Material handling equipment (MHE) is mechanical equipment used for the movement, storage, control, and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption, and disposal. [1] The different types of equipment can be classified into four major categories: [2] transport equipment, positioning equipment, unit load formation equipment, and storage equipment.
Transport equipment is used to move material from one location to another (e.g., between workplaces, between a loading dock and a storage area, etc.), while positioning equipment is used to manipulate material at a single location. [3] The major subcategories of transport equipment are conveyors, cranes, and industrial trucks. Material can also be transported manually using no equipment.
Conveyors are used when material is to be moved frequently between specific points over a fixed path and when there is a sufficient flow volume to justify the fixed conveyor investment. [4] Different types of conveyors can be characterized by the type of product being handled: unit load or bulk load; the conveyor's location: in-floor, on-floor, or overhead, and whether or not loads can accumulate on the conveyor. Accumulation allows intermittent movement of each unit of material transported along the conveyor, while all units move simultaneously on conveyors without accumulation capability. [5] For example, while both the roller and flat-belt are unit-load on-floor conveyors, the roller provides accumulation capability while the flat-belt does not; similarly, both the power-and-free and trolley are unit-load overhead conveyors, with the power-and-free designed to include an extra track in order to provide the accumulation capability lacking in the trolley conveyor. Examples of bulk-handling conveyors include the magnetic-belt, troughed-belt, bucket, and screw conveyors. A sortation conveyor system is used for merging, identifying, inducting, and separating products to be conveyed to specific destinations, and typically consists of flat-belt, roller, and chute conveyor segments together with various moveable arms and/or pop-up wheels and chains that deflect, push, or pull products to different destinations. [6]
Cranes are used to transport loads over variable (horizontal and vertical) paths within a restricted area and when there is insufficient (or intermittent) flow volume such that the use of a conveyor cannot be justified. Cranes provide more flexibility in movement than conveyors because the loads handled can be more varied with respect to their shape and weight. Cranes provide less flexibility in movement than industrial trucks because they only can operate within a restricted area, though some can operate on a portable base. Most cranes utilize trolley-and-tracks for horizontal movement and hoists for vertical movement, although manipulators can be used if precise positioning of the load is required. The most common cranes include the jib, bridge, gantry, and stacker cranes.
Industrial trucks are trucks that are not licensed to travel on public roads (commercial trucks are licensed to travel on public roads [7] ). Industrial trucks are used to move materials over variable paths and when there is insufficient (or intermittent) flow volume such that the use of a conveyor cannot be justified. They provide more flexibility in movement than conveyors and cranes because there are no restrictions on the area covered, and they provide vertical movement if the truck has lifting capabilities. Different types of industrial trucks can be characterized by whether or not they have forks for handling pallets, provide powered or require manual lifting and travel capabilities, allow the operator to ride on the truck or require that the operator walk with the truck during travel, provide load stacking capability, and whether or not they can operate in narrow aisles.
Hand trucks (including carts and dollies), the simplest type of industrial truck, cannot transport or stack pallets, is non-powered, and requires the operator to walk. A pallet jack, which cannot stack a pallet, uses front wheels mounted inside the end of forks that extend to the floor as the pallet is only lifted enough to clear the floor for subsequent travel. [8] A counterbalanced lift truck (sometimes referred to as a forklift truck, but other attachments besides forks can be used) can transport and stack pallets and allows the operator to ride on the truck. The weight of the vehicle (and operator) behind the front wheels of truck counterbalances weight of the load (and weight of vehicle beyond front wheels); the front wheels act as a fulcrum or pivot point. Narrow-aisle trucks usually require that the operator stand-up while riding in order to reduce the truck's turning radius. Reach mechanisms and outrigger arms that straddle and support a load can be used in addition to the just the counterbalance of the truck. On a turret truck, the forks rotate during stacking, eliminating the need for the truck itself to turn in narrow aisles. An order picker allows the operator to be lifted with the load to allow for less-than-pallet-load picking. Automated guided vehicles (AGVs) are industrial trucks that can transport loads without requiring a human operator.
Rail or wheel steered transfer carts are preferred for areas that do not have favourable conditions for the operation of forklifts. Rail transfer carts are carts that can move on the rail line. Wheel steered transfer carts can move independently of the route with battery powered energy systems.
An electric tug is a small battery powered and pedestrian operated machine capable of either pushing or pulling a significantly heavier load than itself.
Commonly used to assist in moving smaller loads where larger equipment would struggle, manual handling equipment such as pallet trucks, trolleys, and sack trucks can be an essential part of any material handling.
A yard ramp, sometimes called a mobile yard ramp, is a movable metal ramp for loading and unloading of vehicles. A yard ramp is placed at the back of a vehicle to provide access for forklifts to ascend the ramp. Using a yard ramp for vehicle loading or unloading allows the work to be carried out by a forklift. [10]
Positioning equipment is used to handle material at a single location. It can be used at a workplace to feed, orient, load/unload, or otherwise manipulate materials so that are in the correct position for subsequent handling, machining, transport, or storage. As compared to manual handling, the use of positioning equipment can raise the productivity of each worker when the frequency of handling is high, improve product quality and limit damage to materials and equipment when the item handled is heavy or awkward to hold and damage is likely through human error or inattention, and can reduce fatigue and injuries when the environment is hazardous or inaccessible. [11] In many cases, positioning equipment is required for and can be justified by the ergonomic requirements of a task. Examples of positioning equipment include lift/tilt/turn tables, hoists, balancers, manipulators, and industrial robots. Manipulators act as “muscle multipliers” by counterbalancing the weight of a load so that an operator lifts only a small portion (1%) of the load's weight, and they fill the gap between hoists and industrial robots: they can be used for a wider range of positioning tasks than hoists and are more flexible than industrial robots due to their use of manual control. [12] They can be powered manually, electrically, or pneumatically, and a manipulator's end-effector can be equipped with mechanical grippers, vacuum grippers, electromechanical grippers, or other tooling.
Unit load formation equipment is used to restrict materials so that they maintain their integrity when handled a single load during transport and for storage. If materials are self-restraining (e.g., a single part or interlocking parts), then they can be formed into a unit load with no equipment. Examples of unit load formation equipment include pallets, skids, slipsheets, tote pans, bins/baskets, cartons, bags, and crates. A pallet is a platform made of wood (the most common), paper, plastic, rubber, or metal with enough clearance beneath its top surface (or face) to enable the insertion of forks for subsequent lifting purposes. [13] A slipsheet is a thick piece of paper, corrugated fiber, or plastic upon which a load is placed and has tabs that can be grabbed by special push/pull lift truck attachments. They are used in place of a pallet to reduce weight and volume, but loading/unloading is slower.
Storage equipment is used for holding or buffering materials over a period of time. The design of each type of storage equipment, along with its use in warehouse design, represents a trade-off between minimizing handling costs, by making material easily accessible, and maximizing the utilization of space (or cube). [14] If materials are stacked directly on the floor, then no storage equipment is required, but, on average, each different item in storage will have a stack only half full; to increase cube utilization, storage racks can be used to allow multiple stacks of different items to occupy the same floor space at different levels. The use of racks becomes preferable to floor storage as the number of units per item requiring storage decreases. Similarly, the depth at which units of an item are stored affects cube utilization in proportion to the number of units per item requiring storage.
Pallets can be stored using single- and double-deep racks when the number of units per item is small, while pallet-flow and push-back racks are used when the units per item are mid-range, and floor-storage or drive-in racks are used when the number of units per item is large, with drive-in providing support for pallet loads that cannot be stacked on top of each other. Individual cartons can either be picked from pallet loads or can be stored in carton-flow racks, which are designed to allow first-in, first-out (FIFO) carton access. For individual piece storage, bin shelving, storage drawers, carousels, and A-frames can be used.
Engineered systems are automated solutions designed to streamline and optimize material handling processes. [15] An automatic storage/retrieval system (AS/RS) is an integrated computer-controlled storage system that combines storage medium, transport mechanism, and controls with various levels of automation for fast and accurate random storage of products and materials. [16]
Equipment used to collect and communicate the information that is used to coordinate the flow of materials within a facility and between a facility and its suppliers and customers. The identification of materials and associated control can be performed manually with no specialized equipment. [17]
A forklift is a powered industrial truck used to lift and move materials over short distances. The forklift was developed in the early 20th century by various companies, including Clark, which made transmissions, and Yale & Towne Manufacturing, which made hoists.
A crane is a machine used to move materials both vertically and horizontally, utilizing a system of a boom, hoist, wire ropes or chains, and sheaves for lifting and relocating heavy objects within the swing of its boom. The device uses one or more simple machines, such as the lever and pulley, to create mechanical advantage to do its work. Cranes are commonly employed in transportation for the loading and unloading of freight, in construction for the movement of materials, and in manufacturing for the assembling of heavy equipment.
Logistics automation is the application of computer software or automated machinery to logistics operations in order to improve its efficiency. Typically this refers to operations within a warehouse or distribution center, with broader tasks undertaken by supply chain engineering systems and enterprise resource planning systems.
Heavy equipment, heavy machinery, earthmovers, construction vehicles, or construction equipment, refers to heavy-duty vehicles specially designed to execute construction tasks, most frequently involving earthwork operations or other large construction tasks. Heavy equipment usually comprises five equipment systems: the implement, traction, structure, power train, and control/information.
A warehouse is a building for storing goods. Warehouses are used by manufacturers, importers, exporters, wholesalers, transport businesses, customs, etc. They are usually large plain buildings in industrial parks on the outskirts of cities, towns, or villages.
A pallet is a flat transport structure, which supports goods in a stable fashion while being lifted by a forklift, a pallet jack, a front loader, a jacking device, or an erect crane. Many pallets can handle a load of 1,000 kg (2,200 lb). While most pallets are wooden, pallets can also be made of plastic, metal, paper, and recycled materials.
A distribution center for a set of products is a warehouse or other specialized building, often with refrigeration or air conditioning, which is stocked with products (goods) to be redistributed to retailers, to wholesalers, or directly to consumers. A distribution center is a principal part, the order processing element, of the entire order fulfillment process. Distribution centers are usually thought of as being demand driven. A distribution center can also be called a warehouse, a DC, a fulfillment center, a cross-dock facility, a bulk break center, and a package handling center. The name by which the distribution center is known is commonly based on the purpose of the operation. For example, a "retail distribution center" normally distributes goods to retail stores, an "order fulfillment center" commonly distributes goods directly to consumers, and a cross-dock facility stores little or no product but distributes goods to other destinations.
A telescopic handler, also called a lull, telehandler, teleporter, reach forklift, or zoom boom, is a machine widely used in agriculture and industry. It is somewhat like a forklift but has a boom, making it more a crane than a forklift, with the increased versatility of a single telescopic boom that can extend forwards and upwards from the vehicle. The boom can be fitted with different attachments, such as a bucket, pallet forks, muck grab, or winch.
A loading dock or loading bay is an area of a building where goods vehicles are loaded and unloaded. They are commonly found on commercial and industrial buildings, and warehouses in particular. Loading docks may be exterior, flush with the building envelope, or fully enclosed. They are part of a facility's service or utility infrastructure, typically providing direct access to staging areas, storage rooms, and freight elevators.
An automated guided vehicle (AGV), different from an autonomous mobile robot (AMR), is a portable robot that follows along marked long lines or wires on the floor, or uses radio waves, vision cameras, magnets, or lasers for navigation. They are most often used in industrial applications to transport heavy materials around a large industrial building, such as a factory or warehouse. Application of the automatic guided vehicle broadened during the late 20th century.
An automated storage and retrieval system consists of a variety of computer-controlled systems for automatically placing and retrieving loads from defined storage locations. Automated storage and retrieval systems (AS/RS) are typically used in applications where:
A semi-trailer is a trailer without a front axle. The combination of a semi-trailer and a tractor truck is called a semi-trailer truck.
Ground support equipment (GSE) is the support equipment found at an airport, usually on the apron, the servicing area by the terminal. This equipment is used to service the aircraft between flights. As the name suggests, ground support equipment is there to support the operations of aircraft whilst on the ground. The role of this equipment generally involves ground power operations, aircraft mobility, and cargo/passenger loading operations.
Automated truck loading systems (ATLS) is an automation system for trucking. They are used in the material handling industry to refer to the automation of loading or unloading trucks and trailers with product either on or without pallets, slip sheets, racks, containers, using several different types of automated guided vehicle systems (AGV) or engineered conveyor belt systems that are integrated into vehicles, automating the shipping / receiving and logistics operations.
A straddle carrier or straddle truck is a freight-carrying vehicle that carries its load underneath by "straddling" it, rather than carrying it on top like a conventional truck. The advantage of the straddle carrier is its ability to load and unload without the assistance of cranes or forklifts. The lifting apparatus under the carrier is operated by the driver without any outside assistance and without leaving the driver's seat.
Pallet rack is a material handling storage aid system designed to store materials on pallets. Although there are many varieties of pallet racking, all types allow for the storage of palletized materials in horizontal rows with multiple levels. Forklift trucks are usually required to place the loaded pallets onto the racks for storage. Since the Second World War, pallet racks have become a ubiquitous element of most modern warehouses, manufacturing facilities, retail centers, and other storage and distribution facilities. All types of pallet racking increase storage density of the stored goods. Costs associated with the racking increases with increasing storage density.
A conveyor system is a common piece of mechanical handling equipment that moves materials from one location to another. Conveyors are especially useful in applications involving the transport of heavy or bulky materials. Conveyor systems allow quick and efficient transport for a wide variety of materials, which make them very popular in the material handling and packaging industries. They also have popular consumer applications, as they are often found in supermarkets and airports, constituting the final leg of item/ bag delivery to customers. Many kinds of conveying systems are available and are used according to the various needs of different industries. There are chain conveyors as well. Chain conveyors consist of enclosed tracks, I-Beam, towline, power & free, and hand pushed trolleys.
The term unit load refers to the size of an assemblage into which a number of individual items are combined for ease of storage and handling, for example a pallet load represents a unit load which can be moved easily with a pallet jack or forklift truck, or a container load represents a unit for shipping purposes. A unit load can be packed tightly into a warehouse rack, intermodal container, truck or boxcars, yet can be easily broken apart at a distribution point, usually a distribution center, wholesaler, or retail store for sale to consumers or for use.
Material handling involves short-distance movement within the confines of a building or between a building and a transportation vehicle. It uses a wide range of manual, semi-automated, and automated equipment and includes consideration of the protection, storage, and control of materials throughout their manufacturing, warehousing, distribution, consumption, and disposal. Material handling can be used to create time and place utility through the handling, storage, and control of waste, as distinct from manufacturing, which creates form utility by changing the shape, form, and makeup of material.
A Drum handler is a piece of mechanical equipment that is used to securely grip, lift and transport cylindrical modules such as steel drums, barrels, plastic drums and fiber drums. It has spring-loaded metal arms to create a tight and secure grip. This equipment is commonly used in chemical and petroleum industries, as well as industries that require shipping and storing of cylindrical modules.