OPERATIONS MANAGEMENT-MATERIAL
HANDLING HANDLING
Material handling may be broadly defined as the movements of materials from one Material handling may be broadly defined as the movements of materials from one
place to another. It may
place to another. It may be picking up or putting down, moving horizontally or be picking up or putting down, moving horizontally or verticall
vertically y or in any inclined plans of materials, of any kind in their raw, semi-or in any inclined plans of materials, of any kind in their raw, semi-finished or semi-finished state.
finished or finished state.
OBJECTIVEOBJECTIVE
Material handling often does not add anything to the value of Material handling often does not add anything to the value of the product butthe product but only increases the cost. Handling costs constitute a
only increases the cost. Handling costs constitute a substantial portion of thesubstantial portion of the total cost of production. Besides, material handling is also
total cost of production. Besides, material handling is also found to befound to be responsible for a large percentage of
responsible for a large percentage of product damage. 80 to 90% of product damage. 80 to 90% of industrialindustrial accidents and other disadvantages. In spite of this, material
accidents and other disadvantages. In spite of this, material handling is anhandling is an essential feature of industrial activity. Materials have to be moved from one essential feature of industrial activity. Materials have to be moved from one place to another without which all the activities
place to another without which all the activities would come to a standstill.would come to a standstill.
Material handling often accounts for improved utilization of men and mac
Material handling often accounts for improved utilization of men and mac hines,hines, and provides for specialization of skills and the
and provides for specialization of skills and the related advantages.related advantages.
Since material handling cannot be eliminated completely in any organisation,Since material handling cannot be eliminated completely in any organisation, the objective of material handling may be
the objective of material handling may be stated as instituting an efficientstated as instituting an efficient system of handling. Eliminating unnecessary a
system of handling. Eliminating unnecessary and wasteful handling systemnd wasteful handling system saves money and time, reduces damage to materials and makes the work safer.
saves money and time, reduces damage to materials and makes the work safer.
OPERATIONS MANAGEMENT-MATERIAL OPERATIONS MANAGEMENT-MATERIAL
HANDLING HANDLING
Some PrinciplesSome Principles
Some of the major principles in the design of an efficient system of material Some of the major principles in the design of an efficient system of material
handling are:
handling are:
a)
a) Reduce handlReduce handling ting to a o a minimum: minimum: As far As far as possible, as possible, materials should materials should alwaysalways move towards completion, over the shortest distance w
move towards completion, over the shortest distance without back-tracking. Aithout back-tracking. A large amount of handling can be eliminated by planning the location of
large amount of handling can be eliminated by planning the location of operations so that one operation finishes right where the
operations so that one operation finishes right where the next begins. The flownext begins. The flow of product should receive top priority in planning of layout.
of product should receive top priority in planning of layout.
b)
b) Avoid re-handling: IAvoid re-handling: It may not be possible to elimit may not be possible to eliminate re-handling completely.nate re-handling completely.
Nevertheless, re-handling is a wasteful and costly operation.
Nevertheless, re-handling is a wasteful and costly operation. Re-handling canRe-handling can be reduced by (i) not keeping anything on floor, (ii)
be reduced by (i) not keeping anything on floor, (ii) avoiding transfers fromavoiding transfers from floor to container or vice versa
floor to container or vice versa or from container to or from container to container, and (iii) avoidingcontainer, and (iii) avoiding making of materials.
making of materials.
c)
c) Combine handling Combine handling with other operations: Many twith other operations: Many times, handling may be made aimes, handling may be made a productive activ
productive activity ity by combining with other operations, such as production,by combining with other operations, such as production, inspection and storage. In process industries, materials undergo physical and inspection and storage. In process industries, materials undergo physical and chemical changes while in movement, handling devices may be
chemical changes while in movement, handling devices may be used as liveused as live storage of materials may be sorted and inspected while they are being handled storage of materials may be sorted and inspected while they are being handled
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d) Ensure safety in handEnsure safety in handling: Safety is a ling: Safety is a key word in handkey word in handling. A lling. A large percentagearge percentage of
of industrial accidents are attributed to poor handling practices. industrial accidents are attributed to poor handling practices. Even costlier Even costlier in terms of money is
in terms of money is the damage to equipment and products due to improper the damage to equipment and products due to improper handling methods. A good handling system should ensure safety to workers handling methods. A good handling system should ensure safety to workers and materials. Manual handling of heavy objects, materials
and materials. Manual handling of heavy objects, materials scattered on thescattered on the floor or projecting into aisles are but a few causes of accidents. Keeping floor or projecting into aisles are but a few causes of accidents. Keeping gangways and aisles clear is one of
gangways and aisles clear is one of the primary precautions against accidentsthe primary precautions against accidents in handling.
in handling.
e)
e) Handle materials in unHandle materials in unit loads: It iit loads: It is easier and quicker to s easier and quicker to move a number of move a number of materials at a unit rather
materials at a unit rather than piece by piece. Modern material than piece by piece. Modern material handling deviceshandling devices are designed to take advantage of unutilized loads.
are designed to take advantage of unutilized loads.
f)
f) Use gravitUse gravity where possible and mechanical y where possible and mechanical means, if necessary: The simeans, if necessary: The simplestmplest and cheapest way to handle materials is by using gravity. Often chutes and and cheapest way to handle materials is by using gravity. Often chutes and inclined boards can be conveniently used to transport materials
inclined boards can be conveniently used to transport materials quickly to thequickly to the point of use without much investment on costly handling equipment. Where it point of use without much investment on costly handling equipment. Where it is not possible to use gravit
is not possible to use gravity for y for various practical reasons, some mechanicalvarious practical reasons, some mechanical means should be considered. Lifting and carrying of heavy materials
means should be considered. Lifting and carrying of heavy materials mechanically saves time and reduces fatigue of workers.
mechanically saves time and reduces fatigue of workers.