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MATERIALS HANDLING
I. INTRODUCTION
Material handling is a field involving the transport, storage, and control of goods and
products throughout the processes of manufacturing, distribution, consumption and disposal of
all related materials. The focus of the material handling industry is on the methods, mechanical
equipment, systems and related controls used to achieve necessary functions.
Selection of material handling equipment is an important decision as it affects both the cost and
efficiency of handling system. The following factors are to be taken into account while selecting
the material handling equipment.
1. Properties of the Material
Whether the material is solid, liquid or gas, and in what size, shape and weight it is to be moved,
are important decisions and can be lead to a preliminary elimination from the range of available
equipment under review. Similarly, if the material is fragile, corrosive or toxic this will imply that
certain handling method and containers will be preferable to others.
3. Production Flow
If the flow is fairly constant between two fixed positions that are not likely to be changed, fixed
equipment such as conveyors or chutes can be successfully used. If, on the other hand, the flow
is not constant and the direction changes occasionally from one point to another because several
products are being produced simultaneously, moving equipment such as trucks would be
preferable.
4. Cost Considerations
This is the most important consideration. The above factors can help narrow the range of
suitable equipment, while costing can help in taking the final decision. Several cost elements
need to be taken into consideration when comparisons are made between various items of
equipment that are all capable of handling the same load. Initial investment and operating and
maintenance cost are the major costs to be considered. By calculating and comparing the total
cost of each items of equipment under consideration, a more rational decision can be reached
on the most appropriate choice.
5. Nature of Operations
Selection of equipment also depends on the nature of operations like whether handling is
temporary or permanent, whether the flow is continuous or intermittent and material, flow
pattern-horizontal or vertical.
6. Engineering Factors
Engineering factors such as door, ceiling dimensions, floor space, floor conditions and structural
strengths are also taken in consideration in the selection of equipment.
7. Equipment reliability
Reliability of the equipment and supplier reputation and the after sale services plays an important
role in selecting the equipment.
Goals of Material Handling
1. Maintain product quality, reduce damage and provide protection of materials.
2. Promote safety and improve working conditions.
Improve productivity through:
Maintain, and replace as needed, all equipment and develop a preventive maintenance
program
4. Integrate all material handling equipment into a system
5. Reduce tare weight (describe the weight of packaging material).
6. Control inventory.
How Does Materials Handling Works
Material handling is a necessary and significant component of any warehousing and
logistics activity. Material handling means providing the right amount of the right material, in the
right condition, at the right place, at the right time, in the right position and for the right cost, by
using the right method. It applies to the movement of raw materials, work in process, finished
goods, packing materials, and disposal of scraps. In general, hundreds and thousands of tons of
materials are handled daily requiring the use of a large amount of manpower and equipment while
the movement of materials takes place from one processing area to another or from one
department to another department of the plant.
As a process, material handling incorporates a wide range of manual, semi-automated
and automated equipment and systems that support logistics and make the supply chain work.
Their application helps with:
Forecasting
Resource allocation
Production planning
Flow and process management
Inventory management and control
Customer delivery
After-sales support and service
Before planning, one should be very clear about perspective, material handling equation which
emphasizes the necessity of careful analyzing both the material to be handled and the move to
be made before selecting method. Such an equation is also helpful in the planning stage of
selection of materials handling equipment for the proposed project. (Comprehensive production
and operation management (1st ed., p. 304), Arora, K. (2004))
Viewing the complex nature of materials handling, one can conclude that it needs through
planning for smooth and economic running of any productive and distributive system. It further
needs a large amount of data necessary for planning, no matter one is using it within an industry
or on a national transportation basis.
III. MATERIAL HANDLING SYSTEMS CLASSIFICATION
Mechanized System
Most mechanized systems combine different handling devices
Moderate fixed and variable cost with good flexibility
Examples
o Forklift
o Rider pallet trucks
o Towlines
o Tractor trailers
o Conveyors
o Carousels
o Paperless picking
labor capability: machine
Control capability: human
Automated System
Automated materials handling (AMH) refers to any automation that reduces or eliminates
the need for humans to check-in, check-out, sort material, or to move totes and bins
containing library material.
Highest fixed cost, lowest variable and labor cost with low flexibility
Potential to automate is the elimination of direct labor by substituting capital equipment
Examples
o Order selection systems
o Automated storage and retrieval system (AS/RS)
The mechanical equipment used in AMH systems includes:
o check-in machines
o sorters
o conveyors
o singulators
o stackers and unstackers
o totes
o bins
o trolleys
o tote carriers.
labor capability: machine
Control capability: machine
Semi-automated System
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, although ongoing advances in sensing, machine intelligence, and
robotics have made it possible to fully automate an increasing number of handling tasks.
High fixed cost, low variable cost with low flexibility
Examples:
Moderate fixed and variable cost with high flexibility and utilization
Offers selected benefits of automation without substantial capital investment
Main drawback is accountability regarding work assignment
Examples
o RF wireless (Wi-Fi)
Use lift trucks, RFID scanners and data collection terminals
o Pick-to-light carousel system
Characteristics of Materials
size
weight
shape
other (slippery, fragile, sticky, explosive, frozen)
Storage equipment is usually limited to non-automated examples, which are grouped in with
engineered systems. Storage equipment is used to hold or buffer materials during downtimes,
or times when they are not being transported. These periods could refer to temporary pauses
during long-term transportation or long-term storage designed to allow the buildup of stock. The
majority of storage equipment refers to pallets, shelves or racks onto which materials may be
stacked in an orderly manner to await transportation or consumption. Many companies have
investigated increased efficiency possibilities in storage equipment by designing proprietary
packaging that allows materials or products of a certain type to conserve space while in inventory.
Examples of storage and handling equipment include:
Source: http://www.ontarioindustrial.com/
Stacking frames
Source: https://www.worksafe.qld.gov.au
Shelves, bins and drawers
Source: http://www.nationwideindustrialsupply.com
Mezzanines
Source: http://www.aw-systems.com
2. Engineered Systems
There are several types of automated storage and retrieval systems. Their common feature is
the ability to quickly and directly access each designated storage location. There are also
different levels of automation for these systems, depending on the type of equipment
used. Storage and retrieval systems primarily are used to:
Store raw materials or bulk containers of goods for later use in manufacturing or distribution
operations
Temporarily store or buffer items between various manufacturing processes
Store and stage items for picking and kitting in distribution or assembly operations
Store and sequence finished goods in manufacturing facilities prior to shipping
Some of the most common type of Automated Storage and Retrieval System are as follows:
CONVEYORS
Source: http://www.automatedconveyors.com/
Drag Chain is typically used for handling
extremely heavy loads, special pallet
configurations, and extremely low- to high-
temperature areas.
Source: http://sites.dksh.com/htm/620/en/Drag-Chain-
Interflex-SLE-Steel-line.htm
Source: http://www.arrcoolingtowers.com/roller-
conveyors.html
http://www.lewcoinc.com/conveyors/conveyors
Diverter
Stationary or movable arms that
deflect, push, or pull a product to
desired destination
Since they do not come in contact with
the conveyor, they can be used with
almost any flat surface conveyor
Usually hydraulically or pneumatically
operated, but also can be motor driven Source: http://www4.ncsu.edu/
Simple and low cost
Pop-Up Device
One or more rows of powered rollers or
wheels or chains that pop up above
surface of conveyor to lift product and
guide it off conveyor at an angle;
wheels are lowered when products not
required to be diverted
Only capable of sorting flat-bottomed
Source: http://www4.ncsu.edu/
items
Pop-up rollers are generally faster than
pop-up wheels
Sliding Shoe Sorter
Sliding shoe sorter (a.k.a. moving slat
sorter) uses series of diverter slats that
slide across the horizontal surface to
engage product and guide it off
conveyor
Slats move from side to side as
product flows in order to divert the
product to either side Source: http://www4.ncsu.edu/
Gentle and gradual handling of products
- AGVs good for low-to-medium volume medium-to-long distance random material flow
operations (e.g., transport between work cells in a flexible manufacturing system (FMS)
environment)
i. Fixed path: Physical guidepath (e.g., wire, tape, paint) on the floor used for guidance
ii. Free-ranging: No physical guidepath, thus easier to change vehicle path (in software), but
absolute position estimates (from, e.g., lasers) are needed to correct dead-reckoning error
a. Tow AGV
- Used to pull a train of trailers
- Automated version of a tractor trailer
Trailers usually loaded manually (early type of
AGV, not much used today)
Source: http://www4.ncsu.edu/
b. Unit Load AGV
- Have decks that can be loaded
manually or automatically
- Deck can include conveyor or lift/lower
mechanism for automatic loading
- Typically 4 by 4 feet and can carry 1
2,000 lb. loads
- Typically less than 10 vehicles in AGV Source: http://www4.ncsu.edu/
system
c. Assembly AGV
- Used as assembly platforms (e.g., car
chassis, engines, appliances)
- Greatest development activity during
the 1980s (alternative to AEMs)
- Typically 50100 vehicles in AGV
system
Source: http://www4.ncsu.edu/
3. Industrial Trucks
This term is another broad definition that can be applied to many different types of equipment.
Such pieces of equipment do have one thing in common, though they all provide transportation.
Trucks have the capability to lift via powered or manual means, and can be ridden upon in a
drivers cab, or simply power-assisted when pushed. Such tucks can also be steered by human
intervention, or can be completely automated, following a pre-defined track on the production
floor, sunken or raised tracks, or colored strips that are laid out and sensed by optical sensors.
Such automated industrial trucks also have anti-collision technology that senses when an
employee or other obstacle is near.
Pallet/Non-Pallet: Does the truck have forks for handling pallets, or does the truck have
a flat surface on which to place loads. Non-Pallet (usually) other means required to load
truck.
Manual/Powered: Does the truck have manual or powered vertical (lifting) and/or
horizontal (travel) movement capabilities. Manual => walk => operator provides the force
needed for lifting loads and/or pushing the vehicle. Powered => on-board power source
(e.g., batteries) used for lifting and/or travel.
Walk/Ride: For non-automated trucks, can the operator ride on the truck (in either a
standing or sitting position) or is the operator required to walk with the truck during travel.
Walk => manual or powered travel possible => powered travel speed limited to a normal
walking pace. Ride => powered => travel speed can be faster than a walking pace.
Stack/No Stack: Can the truck be used to lift loads for stacking purposes. Stack => can
also be used as no stack => more expensive to add stacking capability. No Stack may lift
a load a few inches to clear the floor for subsequent travel (e.g., pallet jack), but the loads
cannot be stacked on top of each other or on shelves.
Narrow Aisle: Is the lift truck designed to have a small turning radius or does it not have
to turn at all in an aisle when loading/unloading. Narrow Aisle => greater cost and (usually)
standing operator => less aisle space required. Counterbalance and/or straddle used for
load support. Small turning radius => load support via straddle or reaching capabilities.
No turning required => even narrower aisle => only one-side loading (sideloaders) or the
capability to rotate the load (turret truck).
Automated: Is the truck automated so that it can transport loads without requiring an
operator. Non-Automated => direct labor cost of operator is by far the largest cost to
operate a non-automated truck. Semi-Automated => operator used to control
loading/unloading, but automated transport control (e.g., the S/R machine of a Man-on-
board AS/RS). Automated => Automated Guided Vehicle (AGV) => no direct labor cost,
but higher equipment costs.
Hand Truck
Source: http://www4.ncsu.edu/
Dolly - Three or more wheeled hand truck with
a flat platform in which, since it has no handles,
the load is used for pushing
Source: http://www4.ncsu.edu/
Floor Hand Truck - Four or more wheeled
hand truck with handles for pushing or hitches
for pulling. Sometimes referred to as a "cart"
or "(manual) platform truck".
Source: http://www4.ncsu.edu/
Pallet Jack - Front wheels are mounted inside the end of the forks and extend to the floor as
the pallet is only lifted enough to clear the floor for subsequent travel
Pallet restrictions: reversible pallets cannot be used, double-faced nonreversible pallets cannot
have deckboards where the front wheels extend to the floor, and enables only two-way entry into
a four-way notched-stringer pallet because the forks cannot be inserted into the notches.
Source: http://www4.ncsu.edu/
Powered Pallet Jack - Powered lifting and/or
travel
Source: http://www4.ncsu.edu/
Walkie Stacker
Source: http://www4.ncsu.edu/
Powered Walkie Stacker - Powered lifting
and/or travel (and either counterbalance or
straddle load support)
Source: http://www4.ncsu.edu/
Source: http://www4.ncsu.edu/
Source: http://www4.ncsu.edu/
Rider Platform Truck - Operator
can ride on truck
Source: http://www4.ncsu.edu/
Source: http://www4.ncsu.edu/
Stand-Up Counterbalanced Lift Truck
- Operator stands up, giving vehicle
narrow-aisle capability; 9-11 ft. minimum
aisle width requirement;
Source: http://www4.ncsu.edu/
Turret Truck
- Greater stacking height compared to other narrow-aisle trucks (40 ft. vs. 25 ft.), but greater
investment cost
- Forks rotate to allow for side loading and, since truck itself does not rotate during stacking,
the body of the truck can be longer to increase its counterbalance capability and to allow
the operator to sit
- Can function like a sideloader for transporting greater-than-pallet-size load
Source: http://www4.ncsu.edu/
Operator-Up Turret Truck - Operator lifted
with the load to allow precise stacking and
picking; 5-7 ft. minimum aisle width
Source: http://www4.ncsu.edu/
requirement
Order Picker
- Similar to NA straddle truck, except operator lifted with the load to allow for less-than-unit-
load picking
- Typically has forks to allow the truck to be used for pallet stacking and to support a pallet
during less-than-pallet-load picking
- "Belly switch" used for operator safety during picking
Sideloader
- Forks mounted perpendicular to direction of travel to allow for side loading and straddle
load support
- 5-6 ft. minimum aisle width requirement
- Can be used to handle greater-than-pallet-size loads (e.g., bar stock)
Tractor-Trailer
- Non-load-carrying tractor used to pull a train of trailers (i.e., dollies or floor hand trucks)
- Extends the transporting capacity of floor hand trucks
- Typically used at airports for baggage handling
Source: http://www.ameco.eu.com/our-
products/stackers/
Reclaimers - These devices work closely with
stackers. Reclaimers are also large pieces of
machinery. They are used to recover bulk
material that has been placed in a stockpile.
Reclaimers often use bucket wheels to
recover the material from stockpiles and, like
stackers, are capable of moving horizontally,
vertically, and rotationally. The majority of
reclaimers used today are computer
automated.
Source: http://www.zyfzg.com/82.html
Bucket elevators - Elevating products to
processing or storage is easy with our
industrial duty bucket elevators
Source:http://www.ashoka.cc/material-handling-
equipment.html
Hoppers - Hoppers are wide, bin-like entries :
that help feed bulk materials into other https://www.rouramh.com/
machines. Generally, a hopper is open at the
top and it tapers at the bottom to assist with
feeding the machine.
REFERENCES
Anon, (2017). Material Handling Systems. [online] Available at:
http://www2.isye.gatech.edu/~mgoetsch/cali/logistics_systems_design/material_handling_systems/materi
al_handling_systems.pdf [Accessed 12 Feb. 2017].
Bayt.com. (2017). What is the Types of Material Handling Equipment?. [online] Available at:
https://www.bayt.com/en/specialties/q/184810/what-is-the-types-of-material-handling-equipment/
[Accessed 12 Feb. 2017].
Galecia.com. (2017). Automated Materials Handling: More Information | The Galecia Group. [online]
Available at: http://galecia.com/content/automated-materials-handling-more-information [Accessed 12 Feb.
2017].
Isddd.com. (2017). Automated Storage and Retrieval Systems | Integrated Systems Design. [online]
Available at: http://www.isddd.com/storage-retrieval-systems [Accessed 12 Feb. 2017].
Kaseconveyors.com. (2017). Belt Conveyors | Screw Conveyors | Bucket Elevators | Bulk Material Handling
Equipment Manufacturer. [online] Available at: http://www.kaseconveyors.com/ [Accessed 12 Feb. 2017].
Lom200704.blogspot.com. (2017). Material Handling Equipment: Goals of Material Handling. [online]
Available at: http://lom200704.blogspot.com/2007/01/goals-of-material-handling.html [Accessed 12 Feb.
2017].
San Jose, D., Thang, S. and Muhammad, I. (2017). Selection of Material Handling Equipment. [online]
Asilogi.blogspot.com. Available at: http://asilogi.blogspot.com/2008/01/selection-of-material-handling.html
[Accessed 12 Feb. 2017].