Material Handling (PDF)

Mechanical Engineering Department Material Handling Engr. Edward Henrick H. Aguda, M.Sc., PME Faculty of Engineering, University of Santo Tomas  Shoes Cars Pen Electronics Linen Medicine Utensils Mobile Phones Oven Fan “They are all MA...

Mechanical Engineering Department Material Handling Engr. Edward Henrick H. Aguda, M.Sc., PME Faculty of Engineering, University of Santo Tomas  Shoes Cars Pen Electronics Linen Medicine Utensils Mobile Phones Oven Fan “They are all MANUFACTURED”  NATURAL RESOURCES Ores, Coals, Oil, Natural Gas, Trees, Water FLOW OF MANUFACTURING GOODS Mining Manufacturing Assembly Getting the natural Transforming natural System to combine resources resources to products products Material Handling Moving the resources MATERIAL HANDLING is the art and science associated with the movement, storage, control, and protection of goods and materials throughout the process of their manufacture, Consumers distribution, consumption, and disposal. Material Handling What? SKU? Best Where? JIT? Solution How? AGV? Possible When? RFID? Engineers Why? MFA? FLOW OF MANUFACTURING GOODS Material Handling Equipment Logistics Refers to the activities of the flow within a facility Refers to the management of the flow RAW POWER, HP, kW Efficiency MATERIAL HANDLING EQUIPMENT refers to a range of devices and systems used to facilitate the movement, protection, storage, and control of materials or products throughout a facility or supply chain. These tools are essential for improving efficiency, safety, and accuracy in material handling operations. MATERIAL HANDLING EQUIPMENTS refers to a range of devices and systems used to facilitate the movement, protection, storage, and control of materials or products throughout a facility or supply CONVEYOR chain SCREW PRESS RADIAL PUMP LOGISTICS Logistics is a broader concept that encompasses the entire process of planning, implementing, and controlling the efficient flow and storage of goods, services, and related information from the point of origin to the point of consumption. It includes the management of material handling, transportation, inventory, warehousing, and distribution. ESSENCE MATERIAL HANDLING Most Priority 1. Efficient and safe movement of materials to the desired place. 2. Timely movement of the materials when needed. 3. Supply of materials at the desired rate. IE / ME Engineers 4. Storing of materials utilizing minimum space. Best Solution Possible 5. Lowest cost solution to the materials handling activities Least Priority WHAT MH ACHIEVES 1. Cut down indirect labour cost. 2. Reduce damage of materials during storage and movement. 3. Maximise space utilization by proper storage of materials 4. Improve customer services by supplying IE / ME Engineers materials in a manner convenient for handlings Efficiency = 5. Increase efficiency and saleability of product Profit  Product Total Movement PRODUCT Characteristics Quantity Sequences Required Manual Physical Timing / Machinery Required Chemical Rate Load Sensitivity What? 1000 qty, 80kg bag of cement Why? Storeroom to Industrial Truck Where? Storeroom to Industrial Truck When? Once Week, Every Morning until 5pm How? Manual Method Who? Four Workers MATERIAL HANDLING EQUATION WHAT WHY WHERE WHEN HOW WHO + = MATERIALS MOVES METHODS MATERIAL HANDLING PRINCIPLES are fundamental guidelines used to design and manage the efficient movement, protection, storage, and control of materials and products throughout the manufacturing, warehousing, distribution, consumption, and disposal processes. 1. PLANNING PRINCIPLE A plan is a prescribed course of action that is defined in advance of implementation. In its simplest form, a material handling plan defines the material (what) and the moves (when and where); together they define the method (how and who). “The plan should be developed in consultation between the planner and all who will use and benefit from the equipment to be employed” Stakeholder Meetings Planning document / Method Statement 2. STANDARDIZATION PRINCIPLE Standardization means less variety and customization in the methods and equipment employed Standardization applies to sizes of containers and other load forming components as well as Less Variety = Less Complexity operating procedures and equipment. 3. WORK PRINCIPLE The measure of work is material flow (volume, weight, or count per unit of time) multiplied by the distance moved. Simplifying processes by reducing, combining, shortening or eliminating unnecessary moves will reduce work 4. ERGONOMIC PRINCIPLE Ergonomics is the science that seeks to adapt work or working conditions to suit the abilities of the worker. Equipment should be selected that eliminates repetitive and strenuous manual labor and which effectively interacts with human operators and users 5. UNIT LOAD PRINCIPLE A unit load is one that can be stored or moved as a single entity at one time, such as a pallet, container, or tote, regardless of the number of individual items that make up the load. Less effort and work is required to collect and move many individual items as a single load than to move many items one at a time. 6. SPACE UTILIZATION PRINCIPLE Space in material handling is three-dimensional and therefore is counted as cubic space. In storage areas, the objective of maximizing storage density must be balanced against accessibility and selectivity. 7. SYSTEM PRINCIPLE A system is a collection of interacting and/or interdependent entities that form a unified whole. Inventory levels should be minimized at all stages of “Just in time” production and distribution while respecting a management strategy that aligns raw-material orders considerations of process variability and customer service. from suppliers directly with production schedules 8. AUTOMATION PRINCIPLE Automation is a technology concerned with the application of electromechanical devices, electronics, and computer-based systems to operate and control production and service activities. It suggests the linking of multiple mechanical operations to create a system that can be controlled by programmed instructions Computerized material handling systems should be considered where appropriate for effective integration of material flow and information management. 9. ENVIRONMENTAL PRINCIPLE Environmental consciousness stems from a desire not to waste natural resources and to predict and eliminate the possible negative effects of our daily actions on the environment Containers, pallets and other products used to form and Materials specified as hazardous have special protect unit loads should be designed for reusability when needs with regard to spill protection, possible and/or biodegradability as appropriate. combustibility and other risks 10. LIFE-CYCLE COST PRINCIPLE Life-cycle costs include all cash flows that will occur from the time the first dollar is spent to plan or procure a new piece of equipment, or to put in place a new method, until that method and/or equipment is totally replaced. A long-range plan for replacement of the equipment when it becomes obsolete should be prepared.  Mechanical Engineering Department Material Handling: WHAT Engr. Edward Henrick H. Aguda, M.Sc., PME Faculty of Engineering, University of Santo Tomas CLASSIFICATION OF MATERIALS Solid, Liquid, Gas, Slurry UNIT LOAD BULK LOAD UNIT LOAD MATERIAL refers to the standardization of goods or materials into a single, manageable unit that can be easily handled, stored, and transported. This concept is fundamental in logistics and supply chain management because it helps streamline operations and increase efficiency. Shape of unit loads Position of C.G. of load Mass of unit load Volume per unit Type of material Geometrical shape Specific physical and chemical properties Loads sensitive BULK LOAD MATERIAL refers to a large quantity of material that is not packaged into individual units but is handled in a loose, unpackaged form. This approach is often used for materials that are not practical to handle individually. Lump-size Bulk Weight Specific Weight Moisture Content Abrasiveness BULK LOAD MATERIAL refers to a large quantity of material that is not packaged into individual units but is handled in a loose, unpackaged form. This approach is often used for materials that are not practical to handle individually. Average Bulk Angle of Material Density kg/m3 Repose Alumina 800–1040 22 Cement, Portland 1500 39 Coal, anthracite 960 27 Iron ore 1600–3200 35 Lime, hydrated 560–720 40 Rice Grain 720-768 20 Sand, foundry 1440 39 Slag 1280–1440 25 Wheat 720–768 28 SOLID composed of molecules or atoms that are tightly packed together that can maintain a rigid structure. Unit Load Bulk Load Material Material LIQUID composed of molecules or atoms that strong enough to keep them relatively close together Unit Load Bulk Load Material Material GAS Gases are composed of molecules or atoms that are in constant random motion, colliding with each other and the walls of their container Unit Load Bulk Load Material Material SLURRY a mixture of solid particles suspended in a liquid, in which the solid particles are not dissolved in the liquid. Unit Load Bulk Load Material Material  Mechanical Engineering Department Material Handling Equipment Engr. Edward Henrick H. Aguda, M.Sc., PME Faculty of Engineering, University of Santo Tomas  CLASSIFICATION OF EQUIPMENTS Storage Transport Conveyor Hoisting Auxiliary STORAGE CONTAINER is any vessel or device used to hold, protect, and transport materials or products. Its primary function is to facilitate the safe and efficient handling of goods during shipping, storage, and distribution SHOP CONTAINER Designed to hold a specific quantity or type of goods (unit load) for efficient handling within a shop, warehouse, or retail environment. These containers facilitate the organization, movement, and storage of products in a unitized form, which simplifies inventory management and streamlines operations 2000 kg 1000 kg 500 kg PALLET SKID It is essentially a platform used for assembling, storing It is essentially a platform provided with legs so that a and handling of materials as a unit load. Essential platform truck may get inside it and raise it from ground. feature of a pallet is that the forks of a lift truck can be Skids are thus single-faced and non-stackable. inserted at the bottom side of the platform, while the pallet is resting on floor and thus can raise the pallet with load and move it to desired place MORE STABLE AND CHEAPER AND CAN BE CAN BE STACKED DRAGGED PALLET PATTERN refers to the specific way items or products are organized and stacked on a pallet for transportation and storage. Proper pallet patterns are crucial for maximizing space, ensuring stability, and preventing damage during handling and shipping UNIT LOAD DEVICE is a device that restrains cargo, mail, perishable goods and baggage during air transportation. This is either the solid metal containers you’ve probably seen at an airport or a pallet with mesh netting that holds the contents in place LD3 = 1500 kg LD7 = 5000 kg LD9 = 6000 kg INTERMODAL CONTAINER is a large metal crate designed and built for intermodal freight transport, meaning these containers can be used across different modes of transport – such as from ships to trains to trucks WAREHOUSE A warehouse is a commercial building or facility used for the storage of goods, materials, products, and inventory. It serves as a central location where items are stored temporarily until they are needed for distribution, sale, manufacturing, or other purposes. BULK CONTAINER Designed To accommodate and manage large quantities of materials that are stored in bulk rather than as individual items or packaged units. This type of storage is designed to handle, store, and sometimes process bulk quantities efficiently BIN A bin is a large container of cylindrical or rectangular shape made from sheet metal supported on legs. Filling of bins is from the open or covered top and discharge is from the bottom opening. Inside agitators or outside vibrators are used for facilitating flow of materials from the discharge opening. BUNKERS A bunker is essentially a large bin, used for storage of materials like coal in a power station. These may be a few hundred meters in length. Belt conveyors, with automatic trippers, dumpers etc. are used for filling of the bunkers SILOS is a large, vertical storage structure designed for holding bulk materials such as grains, cement, coal, or other bulk substances. Silos are commonly used in agriculture, construction, and industrial processes to store materials in a controlled and efficient manner. Underground Silo Missile Silo OPEN PILE STORAGE Some solids, in bulk are frequently stored in open storage piles. These materials which are not weathered easily and need to be stored and reclaimed at substantial hourly rate are kept in open pile storage. The piles can contain materials from 5000 tons to some million tons, while handling rate may vary from 100 to 2000 tonnes per hour ENGINEERING DESIGN storage tank involves multiple engineering considerations to ensure the tank can safely and effectively store the intended materials. The design process typically includes several key steps, each addressing different aspects of tank functionality and safety. Requirements and Specifications Compliance and Standards Material Selection Cost  GLOBAL SUPPLY CHAIN TRANSPORTATION Road Maritime Air Rail Pipeline INDUSTRIAL VEHICLES/TRUCKS These are manual or power driven vehicles suitable for movement of mixed or unitized load, intermittently, where primary function is maneuvering or transporting. The vehicle/truck is physically moved along with the load from one point to another via a flat or slightly inclined route. This classification excludes highway vehicles, railroad cars, marine carriers and aircrafts.  Industrial Vehicles Non-Powered Trucks Powered Trucks have no source of motive power, these are are vehicles designed for the movement, lifting, and generally moved manually or are attached to other transportation of heavy materials, goods, and powered moving equipment/units products within warehouses, factories, construction sites, and other industrial settings TWO-WHEEL HAND TRUCK These are generally used for moving unit or unitized loads like bags, barrels, boxes, cartons, bales, cylinders etc. by pushing the truck manually MULTILE-WHEEL HAND TRUCK These trucks generally consists of a platform or framework mounted on 3 or 4 or more number of wheels. The truck is generally provided with a handle for pushing or pulling the platform MULTILE-WHEEL HAND TRUCK These trucks generally consists of a platform or framework mounted on 3 or 4 or more number of wheels. The truck is generally provided with a handle for pushing or pulling the platform Different Design of Dollies Maximum load = 700 kg HAND LIFT TRUCK These hand trucks are provided with a mechanism of lifting its platform, which can be rolled under a pallet or skid, and raised to lift the pallet or skid with load to clear the ground and then move this load from one place to another Maximum load = 700 kg FORKLIFT is a specialized vehicle designed for the lifting, moving, and transportation of heavy materials and goods Maximum load = 3000 kg PLATFORM LIFT TRUCK is a type of powered industrial vehicle used to provide temporary access to elevated areas for maintenance, construction, repair, or other tasks. TRACTORS are used in a wide field of activities, starting from agriculture to earth-moving, municipal waste handling, construction and industries. A tractor may be fitted with different attachments to do different jobs like sweeping sidewalks, plough snow, excavate ground, scoop loading, bull dozing etc. TRAILER Are load bearing wheeled vehicles or cars without any motive power, designed to be drawn by a tractor or truck. Trailers are classified as semitrailer and full trailers. A semi trailer is a truck-trailer having one or more axles and constructed so that a part of its weight is carried by the truck/tractor. A full trailer is constructed to carry almost all its weight on its own wheels ENGINEERING DESIGN Engineering considerations include ensuring the forklift's design aligns with load capacity and stability requirements, selecting appropriate tires and counterweights, and accommodating the operational environment, such as surface conditions and space constraints. Safety features like good visibility, warning systems, and proper training are essential to prevent accidents CONVEYOR SYSTEM These are gravity or powered equipment commonly used for moving bulk or unit load continuously or intermittently, uni-directionally from one point to another over fixed path, where the primary function is conveying of the material by the help of movement of some parts/components of the equipment. The equipment as a whole does not move. BELT CONVEYOR A belt conveyor consists of an endless flat and flexible belt of sufficient strength, made of fabric, rubber, plastic, leather or metal, which is laid over two metallic flat pulleys at two ends, and driven in one direction by driving one of the two end pulleys. Belt conveyors are the most common type of conveyor and are generally employed for continuous flow of material. CHAIN CONVEYOR Characterized by one or multiple strands of endless chains that travel entire conveyor path, driven by one or a set of sprockets at one end and supported by one or a set of sprockets on the other end. Materials to be conveyed are carried directly on the links of the chain or on specially designed elements attached to the chain. Commonly used for heavy unit loads. CABLE CONVEYOR These conveyors form a distinct group of materials handling equipment to transport people and bulk materials in load carrying buckets, using overhead moving cables and/or wire ropes and are composed of one or more spans from the loading point to the discharge point/points covering long distances up to several kilometers. Commonly used for loads to be move on high elevation or uneven terrain. ROLLER CONVEYOR A roller conveyor supports unit type of load on a series of rollers, mounted on bearings, resting at fixed spacings on two side frames which are fixed to stands or trestles placed on floor at certain intervals. A roller conveyor essentially coveys unit loads with at least one rigid, near flat surface to touch and maintain stable equilibrium on the rollers, like ingots, plates, rolled stock, pipes, logs, boxes, crates, moulding boxes etc SCREW CONVEYOR A screw conveyor consists of a continuous or interrupted helical screw fastened to a shaft which is rotated in a U- shaped trough to push fine grained bulk material through the trough. ENGINEERING DESIGN It's crucial to consider load capacity, conveyor type, speed, and throughput to match the specific needs of the application. Ensure material compatibility with the conveyor’s construction, and evaluate the operating environment, space constraints, and ease of maintenance. Safety features must be incorporated to protect operators, while cost and budget constraints should be analyzed for both initial and long-term expenses HOISTING EQUIPMENT These equipment are generally utilized to lift and lower and move unit and varying loads intermittently, between points within an area known as the reach of the equipment, where the primary function is transferring. A hoisting equipment may also be mounted on a powered vehicle when the movement of the lifted load is not limited within a fixed area of operation. HOIST Hoist is an apparatus for raising or lowering a load suspended from a hook on the end of a chain or wire rope. A hoist may be fixed i.e., stationary, base mounted or supported from overhead by a clevis or hook WINCHES is an equipment for pulling a heavy load by winding one or two ropes on a rope drum. It is a stationary equipment which is fixed to the floor or wall. ELEVATORS is used to signify a group of materials handling equipment which carries materials up or down. The group includes a number of diverse type of equipment like bucket elevators, skip hoists, freight elevators, lifts etc. Some of these equipment have been discussed in this section CRANE is a materials handling equipment for lifting or lowering a load by a hook and moving (transferring) it horizontally, in which the hoisting mechanism is an integral part of the equipment. A crane may be driven manually or by power and may be fixed or mobile Stationary crane Revolving crane Mobile crane DERRICK is an apparatus consisting of one or two masts or fabricated strut members supported at the bottom by a pivoting arrangement and held at the top by guys or braces, with or without a boom, for use with a hoisting mechanism and operating rope, for lifting and lowering a load and moving it horizontally ROBOTIC HANDLING Are specially designed robots tasked of move a part from one location to another within the workplace or a slightly more complex operation. Robotic systems can work around the clock without breaks, further boosting operational efficiency and throughput Cylindrical Arm Robot Cartesian coordinate robots Articulated Robots ENGINEERING DESIGN Engineering considerations include determining the maximum load capacity and ensuring the crane can handle the required weight safely. Evaluate the reach and height requirements to ensure the crane can access all necessary areas within the operational space. Consider the type of crane (e.g., overhead, mobile, tower) based on the specific application and environment AUXILIARY EQUIPMENT A large number of equipment and attachments which are used to improve the functionally of the primary material handling equipment. Many of these auxiliary equipment are of standard design and specifications and built by specialist manufacturers GATES Gates are used in conjunction with various bulk materials storage hoppers (bins, silos etc.) to close or open the outlet and adjust discharge of materials in batches from the hoppers CHUTES are inclined connections between two systems of materials handling equipment or production equipment, in the form of troughs of definite geometrical cross section or pipes, which convey unit or bulk load by gravity. LEVEL CONTROL is measurement of level of materials in large hoppers, bins or silos through bulk solid level measurement devices. These give measurement of volume of materials in the hopper