Material handling

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Lift trucks provisioning a navy ship US Navy 050831-N-3725R-004 Fork trucks from the amphibious assault ship USS Iwo Jima (LHD 7) load stores from the pier to the ship prior to getting underway from Naval Station Norfolk.jpg
Lift trucks provisioning a navy ship
Loading and removing cargo from a Lufthansa Airbus A380 at Frankfurt Airport. Airbus A380-800 of Lufthansa in Frankfurt Germany - Aircraft ground handling at FRA EDDF.jpg
Loading and removing cargo from a Lufthansa Airbus A380 at Frankfurt Airport.

Material handling involves short-distance movement within the confines of a building or between a building and a transportation vehicle. [1] 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. [2] 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. [3]

Contents

Role

Material handling plays an important role in manufacturing and logistics. Almost every item of physical commerce has been transported on a conveyor or lift truck or another type of material handling equipment in manufacturing plants, warehouses, and retail stores. While material handling is usually required as part of every production worker's job, over 650,000 people in the U.S. work as dedicated "material moving machine operators" and have a median annual wage of $31,530 (May 2012). [4] These operators use material handling equipment to transport various goods in a variety of industrial settings including moving construction materials around building sites or moving goods onto ships.

Design of material handling systems

Material flow diagram between activities in a layout TG-usine-apres.JPG
Material flow diagram between activities in a layout

Material handling is integral to the design of most production systems since the efficient flow of material between the activities of a production system is heavily dependent on the arrangement (or layout) of the activities. If two activities are adjacent to each other, then material might easily be handed from one activity to another. If activities are in sequence, a conveyor can move the material at low cost. If activities are separated, more expensive industrial trucks or overhead conveyors are required for transport. The high cost of using an industrial truck for material transport is due to both the labor costs of the operator and the negative impact on the performance of a production system (e.g., increased work in process) when multiple units of material are combined into a single transfer batch in order to reduce the number of trips required for transport. [5]

The unit load concept

Production batch can be split into a smaller transfer batch containing several unit loads, each of which can contain multiple parts Unit Load Size.png
Production batch can be split into a smaller transfer batch containing several unit loads, each of which can contain multiple parts

A unit load is either a single unit of an item, or multiple units so arranged or restricted that they can be handled as a single unit and maintain their integrity. Although granular, liquid, and gaseous materials can be transported in bulk, they can also be contained into unit loads using bags, drums, and cylinders. [6] Advantages of unit loads are that more items can be handled at the same time (thereby reducing the number of trips required, and potentially reducing handling costs, loading and unloading times, and product damage) and that it enables the use of standardized material handling equipment. Disadvantages of unit loads include the negative impact of batching on production system performance, and the cost of returning empty containers/pallets to their point of origin. [7]

Stretch-wrapping machine used to form a unit load Pallet wrapper.jpg
Stretch-wrapping machine used to form a unit load

In-process handling

Unit loads can be used both for in-process handling and for distribution (receiving, storing, and shipping). Unit load design involves determining the type, size, weight, and configuration of the load; the equipment and method used to handle the load; and the methods of forming (or building) and breaking down the load. For in-process handling, unit loads should not be larger than the production batch size of parts in process. Large production batches (used to increase the utilization of bottleneck activities) can be split into smaller transfer batches for handling purposes, where each transfer batch contains one or more unit loads, and small unit loads can be combined into a larger transfer batch to allow more efficient transport. [8]

Distribution

Narrow-aisle lift truck used in distribution ALMACEN CAYCO carpetilla.jpg
Narrow-aisle lift truck used in distribution

Selecting a unit load size for distribution can be difficult because containers/pallets are usually available only in standard sizes and configurations; truck trailers, rail boxcars, and airplane cargo bays are limited in width, length, and height; and the number of feasible container/pallet sizes for a load may be limited due to the existing warehouse layout and storage rack configurations and customer package/carton size and retail store shelf restrictions. Also, the practical size of a unit load may be limited by the equipment and aisle space available and the need for safe material handling. [9]

Health and safety

Manual material handling work contributes to a large percentage of the over half a million cases of musculoskeletal disorders reported annually in the United States. Musculoskeletal disorders often involve strains and sprains to the lower back, shoulders, and upper limbs. They can result in protracted pain, disability, medical treatment, and financial stress for those afflicted with them, and employers often find themselves paying the bill, either directly or through workers’ compensation insurance, at the same time they must cope with the loss of the full capacity of their workers. [10] [11]

Scientific evidence shows that effective ergonomic interventions can lower the physical demands of MMH work tasks, thereby lowering the incidence and severity of the musculoskeletal injuries they can cause. Their potential for reducing injury related costs alone make ergonomic interventions a useful tool for improving a company’s productivity, product quality, and overall business competitiveness. But very often productivity gets an additional and solid shot in the arm when managers and workers take a fresh look at how best to use energy, equipment, and exertion to get the job done in the most efficient, effective, and effortless way possible. Planning that applies these principles can result in big wins for all concerned. [10] [11]

Types

Manual handling

NIOSH Lifting Equation applied to loading punch press stock task Niosh-lifting-equation-illustration.gif
NIOSH Lifting Equation applied to loading punch press stock task

Manual handling refers to the use of a worker’s hands to move individual containers by lifting, lowering, filling, emptying, or carrying them. It can expose workers to physical dangers that can lead to injuries: a large percentage of the over half a million cases of musculoskeletal disorders reported in the U.S. each year arise from manual handling, and often involve strains and sprains to a person's lower back, shoulders and upper limbs. [12]

Ergonomic improvements can be used to modify manual handling tasks to reduce injury. These improvements can include reconfiguring the task and using positioning equipment like lift/tilt/turn tables, hoists, balancers, and manipulators to reduce reaching and bending. [13] The NIOSH (National Institute for Occupational Safety and Health) 1991 Revised Lifting Equation [14] can be used to evaluate manual lifting tasks. Under ideal circumstances, the maximum recommended weight for manual lifting to avoid back injuries is 51 lb (23.13 kg). Using the exact conditions of the lift (height, distance lifted, weight, position of weight relative to body, asymmetrical lifts, and objects that are difficult to grasp), six multipliers are used to reduce the maximum recommended weight for less than ideal lifting tasks.

Automated handling

Industrial robot FANUC R2000iB AtWork.jpg
Industrial robot

Whenever technically and economically feasible, equipment can be used to reduce and sometimes replace the need to manually handle material. Most existing material handling equipment is only semi-automated because a human operator is needed for tasks like loading/unloading and driving that are difficult and/or too costly to fully automate. However, ongoing advances in sensing, machine intelligence, and robotics have made it possible to fully automate an increasing number of handling tasks. [15] A rough guide to determine how much can be spent for automated equipment that would replace one material handler is to consider that, with benefits, the median moving machine operator costs a company $45,432 per year. [16] Assuming a real interest rate of 1.7% [17] and a service life of 5 years [18] with no adoption/adaptation cost, no learning cost, no training cost, and no operating cost for equipment with no salvage value, [19] a company should be willing to pay up to

to purchase automated equipment to replace one worker. [20] In many cases, automated equipment is not as flexible as a human operator, both with respect to not being able to do a particular task as well as a human and not being able to be as easily redeployed to do other tasks as needs change.

Benefits of materials handling

See also

Notes and references

  1. Coyle, J.J. (1992). Management of Business Logistics. Mason, OH: South-Western. p. 308.
  2. "Material handling". MHI. Retrieved 2014-10-02.
  3. Apple, J.M. (1972). Material Handling System Design. New York: Ronald.
  4. "Occupational Outlook Handbook". BLS. Retrieved 2015-05-14.
  5. Hopp, W.J. (2011). Factory Physics. Long Grove, IL: Waveland. pp. 318–327.
  6. Kulwiec, R.A. (1981). Basics of Material Handling. Charlotte, NC: MHI. p. 10.
  7. Sule, D.R. (1994). Manufacturing Facilities: Location, Planning, and Design. Boston: PWS. p. 249.
  8. Askin, R.G. (1993). Modeling and Analysis of Manufacturing Systems. New York: Wiley. p. 292.
  9. Kay, M.G. (2012). "Material Handling Equipment" (PDF). pp. 5–6. Retrieved 2014-10-02.
  10. 1 2 "NIOSH Lifting Equation App: NLE Calc". U.S. National Institute for Occupational Safety and Health . 2017-08-09. Retrieved 6 February 2019.
  11. 1 2 "Applications manual for the revised NIOSH lifting equation". U.S. National Institute for Occupational Safety and Health. 1994-01-01. doi: 10.26616/NIOSHPUB94110 .
  12. "Ergonomic Guidelines for Manual Material Handling" (PDF). California Department of Industrial Relations. 2007. Retrieved 2015-05-15.
  13. "HSE: Making the best use of lifting and handling aids" (PDF). Health and Safety Executive.
  14. Waters, T.R. (1994). Applications Manual for the Revised NIOSH Lifting Equation. Cincinnati, OH: Centers for Disease Control and Prevention.
  15. "Material Handling and Logistics U.S. Roadmap" (PDF). MHI. January 2014. Archived from the original (PDF) on 2015-09-12. Retrieved 2015-05-08.
  16. $31,530 median wage divided by 0.694, where wages represent 69.4% and benefits 30.6% of total labor cost ( "Employer Costs for Employee Compensation". BLS. December 2014. Retrieved 2015-05-15.).
  17. Average U.S. rate from 2005-2009 ( "Real interest rate". The World Bank. Retrieved 2015-05-15.).
  18. Average service life of Custom Software ( "BEA Depreciation Estimates" (PDF). BEA. 2004. Retrieved 2015-05-15.), conservative assumption since software is a major component of automated equipment and has the shortest service life compared to other components.
  19. Conservative assumption that simplifies the analysis since any positive salvage value would increase the purchase cost estimate.
  20. Amount willing to pay is the present value of an annuity immediate.
  21. Arora, Keshava Chanda; Shinde, Vikas V. (2007). Aspects of Materials Handling. Firewall Media. ISBN   978-81-318-0251-9.
  22. DLSM, Syed Muhamad Faizal (2018-06-22). "The Five Essential Methods for an Efficient Warehouse Operation - SIPMM Publications". publication.sipmm.edu.sg. Retrieved 2023-03-14.

Further reading

Related Research Articles

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<span class="mw-page-title-main">Forklift</span> Powered industrial truck

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. Since World War II, the use and development of the forklift truck have greatly expanded worldwide. Forklifts have become an indispensable piece of equipment in manufacturing and warehousing. In 2013, the top 20 manufacturers worldwide posted sales of $30.4 billion, with 944,405 machines sold.

<span class="mw-page-title-main">Logistics automation</span> Application of computer software or automated machinery

Logistics automation is the application of computer software or automated machinery to improve the efficiency of logistics operations. 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.

<span class="mw-page-title-main">Warehouse</span> Building for storing goods and giving services

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.

<span class="mw-page-title-main">Lift table</span>

A lift table is a device that employs a scissors mechanism to raise or lower goods and/or persons. Typically lift tables are used to raise large, heavy loads through relatively small distances. Common applications include pallet handling, vehicle loading and work positioning. Lift tables are a recommended way to help reduce incidents of musculoskeletal disorders by correctly re-positioning work at a suitable height for operators. Lift tables lend themselves to being easily adapted to a specific use. They can work in hostile environments, be manufactured in stainless steel and have equipment like conveyors, turn-tables, barriers and gates easily added to their deckplates.

<span class="mw-page-title-main">Distribution center</span> Building stocked with goods for delivery

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<span class="mw-page-title-main">Waste collector</span> Person employed by a public or private enterprise to collect and dispose of waste

A waste collector, also known as a garbage man, garbage collector, trashman, binman or dustman, is a person employed by a public or private enterprise to collect and dispose of municipal solid waste (refuse) and recyclables from residential, commercial, industrial or other collection sites for further processing and waste disposal. Specialised waste collection vehicles featuring an array of automated functions are often deployed to assist waste collectors in reducing collection and transport time and for protection from exposure. Waste and recycling pickup work is physically demanding and usually exposes workers to an occupational hazard.

<span class="mw-page-title-main">Automated guided vehicle</span> Type of portable robot

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<span class="mw-page-title-main">Manual handling of loads</span> Use of the human body to lift, lower, carry or transfer loads

Manual handling of loads (MHL) or manual material handling (MMH) involves the use of the human body to lift, lower, carry or transfer loads. The average person is exposed to manual lifting of loads in the work place, in recreational atmospheres, and even in the home. To properly protect one from injuring themselves, it can help to understand general body mechanics.

<span class="mw-page-title-main">Material-handling equipment</span> Machinery and equipment used for transporting objects and materials

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. The different types of equipment can be classified into four major categories: transport equipment, positioning equipment, unit load formation equipment, and storage equipment.

<span class="mw-page-title-main">Conveyor system</span> Equipment used for conveying materials

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.

Order processing is the process or work-flow associated with the picking, packing, and delivery of the packed items to a shipping carrier and is a key element of order fulfillment. Order processing operations or facilities are commonly called “distribution centers” or “DC 's”. There are wide variances in the level of automation associating to the “pick-pack-and-ship” process, ranging from completely manual and paper-driven to highly automated and completely mechanized; computer systems overseeing this process are generally referred to as Warehouse Management Systems or “WMS”.

<span class="mw-page-title-main">Packaging machinery</span>

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Warehouse execution systems (WES) are computerized systems used in warehouses and distribution centers to manage and orchestrate the physical flow of products from receiving through shipping. Warehouses are storage facilities for raw materials and parts used in manufacturing operations; distribution centers (DCs) are facilities that store and distribute finished goods to retail locations, consumers, and other end customers.

<span class="mw-page-title-main">Ergonomic hazard</span> Physical conditions that may pose a risk of injury

Ergonomic hazards are physical conditions that may pose a risk of injury to the musculoskeletal system due to poor ergonomics. These hazards include awkward or static postures, high forces, repetitive motion, or short intervals between activities. The risk of injury is often magnified when multiple factors are present.

Engineering controls are strategies designed to protect workers from hazardous conditions by placing a barrier between the worker and the hazard or by removing a hazardous substance through air ventilation. Engineering controls involve a physical change to the workplace itself, rather than relying on workers' behavior or requiring workers to wear protective clothing.

Manual material handling (MMH) work contributes to a large percentage of the over half a million cases of musculoskeletal disorders reported annually in the United States. Musculoskeletal disorders often involve strains and sprains to the lower back, shoulders, and upper limbs. They can result in protracted pain, disability, medical treatment, and financial stress for those afflicted with them, and employers often fi nd themselves paying the bill, either directly or through workers’ compensation insurance, at the same time they must cope with the loss of the full capacity of their workers.