Guidelines for Effective Utilisation of Material Handling Equipment

Simply selecting and installing material handling (MH) equipment is not enough; it must be utilized effectively to realize its full benefits in terms of cost savings, efficiency, and safety. These guidelines help maximize the performance and return on investment from MH systems.

Key Guidelines for Effective Utilization:

1. Eliminate Handling (If Possible): Before optimizing a handling task, question if it's necessary at all. Can layout changes, process redesign, or supplier integration eliminate the need for the move? This offers the greatest potential saving.
2. Minimize Travel Distance: Keep movement distances as short as possible through optimized layouts and workflow design. Shorter moves mean less time, energy, and cost.
3. Utilize Gravity: Incorporate gravity feeds (chutes, sloped conveyors) whenever safe and practical – it's free energy.
4. Maximize Unit Loads: Handle materials in the largest practical, standardized unit loads (pallets, containers) to reduce the number of trips and handling motions required.
5. Ensure Straight-Line Flow: Aim for smooth, direct flow paths, minimizing backtracking, congestion, and cross-traffic.
6. Maintain Equipment Reliability: Implement a rigorous preventive and predictive maintenance program for all MH equipment to minimize unexpected breakdowns and ensure availability when needed.
7. Optimize Equipment Utilization:
   • Schedule work to keep equipment operating productively as much as possible, minimizing idle time.
   • Use equipment near its rated capacity where safe, avoiding consistent under-loading.
   • Consider multi-purpose or flexible equipment if utilization for a single task is low.
8. Standardize Methods and Equipment: Use standard procedures and common equipment types across the facility to simplify training, improve interchangeability, and reduce spare parts inventory.
9. Prioritize Safety: Ensure all equipment has appropriate safety features, operators are thoroughly trained and certified, safe operating procedures are followed strictly, and workspaces are kept clear.
10. Integrate Systems: Ensure MH activities are well-coordinated with production schedules, inventory control systems, and shipping/receiving operations. Use information systems (like WMS or EAM) for better control.
11. Train Personnel: Properly train operators on efficient and safe equipment operation, and train maintenance staff on correct repair and upkeep procedures.
12. Measure and Monitor Performance: Continuously track key MH metrics (cost per unit, utilization rates, downtime, safety incidents) to identify areas for improvement.

• Indian Example: A large warehouse operated by Delhivery or Blue Dart focuses heavily on effective utilization. Unit loads (parcels in standard totes or cages) are used extensively. High-speed conveyors (transport equipment) are kept running near capacity during sorting operations. Flow paths are designed for minimal congestion. Preventive maintenance on sorting systems and conveyors is critical to avoid costly downtime. Performance is constantly monitored using metrics like parcels sorted per hour and sortation accuracy, driven by integrated control systems (WMS, barcode/RFID tracking). Operator training on handling scanners and managing jams is essential.

By following these guidelines, organizations can move beyond simply having MH equipment to truly leveraging it for significant operational improvements.