Transcript Material Handling System.ppt

SYSTEMS CONCEPT
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Adopting a materials handling systems from overall
optimization point of view.
It 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.
Must analyze to ensure the objective of least total cost of
handling.
Must have basic criteria for selecting a handling system
of adequate monetary pay back, if all other things are
equal.
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Systems approach for materials
handling……..
It demands that all elements of
problem, its cause and effect be
analyzed so as to accomplish to
desired objectives.
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Systematic analysis….
Systematic analysis should lead to a solution which
satisfy the following important conditions :
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There should not be any other problem created by the new
system proposed to be implemented.
Amount of return on investment must justify the proposed
handling system.
The system must take care for reasonably long period of
time, and that it must permit expansion or modification
without much cost and difficulty.
The new system must be simple to implement so that it is
easily acceptable by management as well as by operators.
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New handling system must have
technique and method which can
easily fit into the existing system
and has least total cost of the
system and meets the ultimate
objective of the materials
handling.
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Achievements of the systems
approach:
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Increase the production effectiveness.
Minimize unnecessary labor and make the
enterprise more profitable.
Reduce damage due to material handling
Reduce accident rates.
Effective utilization of space by proper layout
planning.
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Steps in Analyzing Materials Handling
Problems:
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Establish the scope of the study.
Pinpoint the areas of plant layout to be covered
by the study.
Determine volume expected to be handled per
unit time by the new system.
Nature and type of the materials to be handled.
Determine the handling cost of the items being
handled by the present system.
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Determine details of distance to be moved, with
details of curves, slopes etc.
Determine, how to move the material i.e., in tray,
bundles, pallets etc.
Determine the details of the equipment used viz.
capacity, speed, flexibility etc.
Determine the time taken for the movement.
A thorough survey should then be made considering
the systems approach.
Alternative, systems should then be evaluated from
all angles including financial, physical, safety,
acceptance by the management and operators, and
its effects on working, safety and overall
environment.
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OBJECTIVES OF MATERIALS HANDLING
Main objective of materials handling is to
reduce product cost, the one overall goal. A
materials handling equipment is not a
production machinery, but is an auxiliary
equipment that improves the flow of
material which in turn reduces stoppages in
production machines and thus increases
their production.
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Objectives of a proper material
handling system
Reduced costs
2. Increased capacity
3. Improved working conditions
4. Improved customer service
1.
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(1) Reduction in Cost:
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Reducing material handling labor.
Material handling work should not be assigned to
skilled or semi-skilled labor.
Reducing indirect labor expenses on activities
connected with storage, inspection, quality control,
repair, tool room, shipping etc.
Reducing damage of materials during handling.
Better utilization of space.
Reducing in process storage.
Increasing productivity.
Reducing expenditure on packaging and other
protective devices.
Decreasing inventory.
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(2) Increase in Capacity :
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By better utilization of space.
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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.
By reducing travel space or excessive wastage of
space.
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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.
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By improving equipment utilization.
 This can be achieved by ensuring regular
supply and distribution of material. This
will reduce the idling of machine.
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By faster loading or -unloading.
 This can be achieved by employing
conveyor system, cranes, loaders, rail
road cars, tiping trucks etc.
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(3)
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Improvement in Working Conditions:
Safety aspects :
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Easy working:
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Safety of men, material and associated equipment not
only prevents loss of money but also enhances the moral
of workers.
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.
Foolproof operation :
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Due to absence of manual handling, there are no chances
of confusion resulting in placing of material at wrong ,
location or disruption of production.
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(4) Improved Customer Service :
Customers service will be improved by
following proper and improved material
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.
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FUNCTIONS OF MATERILAS HANDLING
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Material Handling methods.
Storage methods.
Packaging and packing methods of both raw
material and finished products.
Loading and unloading methods.
Selection of equipment for movement, loading,
unloading and storage.
Selection of auxiliary equipment.
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Repair and maintenance policies and
procedures for handling equipments.
Safety of men, material and equipment
during handling.
Training of personnel engaged on handling
jobs.
Carry out handling cost studies and cost
control and cost reduction methods.
Communication
system
related to
materials handling system.
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Disadvantages of Mechanical Handling
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Additional capital investment.
Loss of flexibility.
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Breakdown.
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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.
Being mechanical and electrical system, the handling system may
breakdown at times, and may take some time for repairs.
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.
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