MECHENG352 - Materials Handling

Question 1

How much product cost is attributed to material handling?

Answer 1

20-50%

Question 2

What is material handling?

Answer 2

Material handling is an activity that we design to use the right method to provide the right amount of the right material at the right place, at the right time, in the right sequence, in the right position and at a minimised cost.

Activity designed to get right method for right amount of right material at right place at right time in right sequence in right position, at minimised cost.

Question 3

Material handling activities

Answer 3

Why - determine if necessary or not
What - material to move
Where - to move to. Scope, source, destination, route
When - Speed or rate, frequency,
How - unit handled, equipment
Who - manpower

Question 4

Typical material handling activities

Answer 4

■ Unloading activities (receiving).
■ Storage and issuing material.
■ In-process handling and in-process storage.
■ Inter-department and intra-plant handling.
■ Handling related to auxiliary functions.
■ Packaging.
■ Warehousing of finished products.
■ Loading and shipping and transport to customer.

Question 5

Material handling relationships with other functions

Answer 5

1. Facility layout
   ■ Material handling is an important consideration in plant layout procedure.
   ■ Material handling system changes and improvements will also normally result in layout changes.
2. Material management
   ■ Material handling must be considered in every aspect of the material management function, e.g., order size in purchasing, inventory, control policies, lot size and scheduling in production.

Question 6

Goal of material handling

Answer 6

■ The primary goal is to reduce unit costs of production.
■ Maintain or improve product quality, reduce damage of materials. ■ Promote safety and improve working conditions
■ Promote productivity.
Also
– Material should flow in a straight line. – Use gravity! It is free power.
– Move more material at one time.
– Mechanise material handling.
– Automate material handling.

Question 7

Material handling equipment

Answer 7

Material handling equipment includes:
 Industrial trucks.
 Automated Guided vehicles (AGVs).
 Monorails
 Conveyors, cranes and hoists.

Question 8

Handling options based on quantity and transport distance

Answer 8

High quant/Long dist = Conveyors, AGV train
Low quant/Long dist = Powered trucks, AGV
High quant/Short dist = Conveyors
Low quant/Short dist = Manual handling, hand trucks

Question 9

Handling options for fixed-position layout

Answer 9

Need: Large product size, low production rate

Cranes, hoists, industrial trucks

Question 10

Handling options for process layout

Answer 10

Variation in product and processing, low and medium production rates

Hand trucks, forklift trucks, AGVs

Question 11

Handling options for product layout

Answer 11

Limited product variety, high production rate

Conveyors for product flow, trucks to deliver components to stations.

Question 12

12 material handling principles

Answer 12

1. The Planning Principle
2. The systems principle
   form a coordinated, operational system that spans receiving, inspection, storage, production, assembly, shipping, and the handling of returns.
3. Simplification principle
   ■ Simplify handling by reducing, eliminating, or combining
   unnecessary movement and/or equipment.
4. Gravity principle
5. Space utilisation principle
6. Unit load principle - appropriately sized unit loads (commonly pallet)
7. Automation principle
8. Equipment selection principle
9. The standardisation principle - standardise handling methods as well as types and sizes of handling equipment
10. The dead weight principle - reduce ratio of equipment weight to product weight
11. The maintenance principle - preventive maintenance
12. The capacity principle