Unit
- Definition: Material handling encompasses the movement, protection, storage, and control of materials throughout the manufacturing and distribution process. It includes all equipment, procedures, and systems used to move raw materials, work-in-process, and finished goods.
- Economic impact: Material handling costs typically represent 15-30% of total production expenses in manufacturing facilities. Efficient handling reduces labor, inventory carrying costs, and product damage, directly improving profit margins.
- Core objectives: The five main objectives are to reduce unit handling costs, decrease cycle times, improve space utilization, enhance safety, and maintain product quality. These objectives must be balanced against capital investment and operational constraints.
- System vs. equipment view: A systems approach considers how individual equipment pieces work together to achieve overall material flow. Piecemeal equipment selection without system integration often leads to bottlenecks and inefficiencies.
- Relation to supply chain: Material handling operations connect internal production stages and link to external logistics. Inbound receiving, work-in-process movement, and outbound shipping all rely on effective handling systems.
- Historical evolution: From manual labor to mechanized conveyors in the early 1900s, then to automated systems and robotics in the late 20th century. Current trends include smart sensors, IoT connectivity, and autonomous mobile robots.
- Key performance metrics: Throughput (units per hour), cycle time (order to delivery), utilization rate (equipment uptime), and damage rate (percentage of goods damaged). These metrics guide system design and improvement.
- Regulatory context: Occupational safety standards (OSHA in the US, similar bodies globally) govern material handling practices, including load limits, aisle widths, and operator training requirements.
Process Flow
- Stage 1 - Receiving: Inbound materials arrive and are unloaded from trucks or railcars using dock levelers, lift trucks, or conveyor systems. Verification against purchase orders occurs at this stage.
- Stage 2 - Inspection and storage: Materials are inspected for damage and quantity, then moved to storage locations using pallet jacks or automated guided vehicles. Inventory records are updated in the warehouse management system.
- Stage 3 - Picking and kitting: Orders are picked from storage using pick-to-light systems, voice picking, or automated retrieval. Components are kitted together for production or shipment.
- Stage 4 - Production feeding: Materials are transported to workstations using conveyors, AGVs, or manual carts. Just-in-time delivery minimizes work-in-process inventory.
- Stage 5 - Assembly and finishing: Parts travel through assembly lines or cells via conveyors or overhead monorails. Completed products move to packaging and final inspection.
- Stage 6 - Packing and shipping: Finished goods are packed, labeled, and staged at shipping docks. Outbound loads are consolidated and loaded onto trailers using dock equipment.
Safety Consideration
Hazard: Workers in material handling areas face risks from moving equipment, falling loads, ergonomic strain, and collisions between pedestrians and vehicles.
Mitigation: Establish clearly marked pedestrian walkways, provide operator training and certification, enforce load weight limits, and implement lockout/tagout procedures for maintenance activities. Regular safety audits reduce incident rates.
Quick Revision
- Material handling is the movement, protection, storage, and control of materials across the supply chain.
- Efficient handling reduces costs by 15-30% and improves safety and quality.
- A systems view integrates equipment and processes to avoid bottlenecks.
- The typical flow is receiving, inspection, storage, picking, production feeding, assembly, and shipping.
- Safety requires training, clear pathways, and adherence to load limits.