Principles of Material Handling

These widely accepted principles provide fundamental guidelines for designing, implementing, and improving material handling systems and procedures. Adhering to these principles helps achieve the objectives of efficient and effective material handling.

Key Principles:

1. Planning Principle: All MH activities should be thoroughly planned based on needs, objectives, and alternatives before execution. (Plan the move).
2. Systems Principle: Integrate MH activities into a coordinated system covering all operational phases (receiving, production, storage, shipping). (See the whole picture).
3. Space Utilisation Principle: Make optimal use of all available cubic space (vertical and horizontal) for handling and storage. (Use space wisely).
4. Unit Load Principle: Handle materials in the largest practical unit loads (e.g., pallets, containers) to minimize the number of moves. (Move more at once).
5. Gravity Principle: Utilize gravity to move materials wherever feasible and safe to conserve energy and reduce costs. (Let gravity help).
6. Material Flow Principle: Plan layouts and sequences to ensure materials move progressively with minimal travel distance, backtracking, or congestion. (Keep flow smooth).
7. Simplification Principle: Reduce, combine, or eliminate unnecessary movements, handling steps, and equipment. (Keep it simple).
8. Safety Principle: Design methods and equipment prioritizing the safety of personnel, materials, and facilities. (Safety first).
9. Mechanisation/Automation Principle: Use mechanical or automated equipment where it enhances efficiency, safety, economy, or control compared to manual methods. (Automate appropriately).
10. Standardisation Principle: Standardize handling methods and equipment types/sizes for interchangeability, flexibility, and easier maintenance/training. (Use common standards).
11. Flexibility Principle: Employ methods and equipment that can adapt to a reasonable range of tasks and future operational changes. (Be adaptable).
12. Equipment Selection Principle: Choose equipment based on a careful analysis of the material characteristics, movement requirements (route, distance, frequency), and method constraints. (Select the right tool).
13. Dead Weight Principle: Minimize the unladen weight of mobile handling equipment relative to its carrying capacity to save energy. (Reduce equipment weight).
14. Motion Principle: Keep transport equipment moving productively; minimize unproductive movement or idle time. (Keep things moving).
15. Idle Time Principle: Reduce unproductive waiting time for both MH equipment and the associated workforce. (Minimize waiting).
16. Maintenance Principle: Implement planned preventive maintenance and timely repairs for all handling equipment to ensure reliability. (Maintain equipment).
17. Obsolescence Principle: Replace outdated or inefficient methods/equipment when improved, economically justifiable alternatives become available. (Update when needed).
18. Capacity Principle: Use handling equipment efficiently, aiming to utilize its rated load capacity where safe and practical. (Use capacity effectively).
19. Control Principle: Use MH systems to improve the tracking, identification, and control of materials throughout the operation. (Maintain control).
20. Performance Principle: Measure the performance of the MH system (e.g., cost per unit handled) and seek continuous improvement. (Measure and improve).

• Indian Example: A warehouse for Myntra (fashion e-commerce) applies several principles. The Unit Load Principle is used when receiving cartons on pallets. The Space Utilisation Principle guides the use of high racking systems. The Material Flow Principle dictates the layout for efficient movement from receiving to storage, picking, packing, and shipping. The Mechanisation Principle is evident in the use of conveyors for moving packed orders and potentially forklifts or reach trucks for storage. The Planning Principle is crucial for managing the complex flow during peak sale seasons.

Applying these principles systematically leads to more efficient, cost-effective, and safer material handling operations.