) Conveyor systems.

(c) Overhead systems: Overhead cranes,

and monorails.

2. Material (Load) Oriented

Systems:

(a) Unit handling system.

(b) Bulk handling systems: conveyors,

power shovels, scoops, cranes, draglines,
and construction equipment.

(c) Liquid material handling systems.

3. Method (Production) Oriented

Systems:

These are described in terms of the

types of production in which they
are used:

(a) Manual system.

(b) Mechanised or automated systems,

(c) Mass production handling systems.

(d) Job shop handling systems.

4. Function Oriented Handling

Systems:

(a) Transportation systems: For

horizontal motion.

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(b) Elevating systems: For vertical motion

over vertical or steeply inclined routes.

(c) Conveying systems: Horizontal,

vertical or combined motions.

(d) Transferring systems: Horizontal,

inclined or declined motions through the
air.

(e) Self-loading systems: Intermittent

motion with machines that pick up, move
and set down, i.e., unit load systems.

10. Principles of Materials

Handling:

Since it is not possible to acquire

experience by a materials handling
engineer himself on all types of problems,
he has to take advantage of others’
experience. On the basis of-experience
gained by himself and also by others he
should try to solve the handling problems.

On the basis of these experiences facts,

systematic approach and other ideas,
certain principles have been developed.
These principles have been implemented,
practiced and perfected during several
years. These principles of material
handling are useful in all the fields may it
be engineering, office or elsewhere.

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The word ‘principle’ can be defined as a

prescribed guide to accepted procedures
established through past practice and is
accepted as authoritative by practitioners,
and without which a system would be less
effective. Therefore, when these principles
of materials handling are applied by
materials handling engineer, even if he is
not much experienced, he can find correct
solution faster.

These principles are general guides, and

can be put to use by means of different
activities. In the table below, principles of
materials handling are given, and against
each of them activities necessary for
implementing the principle are indicated.

Principles Related to Planning:

1. Planning Principle:

All material handling activities should be

planned.

(i) Material should be placed on pallet or

any other support and not on the floor
directly.

(ii) One container should be used

throughout and avoid frequent changes.

(iii) Utilise truss capacities and ceiling

heights.

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(iv) Provide sufficient storage space at the

work-place.

(v) Each operator must be

instructed/trained to follow correct
method.

(vi) Plan for scrap removal means.

(vii) Efforts are made to combine

operations like inspection during
productive operation.

(viii) Minimise movement of men and

material.

2. Systems Principle:

Handling activities be integrated and

coordinated. Handling activities are
receiving, storage, in-process handling,
inspection, packaging, warehousing,
shipping and transportation.

(i) Consider all the handling activities

while giving a detailed consideration to an
activity.

(ii) Material flow between work areas is

planned.

(iii) Integrated activities into the handling

system.

3. Simplification Principle:

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Reduce, combine or eliminate

unnecessary movements and/or
equipment.

(i) Motion Economy principles by applied.

(ii) Reduce or eliminate, long and

complicated movements.

(iii) Deliver the material at correct spot in

first instance.

(iv) Eliminate rehandling.

(v) Reduce variety of equipment.

4. Material Flow Principle:

Material flow pattern must be determined

by operation sequence and pattern of
equipment arrangement.,

(i) Avoid overcrowding.

(ii) Eliminate obstacles in the flow.

(iii) Move in a direct path and avoid back

tracking.

(iv) Move greatest weight and/or bulk for

least distance.

(v) Minimise movements between floors,,

and buildings.

(vi) Plan proper locations of sub-

assemblies.
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(vii) Plan related work areas close

together.

(viii) Avoid traffic jams and take

necessary precautions for cross traffic.

5. Gravity Principle:

Utilize gravity where possible.,

(i) Use slides, chutes, hoppers etc. where

possible

6. Unit Size Principle:

Increase size, quantity, weight of the load

handled. Since larger the load, lesser will
be the cost per unit handled.

(i) Handle unit loads. Unit loads

described separately.

(ii) Use containers.

(iii) Containers should be standardised.

(iv) Use standardised pallets.

(v) Optimise unit loads.

7. Space Utilisation Principle:

Optimum utilisation of building space. As

space means money.

(i) Equipment or work area may be kept

in reasonably close position.
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(ii) Inventory at temporary stores must

not be kept too much.

(iii) Utilise height of building and use rack

to permit higher stocking.

(iv) Use concept of economic order

quantities and economic lot sizes.

(v) Dispose obsolete or scrap items in

time.

(vi) Use handling equipment requiring

minimum aisles.

(vii) Use mobile or overhead equipment.

(viii) Use collapsible containers to save

space required by empty ones.

8. Safety Principle:

Safe handling methods and equipment for

better working conditions and to avoid
unsafe conditions.,

(i) Provide adequate guards and other

safety devices.

(ii) Handling equipment is kept in good

operating conditions.

(iii) Highlight handling hazards, moving

vehicles or danger areas.

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(iv) Make arrangement for removal of

undesirable fire, dust, smoke etc.

(v) Emergency switches or controls be

provided.

(vi) Proper instructions and training for

safe operation to the operators.

(vii) Keep floor clean.

(viii) Provide good housekeeping.

(ix) Keep aisles clear.

(x) Do not overload handling equipment

or devices.

(B) Principles Related to

Equipment:

9. Mechanisation Principle:

For increasing efficiency use mechanised

handling equipment but to the desired
extent only.

(i) Mechanisation is useful for large

quantities, long, frequent, high effort or
hazardous moves.

(ii) Replace excess manual handling or

where large numbers of persons are
engaged on handling jobs.

(iii) Moving heavy containers.

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(iv) Design containers suitable for

mechanical handling.

(v) Use mechanised communication

where required.

10. Flexibility Principle:

Equipment’s capable of handling variety

of tasks be used.,

(i) Buy versatile and flexible equipment.

(ii) Buy adjustable racks.

(iii) Utilise accessories and attachments.

11. Equipment Selection Principle:

Select equipment very carefully

considering all aspects of materials,
movements, and the method.

(i) Select versatile equipment.

(ii) Cost per unit to be handled should be

compared.

(iii) Consider standardization aspects.

(iv) Equipment should be economical on

long term basis.

12. Standardisation Principle:

Standardise equipment as well as

methods.
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(i) Standardise the equipment, containers

and pallets.

(ii) Standardise methods.

(iii) Train employees on standardised

equipment and methods.

13. Light Weight Principle:

Reduce weight of equipment.

(i) Equipment should have less dead

weight to pay load ratio.

(ii) Use light weight pallets, skids and

containers.

14. Motion Principle:

The handling equipment should be kept

in motion i.e., minimum period for
loading, unloading or other idleness.

(i) Reduce loading/unloading time.

(ii) Use mechanical means or other means

for quick loading and unloading.

(iii) Use tractor trailers, so that tractor

can be used for other work while the
trailer is being loaded/unloaded.

(iv) Minimise downtime.

15. Idle-time Principle:

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Reduce idle and unproductive time.

(i) To avoid idle manpower, deliver

material at a desired rate.

(ii) Do not use productive labour for

handling.

(iii) In order to utilise manpower fully,

more than one machine can also be
allotted to one man.

(iv) Equipment should be fully utilised.

16. Obsolescence Principle:

Obsolete methods and equipment be

replaced by efficient methods and
equipment.

(i) Obsolete equipment be identified and

replaced by new equipment.

(ii) Beware of new technological

developments and remain in constant
touch through books, journals, attending,
conferences etc.

17. Maintenance Principle:

Preventive maintenance practices are

adopted for handling equipment.

(i) Preventive maintenance is carried out

to avoid breakdowns.

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(ii) Carry out schedule maintenance and

daily inspections and take remedial
measures.

(iii) Set up regular maintenance schedule.

(iv) Train operators for proper operation

and maintenance.

(v) Maintain adequate spare supplies.

Principles Related to Operation:

18. Control Principle:

Control production and inventory through

materials handling equipment.

(i) Provide direct mechanical paths for

materials movement.

(ii) Materials be moved in lots, batches,

containers of a predetermine quantity or
size.

(iii) Materials handling system should

have built in features of controlling
production, inventory, and accounting.

(iv) Material is moved as per schedule.

19. Capacity Principle:

Production capacity should be fully

achieved.

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(i) Ensure uniform desired rate of flow.

(ii) Equipment is operated at optimum

rate.

(iii) Plan to utilise forward as well as

return runs of the equipment.

(iv) Vehicles, conveyors, containers etc.

should be loaded to full capacity.

(v) Utilise overhead space.

(vi) Aisles should be obstacle free and

wide enough for speedy movement.

(vii) Store items not affected by weather.

20. Performance Principle:

Performance of handling is measured in

terms of cost per unit handled, safe
working condition, and increase in
production rate or reduced manpower for
handling.

This is the effect of all preceding

activities.

11. Limitations of Material

Handling:

While evaluating a material handling

system its disadvantages must also be
considered.

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Some of the disadvantages are:

1. Additional capital investment.

2. Loss of flexibility:

A mechanical system is generally

designed for a particular size, shape,
volume and for a particular sequence of
operation and hence it is difficult to
change, and require additional cost for
modification for likely range of changes in
the product or production techniques.

3. Breakdown:

Being mechanical and electrical system,

the handling system may breakdown at
times, and may take some time for
repairs.

4. Every mechanical handling system

requires timely maintenance, which
means addition of skilled maintenance
manpower, maintenance spares, cost of
maintenance time required for servicing
and arrangement during this period to
continue production.

Related Articles:

Material Handling: Definition, Factors and

Factors | Industries
Selection of Material Handling Devices

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