Definition of Materials Handling

Materials Handling - The movement of raw goods, semi-finished goods, and finished articles through various stages of production and warehousing. (Source: Compton's Interactive Encyclopedia)

Through the useful lectures that we attended in school, we also know that Materials Handling is mainly concerned with the movement, storage, and control of materials in warehouses and production plants. Materials Handling Equipment (MHE) are tools that are useful in facilitating the above-mentioned issues in the Materials Handling portion of the entire logistics function of companies.

In this blog, we are going to elaborate more about the different kinds of equipment that fall under the category of MHE so as to give readers a better understanding of the capability of their functions, as well as how they contribute to overall flow of Materials Handling in a warehouse.

According to the MATERIAL HANDLING INDUSTRY OF AMERICA (MHIA) - the leading trade association representing the material handling and logistics industry, MHEs are classified into 9 broad groups, namely Transport Equipment, Conveyors, Cranes, Industrial Trucks, No Equipment, Positioning Equipment, Unit Load Formation Equipment, Storage Equipment, & Identification & Control.

We will only be focusing on the groups Transport Equipment (Conveyors, Cranes, Forklifts) & Storage Equipment in the following few entries. Please scroll down to take a better look at some of the capabilities of the different MHEs, & enjoy your stay here.

Transport Equipment Part I - Conveyor Systems

What are Conveyors?

Definition: One that conveys, especially a mechanical apparatus that transports materials, packages, or items being assembled from one place to another. (Source)


Conveyors are used when:

1) Materials need to be moved frequently between specific points in the workplace,

2) Movement of materials take place in fixed paths/routes, &

3) There is a sufficient flow volume to justify the fixed conveyor investment.


They can be classified in different ways, some of which are:

1) Type of products handled - Unit load or Bulk load,

2) Location of the conveyor: Overhead, On-floor, or In-floor &

3) Whether or not loads can be loaded on to the conveyor


There are currently many industries making use of Conveyors, including: Food & Bakery, Paper Handling, Pharmaceutical/Medical, Health & Beauty, Automotives, Electronics, & Industrial & Consumer Products.

Companies in the above-mentioned industries can select from the myriad range of conveyors available in the market based on their specific requirements.

Let us now take a look at a few of the many different kinds of conveyor that are more widely used currently.
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1) Chute Conveyors

What's this? Used to link two powered conveyor lines, & convey items between floors.

Areas of Application - Provide accumulation in shipping areas, widely used for the transport of both coarse grain material (such as cereals, mineral ore and coal) and fine powders (as used in the chemical and pharmaceutical industries).

Advantage(s) - Economical; one of the most inexpensive methods of facilitating movement of materials

Disadvantage(s) - Difficult to control the items that being conveyed by the chutes; may result in packages shifting and turning so that jams and blockages could occur.

Video on Chute Conveyor here.

2) Roller Conveyor

a. Powered Roller Conveyor
What? These conveyors are belt or chain-driven, & runs on electricity solely.

Areas of Application - Accumulation of loads (heavy-duty) and merging/sorting of operations.

Advantage(s) - Does not depend on load weight of material, able to control movement of materials on the conveyor (for e.g. stop movement as and when one is required to by setting timing of conveyor).

Disadvantage(s) - Provides limited inclined movement capabilities.

Video on Powered Roller Conveyor here.


b. Gravity Roller Conveyor
What? An alternative to the Wheel Conveyor, movement of materials on this conveyor works on the rationale of gravitional force.

Areas of Application - For heavy-duty applications, and accumulation and sorting of operations.

Advantage(s) - Ablility to move objects without power (cost nothing to run), low capital costs and simple to install.

Disadvantage(s) - Gravity Roller Conveyors cannot convey materials that do not have fixed, solid forms (for e.g. loose powder), and they cannot convey upwards (only downwards due to gravity).

Video on Gravity Roller Conveyor here (with speech, requires Windows Media Player).


3) Vertical Lift Conveyor
What? Conveyor used to elevate or lower materials (in pallets, carton forms) from one level to another in a continuous high speed and high capacity operation. Can be hydraulic or mechanical.

Areas of Application - Additional production or distribution floor space is required, more aisle space for personnel and forklift traffic is required and when multiple floors are required to be tied together (so that there can be more space for production facilities).

Advantage(s) - Vertical Lift Conveyors are more economical than elevators. They can accommodate larger loads, both in size and weight.VRC’s have a smaller footprint then an incline conveyor, conserving valuable floor space.

Disadvantage(s) - Limited loading & unloading, as platform sizes and capacities may be limited due to the positioning of the load in relation to the guide structure.

Video on Vertical Lift Conveyor here.


More links to videos on Conveyors:
http://youtube.com/watch?v=d7fyVYXMIUM#
http://youtube.com/watch?v=7zycL3UI_fc
http://youtube.com/watch?v=E1L_SXlZLjQ
http://www.metacafe.com/watch/290944/choo_choo_train_sushi/

Transport Equipment Part II - Cranes

What are Cranes?

Cranes are lifting devices that are either stationary or mobile, and can lift materials above and beyond the capability of 2 workers. They can also be powered to increase their lifting abilities.

Note: Cranes provide more flexibility in movement than conveyors.

The major types of cranes include the following:

1) Jib crane

2) Bridge crane

3) Gantry crane

4) Stacker crane

Let us now go into details of 3 of the 4 different kinds of cranes.

1) Jib cranes

What? Jib cranes consist of a hoist-type lifting device mounted on a horizontal boom (jib).

Common configurations of the jib crane include:

(a) Pillar support - The jib is attached to a self-supporting floor mounted or floor-to-ceiling mounted mast

(b) Mast support - The jib is mounted on a mast which is supported on top and bottom supports and pivots.

(c) Bracket - The jib is attached to the wall or column by brackets.

(d) Walking - The jib is mounted on heavy undercarriages which may move back and forth on rails in the floor or floor and ceiling.

(e) Interlocking-A bracket crane designed to extend the travel of a monorail hoist by connecting the ends of adjacent jibs.

2) Gantry Crane

What? A gantry crane consists of a hoisting device that rides on a horizontal beam connected to legs with wheels attached to the bottom. Gantry cranes can be used either indoors or outdoors and can be pendant or radio controlled.

Variations are possible when one of the legs is replaced by a runway attached to the building or other fixed object. Gantry cranes are more often used outdoors because of the support legs.

3) Bridge Cranes

What? Bridge cranes are mounted on tracks that are located on opposite walls of the facility. The movement consists of horizontal travel along the length of the runway, horizontal movement across the width of the bridge, and vertical movement provided by the hoist.

Areas of Application - Bridge cranes are best used in low to medium volume activities for lifting large, heavy, or awkward items.

Advantage(s) - The advantages of bridge cranes include no interference with the work on the floor, reduced aisle space requirements, easy access to most areas within the lifting bay, and extension to areas outside the building.

Transport Equipment Part III - Industrial Trucks

What are Industrial Trucks?

Defintion: Industrial trucks are used to move materials over variable paths, with no restrictions on the area covered by the movement.

The major types of industrial trucks are:

1) Hand Trucks
2) Pallet Jacks
3) Walkie Stacker
4) Pallet Trucks
5) Platform Trucks
6) Counter-balanced lift trucks
7) Narrow Aisle Straddle trucks
8) Narrow Aisle Reach Truck
9) Turret Truck
10) Order Picker
11) Side-loader
12) Tractor Trailer
13) Personnel & Burden Carrier
14) Automatic Guided Vehicle (includes Tow AGV, Unit Load AGV, Assembly AGV, Light load AGV, & Fork AGV)

Today, we will be looking at details of the groups Pallet Jacks & Automatic Guided Vehicle (specifically Forklifts)


What is a Forklift Truck?

What? A forklift truck (a.k.a forklift and sideloader) is a powered industrial truck used to lift and transport materials, normally by means of inserting steel forks under the loads. Can be electrically powered or run on fuel.

Areas of Application - Most commonly used to move loads stored on pallets. Forklift trucks are available in many variations and load capacities. In a typical warehouse setting most forklifts used have load capacities of around one to five tons, though machines of over 50 tonnes capacity have been built and operated.

Pictures of diesel fueled internal combustion engine



Electric motor forklifts


Advantage(s) - (of LPG forklifts) Able to operate effectively 24/7 with no loss of power & life-time running costs can be lower than electric trucks, they can be used even in the most sensitive environments. Companies will not face battery disposal problems & there will be no harmful fumes under normal operating conditions.

Disadvantage(s) - Require sufficient aisle space to move around warehouse (or anywhere else relevant)


Pallet Jack

What? A tool used to lift and move pallets; the front wheels are mounted inside the end of the forks, and as the hydraulic jack is raised, the forks are separated vertically from the front wheels, forcing the load upward until it clears the floor. The pallet is only lifted enough to clear the floor for subsequent travel.

Manual Pallet Jacks


Powered pallet jack

Areas of Application - Powered pallet jacks are motorized to allow lifting and moving of heavier and stacked pallets. These generally contain a platform for the user to stand while hauling pallets around a warehouse or loading/unloading trucks. The powered pallet jack is generally moved by a throttle on the handle to move forward or in reverse and steered by swinging the handle in the intended direction.

Advantages - Mobile

Disadvantage(s) - Cannot move through narrow aisles, limited speed


Electronic Platform Trucks

What? Electric platform trucks are electric powered trucks with a large flat surface for holding objects to be transported. Some are also called warehouse utility vehicles, electric trolley carts, or powered platform truck vehicles.

Storage

Material Handling Info

A.Deep-Lane Pallet Rack

What is it and how does it work?


Pushback Rack is a reverse flow storage system which offers the same storage density as Drive-In Rack, but with much greater selectivity. This rack is also known as Reverse Gravity Rack. Pushback Rack allows for a "Last In, First Out" (LIFO) rotation inventory management system as well as a reduction in the number of fork truck aisles needed in your warehouse. This translates into increased productivity, efficiency (time savings) and optimizes your existing space. Loads/pallets are stored and retrieved from the aisle. Loads in each pushback rack lane rest on a cart, which sits atop a rail that slopes gently toward the front (towards the aisle). When a new load/pallet is deposited onto a cart within a lane by a forklift, it "pushes back" the one already at the face as well as those behind it. Depending how "deep" (2 deep to 6 deep) the rack is will determine how many pallets can be stored in that individual lane. Then, when a load/pallet is picked from the face of the rack or lane, the contents of the lane all move gently forward (at a controlled and slow speed) with a new pallet coming to the face, replacing the one just removed. This new pallet (which moved forward) is now also ready to be picked, or another pallet can be added ("pushed back") to fill the lane again.

Applications:
Ideally suited for storing a large quantity of relatively few SKUs; especially effective when one SKU is assigned per bay.
Works best in warehouses with 15 to 30 ft. ceiling clear heights.
Key Benefits


a. -High density - there is theoretically no limit to depth- systems of 20 pallets deep and more have been installed.
b. - Throughput - can keep pace with high volume palletizers, and other production lines.
c. -Productivity - eliminates lift truck travel time - pallet flow lanes do the conveying.



B. Flow Rack


What is it and how does it work?

Flow rack is a gravity flow storage system that provides a low cost and highly efficient first-in/first-out storage solution. Flow racks can be used both for cartons and pallets. Flow rack is one of the fastest options available for piece and/or carton picking. Full pallets can also be picked from flow racks.

Applications
Forward pick operations.
SKUs with high pick activity.
FIFO picking.
Full and split-carton picking.
Secondary carton and pallet storage

The Advantages of Flow Rack Systems:

1. First-in, first-out (FIFO) inventory control.

Loads are transported, via the flow rails from the loading end to the unloading end of the storage system. The first load in is always the first load to be taken out. This constant stock rotation is especially beneficial with perishable or time-sensitive goods, such as food or pharmaceuticals, where a lost product becomes a lost profit.
2.Reduced handling costs.

Once loaded, product rotation is automatic. The SK3400 rack eliminates labor and fork truck operation to rearrange loads. And Steel King flow rails are powered by gravity, requiring no electricity or other utilities.
3.Reduced handling equipment costs.

Fork lifts are required only for the initial loading and final unloading. Because only two aisles are necessary, aisle space can be reduced by 75 percent. Fewer fork lifts, operating fewer hours, and consuming less fuel can accomplish the same handling function.
4.Time and labor savings.

With only two aisles, each dedicated to specific functions (loading or unloading), traffic is more orderly, employees are more efficient and overall productivity is improved.
5.Space savings.

Because storage density can be doubled, storage capacity can be increased within the same storage area, or a portion of your existing storage area can be made available for other uses.
6.Construction cost savings.

By increasing storage capacity within existing facilities, the need for new construction could be eliminated. When new construction is necessary, building size and cost can be reduced by up to 50 percent. A smaller warehousing area, in turn, can reduce insurance, land acquisition costs, and taxes.
7.Operating expense reduction.

Higher density storage and consequently smaller storage areas also mean less area to heat, illuminate, air condition, and/or refrigerate.
8.Decreased fork lift damage.

Decreased fork lift handling of loads can result in less product damage and less potential for collision damage to the rack structure.
9.Flexibility.

Flow storage systems have been successfully installed as a part of virtually every storage function, including raw materials receiving and storage, work-in-process, buffer storage, finished goods, order picking, and cross docking

C. Vertical/Horizontal Carousel



What is that and how does it work?

Horizontal/vertical carousels are high-density storage devices designed to use vertical storage space and increase the ease and accuracy of order/parts picking. Carousels operate by moving bins along a horizontal or vertical axis. The operator remains at a fixed input/output location while the designated load travels to the operator. Loads can be tracked with an inventory management system. Carousels are offered in many standard sizes or can be customized as required. Although generally used for lighter loads (less than 50 pounds per bin), custom designed carousels can handle loads up to 2,000 pounds. Horizontal carousels are available with up to 100 bins with an overall length of 60 feet. Vertical carousels are available with heights up to 25 feet.

Applications:
Forward pick operations.
JIT buffer storage.
Work in process storage.
Small part sorting.
Secure storage.
Finished goods storage.

Advantages:
1.High-density storage.
2.Accommodates a variety of tote and product sizes.
3.Simple controls.
4. Accurate order/part picking.
5 Eliminates walk and search time.
6 . Improved ergonomics and operator safety.
7. Efficient use of storage space.
8. Eliminates bending or stretching to retrieve parts.
9. Provides a secure storage area.
10. Conventional Pallet Rack : -Conventional pallet rack is one of the most affordable types of storage for palletized products. It is relatively easy to modify its location and adjust tier heights as storage requirements change. Conventional pallet racking also allows storage of a wide variety of load footprints in the same rack.

. Shelving

What is it and how does it work?

shelves for product storage is an economical and versatile storage method that is easily modified as requirements change. The vertical height of shelving is usually below six feet but may go up to 15 feet high if movable stairs are to be used for picking product from the higher shelves. Shelving works well with Warehouse Management Systems (WMS) and picking carts.

Applications
1.Forward pick operations.
Primarily for storage of relatively small raw materials and finished goods.
2.Works best in warehouses with 8 to 15 foot ceiling clear heights
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Advantages

.Some of the general advantages of rapid
diagnostic tests are:
· Easy to use, with minimal training
required.
· Relatively rapid; same-day results are
possible, resulting in fewer patients lost
to follow-up.
· A shelf life as long as 1-2 years at
ambient temperatures, with no need for
refrigeration.
· Limited or no need for instrumentation,
allowing these tests to be performed at
the periphery of health systems, often
where there is no laboratory or
electricity.
· In some cases, rapid tests are more
accurate than existing reference-level
laboratory tests.
Some general disadvantages of rapid tests are:
· Cost per test for rapid tests may exceed
traditional testing methods such as
microscopy.
· Most rapid tests have limited shelf lives
that place increased demands on
procurement and distribution systems.
· They are mainly qualitative, producing
only "yes/no" answers that may yield
less information than the existing
laboratory-based quantitative tests.
· They require subjective interpretation,
which may result in reader variation in
results.