By Group - 2

Materials Handling and Equipments

Material handling-definition

•Materials handling deals with the preparation, placement and positioning of materials with a view to facilitate their storage, preservation and movement .•It is a function which facilitates the movement of materials in and outside the store house.•According to American Materials Handling society, “it is the art and science involving movement, packaging and storing of materials in any form by means of gravity, manual effort or power actuated machinery “.

Objectives

To increase equipment and space utilisation. To reduce costs. To increase capacity To improve working conditions To improve customer service

Functions Handling equipments arrangement should

minimize distance moved by products and at the same time handling equipments should not interfere with the production line.

To minimize the distances moved, by adopting shortest routes.

To design containers, packages, drums etc. To economise handling and to reduce

damage to the materials in transit.

To utilize gravity for assisting materials movement wherever possible.

Materials handling equipments should periodically be restored and check ups repairs and maintenance.

To minimize the movement involved in a production operation.

Principles of material handlingOrientation principle: Study the problem thoroughly before preliminary planning to identify existing methods and problems, physical and economic constraints, and to establish future requirements and goals.

Planning principle: Establish a plan to include basic requirements, desirable options, and the consideration of contingencies for all material handling and storage activities.

Systems principle: Integrate those handling and storage activities that are economically viable into a coordinated system of operations, including receiving, inspection, storage, production, assembly, packaging, warehousing, shipping, and transportation.

. Flexibility principle: Use methods and equipment that can perform a variety of tasks under a variety of operating conditions.

Simplify handling by eliminating, reducing, or combining unnecessary movements and/or equipment.

Computerization principle: Consider computerization in material handling and storagesystems, when circumstances warrant, for improved material and information control.

System flow principle: Integrate data flow with physical material flow in handling and storage.

Layout principle: Prepare an operation sequence and equipment layout for all viable system solutions, then select the alternative system that best integrates efficiency and effectiveness.

Unit load principle: Handle product in as large a unit load as possible.

Space utilization principle: Make effective utilization of all cubic space.

Standardization principle: Standardize handling methods and equipment wherever possible.

Ergonomic principle: Recognize human capabilities and limitations by designing material handling equipment and procedures for effective interaction with the people using the system.

Energy principle: Include energy consumption of the material handling systems and material handling procedures when making comparisons or preparing economic justifications.

Ecology principle: Use material handling equipment and procedures that minimize adverse effects on the environment.

Mechanization principle: Mechanize the handling process where feasible to increase efficiency and economy in the handling of materials.

Overview—Material Handling

Involves diverse operations:

Manual material handlingCarrying bags or materialsUnpacking materials

Material handling via machineForkliftCraneRigging

Bulk material handling

used to move and store bulk materials such as ore, liquids, and cereals. This equipment is often seen on farms, mines, shipyards and refineries.

Injuries

Lifting objects is a major cause of back injuries in the work place

Improper storing and handling of material and equipment can cause struck by and crushed by injuries

HazardsImproper manual lifting or carrying loads that are too large or heavy

Being struck by materials or being caught in pinch points

Crushed by machines, falling materials or improperly stored materials

Incorrectly cutting ties or securing devices

Manual Handling

Seek help:

• When a load is too bulky to properly grasp or lift

• When you can’t see around or over the load

• When you can’t safely handle the load

Attach handles to loads to reduce the chances of getting fingers smashed.

Safe Lifting

Break load into parts

Get help with heavy or bulky items

Lift with legs, keep back straight, do not twist

Use handling aids - such as steps, trestles, shoulder pads, handles, and wheels

Avoid lifting above shoulder level

Safe Lifting Training

What should be taught:

• How to lift safely

• How to avoid unnecessary physical stress and strain

• What you can comfortably handle without undue strain

• Proper use of equipment

• Recognizing potential hazards and how to prevent / correct them

Personal Protective Equipment

For loads with sharp or rough

edges, wear gloves or other

hand and forearm protection

When loads are heavy or bulky,

wear steel-toed safety shoes to

prevent foot injuries if the load

is dropped

Materials Handling Equipment

Employees must betrained in the properuse and limitations of the equipment they operate

This includes knowing how to effectively useequipment such asforklifts, cranes, and slings

Forklifts

Center the load on the forks and as close to the mast as possible to minimize the potential for the truck tipping or load falling

Overloading a lift truck makes it hard to control and could make it tip over

Place the load at the lowest position for traveling

Don’t place extra weight on the rear of a counterbalanced forklift to allow an overload

Operating a Forklift Safely

Keep arms and legs inside the truck

Handle only stable loads

Keep speed low - you may have to stop

Be careful when making sharp turnswith a raised load

If a load blocks your view, travel in reverse

No riders, unless there’s an approved seat

Don’t drive with forks raised

Wear safety belts or other restraint devices

Powered Industrial Truck Training

• Truck-related topics• Workplace-related topics• Standard requirements• Trainees must be supervised

by a competent person and not endanger others• Formal instruction• Practical training• Evaluation of performance

Dock Boards (Bridge plates)

Dock boards must

have handholds, or

other effective means

for safe handling.

Earthmoving Equipment

Scrapers, loaders, crawler or wheel tractors, bulldozers, off-highway trucks, graders, tractors

Provide seat belts

Equipment with an obstructed rear view can’t be used in reverse unless the equipment has a signal alarm

Cranes

Check the load chart in the cab

Frequently inspect

Never lift people

Check overhead power lines

Ensure area of travel is clear

Rigging Equipment Slings

Types of slings covered are those made from alloy steel chain, wire rope, metal mesh, natural or synthetic fiber rope, and synthetic web.

Chain Wire rope Metal mesh Synthetic

Sling Inspection

Inspect slings:

Each day before use

Where service conditions warrant

Remove them from service ifdamaged or defective

Bulk material handlingIt is an engineering field that is centered around the design of equipment used for the transportation of materials such as ores and cereals in loose bulk form. It can also relate to the handling of mixed wastes.

Bulk material handling systems are typically composed of moveable items of machinery such as conveyor belts, stackers, reclaimers, bucket elevators, shiploaders, unloaders and various shuttles, hoppers and diverters combined with storage facilities such as stockyards, storage silos or stockpiles.

The purpose of a bulk material handling facility is generally to transport material from one of several locations (i.e. a source) to an ultimate destination.

Conveyor beltConsists of two or more pulleys, with a continuous loop of material - the conveyor belt - that rotates about them.

Conveyors are used as components in automated distribution and warehousing. In combination with computer controlled pallet handling equipment this allows for more efficient retail,

Wholesale manufacturing distribution.

It is considered a labor saving system that allows large volumes to move rapidly through a process, allowing companies to ship or receive higher volumes with smaller storage space and with less labor expense.

StackerA stacker is a large machine used in bulk material handling applications. A stacker's function is to pile bulk material such as limestone, ores and cereals onto a stockpile. A reclaimer can be used to recover the material.

A stacker usually operates on a rail-like structure with movable wheels, but the main operation is performed on a fixed place.

ReclaimerA reclaimer is a large machine used in bulk material handling applications. A reclaimer's function is to recover bulk material such as ores and cereals from a stockpile. A stacker is used to stack the material.

Reclaimers are generally electrically powered by means of a trailing cable.

Bucket elevatorA bucket elevator, also called a grain leg, is a mechanism for hauling flowable bulk materials (most often grain or fertilizer) vertically.

It consists of:Buckets to contain the material;A belt to carry the buckets

and transmit the pull;Means to drive the belt;Accessories for loading the buckets or picking up the material, for receiving the discharged material, for maintaining the belt tension and for enclosing and protecting the elevator.

ShiploaderA Shiploader is a huge machine used for loading bulk solid materials like iron ore, coal, fertilizers, grains into marine vessels for transportation by sea. Shiploaders are a very common sight in ports and jetties from where bulk materials are exported.

SummaryManually handling materials

• When lifting objects, lift with your legs, keep your back straight, do not twist, and use handling aids

Using cranes, forklifts, and slings to move materials• Watch for potential struck by and crushed by dangers• For slings, check their load capacity, inspect them, and

remove them from service when they display signs of stress or wear

Also -• Keep work areas free from debris and materials• Store materials safely to avoid struck by/crushed by

hazards