Material Handling Equipments

Choosing appropriate Material handlingHandling (MH) equipment encompassesis afundamental vastto arraydesigning ofan tools,effective vehicles,MH storagesystem. systems,The andequipment appliancesprovides usedthe physical means for moving, storing, protecting, and controlling materials. The choice of equipmentselection depends heavily on thenumerous factors (as discussed in SectionSec 4.4), including material properties, flow requirements, layout, and cost.

Factors Influencing MH Efficiency (Recap from Evaluation):

Before diving into equipment types, it's useful to remember that overall MH efficiency hinges on:

1. Method Efficiency: How well the chosen handling technique performs (e.g., efficiency per unit weight moved per unit distance).
2. Layout Efficiency: How well the facility layout minimizes travel distances.
3. Facility Utilization: How effectively MH equipment and personnel are used (avoiding idle time).
4. Handling Speed: The rate at which materials are moved, balanced against safety and cost. (The 'Movement/Operations Ratio' mentioned in the original text – total moves divided by productive operations – is an indicator used in evaluation (Sec 4.5) Equipmentto canassess beif excessive handling motions exist, potentially due to poor routing or layout).

Tailoring the System: An effective MH system requires tailoring the layout and equipment to specific operational requirements. The choice often involves a trade-off between efficiency for specific routes and overall system flexibility.

1. Fixed Path Preference: For moving large volumes consistently between a limited number of fixed points (sources and destinations), fixed path equipment (like conveyors) is generally preferred due to potential efficiency and automation benefits.
2. . Variable Path Preference: For situations requiring movement between many different points, handling varied materials, or where routes change frequently (increased flexibility), variable path equipment (like trucks) is usually more suitable.

Broad Classification of MH Equipment:

Material handling equipment is broadly classifiedcategorized based on theits path it takes or its primary function.flexibility:

A.(a) Classification byFixed Path Flexibility:Equipment:

• 1. Fixed Path Equipment:
  • Characteristics:Description: MovesThese devices transport materials along a single, predetermined route.path. OffersThey offer high efficiency and capacitythroughput for continuousspecific or high-volume flow between fixed points,routes but lackslack flexibility.flexibility Installationto is often permanent or semi-permanent.deviate.
  • Examples:
    • Conveyors: (Belt, Roller,roller, Wheel,wheel, Screw,chain, Chain,screw, Slat,pneumatic, Bucket, Pneumatic)etc.) - Used widelyIdeal for transportingcontinuous or high-volume intermittent flow between fixed points. Common in assembly lines, bottling plants, bulk materialsmaterial transport (coal,cement, grain), discrete items (boxes, packages), or assemblies along production lines. Think baggage handling systems at Indian airports or assembly lines in electronics factories..
    • Monorails /Monorails: Overhead Conveyors:tracks Loadscarrying hangindividual fromloads trolleysvia on an overhead track. Good for utilizing vertical space and bypassing floor congestion.trolleys. Used in automotivepainting paintand shops.assembly operations.
    • Chutes: UseUtilize gravity tofor movedownward items downwardsmovement between levels. Simple, low cost.
    • Pipelines:Pulley Drive Equipment: ForRefers fluidgenerally to systems driven by pulleys, often associated with conveyors or gaslifting transport. Essential in oil & gas, chemical industries. mechanisms.
    • LiftsOverhead /Cranes Elevators:(Bridge, Gantry): StandardWhile verticalrestricted transportto betweena floors.defined rectangular or semi-circular area (length, width, height), they offer flexible movement within that area. Excellent for heavy, bulky loads like raw materials or large components, stacking, and sometimes palletizing. Crucial in steel mills, heavy fabrication shops.

• 2.(b) Variable Path Equipment:

  • Characteristics:Description: CanThese traveldevices overhave variousno routesrestrictions on their direction of movement within athe definedavailable area,space providing(aisles, floors). They offer high flexibility for intermittentvaried flows, diverse destinations,routes and changingtasks needs.but Notmay fixedhave tolower athroughput than dedicated fixed-path systems for specific path.point-to-point moves. Their size and maneuverability are key considerations.
  • Examples:
    • Industrial Trucks: Forklifts (various types like counterbalance,counterbalanced, reach, VNA)turret), Pallet Trucks (manual/manual, powered), Platform Trucks, Tow Tractors. The workhorsesbackbone of warehousing and generalflexible material movement.transport, Seenespecially everywherefor fromunit smallloads. IndianAvailable SMEsin many sizes, capacities (ranges), and power sources (electric, petrol/diesel/LPG). Highly maneuverable with numerous available attachments (clamps, rotators, booms) increasing their versatility to largehandle distributionvarious centers.load shapes and types.
    • Mobile Cranes: Cranes (Overheadmounted &on Mobile): Bridge, Gantry, Jib cranes provide flexible lifting/movement within their operating area. Mobile cranes offer location flexibility. Essential in steel plants (like SAILtrucks or JSW), construction sites, and ports.
    • Hoists: Lifting devices used independently or with cranes/monorails.
    • Automated Guided Vehicles (AGVs): Driverless vehiclescrawlers for automatedlifting transport,heavy followingloads guidesat (wires,various lasers, tape). Used in modern warehouses (e.g., Delhivery, Ecom Express hubs) and flexible manufacturing systems. locations.
    • Industrial Robots:Tractors: Used for precise,towing repetitivetrailers carrying materials over longer distances within a facility or yard.

  Major Categories of MH Equipment (Functional Classification):

  While the fixed/variable path distinction is useful, equipment can also be categorized by its primary function:

  1. Conveyors:

     • Function: Transport materials between fixed workstations, continuously or intermittently.
     • Suitability: Best for steady, high-volume flows in mass production or continuous operations.
     • Types: Rollers, wheels, belts, etc.; can be powered or free-rolling (gravity).
     • Considerations: Usually costly to install, less flexible than trucks, require coordination if multiple conveyors converge.

  2. Industrial Trucks:

     • Function: Flexible transport between various points; not fixed in place.
     • Suitability: Ideal for intermittent production, handling tasksdiverse likematerial palletizing,sizes/shapes, machinewarehousing.
     loading/unloading.
     • IncreasinglyTypes: adoptedPetrol, electric, hand-powered. Wide range of capacities and attachments enhances versatility.

  3. Cranes and Hoists:

     • Function: Lifting and moving heavy materials, often utilizing overhead space.
     • Suitability: Handling heavy loads in Indianproduction manufacturingor storage areas; can be used for efficiencyintermittent or continuous needs, but typically serve a limited area.
     • Types: Various crane types (bridge, gantry, jib) and quality.hoists (chain, electric) with different load capacities.

  4. Containers:

     • Function: Holding materials during transport or storage, facilitating unit load handling.
     • Types:
       • 'Dead' Containers: Hold material but don't move themselves (e.g., Cartons, Barrels, Skids, Pallets, Bins, Totes). Pallets and skids are fundamental for unit load systems used with forklifts.
       • 'Live' Containers: Both contain and move material (e.g., Wagons, Wheelbarrows, some automated/self-driven containers related to AGVs). Usually manually operated or automated.

B. Classification by Function (Alternative View):Robots:

• TransportFunction: Equipment:Automated Movesdevices materialsfor betweenhandling, locationstransport, or processing tasks (e.g.,like Conveyors,welding, Trucks,painting). Cranes,Vary AGVs).significantly in size, capability, and maneuverability.
• PositioningSuitability: Equipment:Repetitive Handlestasks, materialhandling atheavy amaterials, singleoperating locationin for manipulationhazardous or feedinguncomfortable into a process (e.g., Hoists, Balancers, Manipulators, Industrial Robots at workstations).environments.
• UnitAdvantage: LoadConsistency, Formationprecision, Equipment: Usedability to restrictwork materialscontinuously soin theydifficult maintainconditions.
integrity
when handled

Selection Complexity: Choosing the optimal equipment is challenging due to the wide variety available and the fact that multiple equipment types might be capable of handling the same material. A careful analysis of material characteristics, movement requirements, layout, cost, flexibility, and safety (as aoutlined singlein objectSec (e.g.,4.4) Pallets,is Skids, Bins, Totes, Cartons, Bags). Palletizers can automate this.

Storage Equipment: Usedcrucial for holdingmaking materialsthe overright timedecision.

(e.g.,Figures Racking systems - selective, drive-in, flow-through; Shelving; Mezzanines; Automated Storage/Retrieval Systems - AS/RS).

Identification & Control Equipment: Used3.1 to collect3.11 andmentioned communicatein informationthe fororiginal trackingtext materialwould flowvisually (e.g.,illustrate Barcodeexamples scanners,like RFIDWheel tags/readers,Conveyor, WarehouseScrew ManagementConveyor, SystemsBelt -Conveyor, WMS)Roller Conveyor, Jib Crane, Bridge Crane, Platform Truck, Fork Truck, Chain Hoist, Electric Hoist, Spiral Chute, Industrial Tractor, Electrical Hoist).

• Indian Example: ITC Limited, with its diverse businesses (FMCG, Agri, Paperboards), uses a wide spectrum of MH equipment. Bulk grain handling at Agri Business division might use screw conveyors and bucket elevators (Fixed Path). Cigarette manufacturing involves high-speed automated conveyors and robotic arms (Fixed/Positioning). Distribution centers for FMCG products rely heavily on forklifts and pallet trucks (Variable Path) for handling pallets and cartons (Unit Load/Containers) stored in racking systems (Storage), tracked via barcode scanners and WMS (Identification/Control).

The selection process involves choosing the most appropriate equipment from these categories based on the specific needs analysis discussed previously.