Material Handling Repair and Maintenance of Equipment

By SANJIVAN SAINI

The book "Material Handling: Repair and Maintenance of Equipment" provides a comprehensive overview of the principles, practices, and techniques involved in the repair and maintenance of material handling equipment. It serves as a valuable resource for individuals working in industries such as manufacturing, logistics, warehousing, and construction, where efficient and reliable material handling is crucial for operational
success.

Chapter 1: Material Handling
Introduction Basis and need of material handling, need, Manual handling, Types of material handling, In terms of specifications, characteristic reach / Load/ maneuverability /prime mover types  and control systems, For equipment without power and using handling machines (fixed / movable handling machines), Using handling machines within and outside industry in warehousing
Chapter 2. Material handling equipment:
 Types of Material handling Equipment For loading and unloading, Loading m/cs used for transportation vehicles, rail wagons, ships and
automatic movement in line production  Material handling Equipment precaution, Safety precaution to be followed while loading Precaution to be taken in gangways
Chapter 3. Material handling equipment for storages :
 Fork lifter, counter balanced rider, narrow aisle reach truck, bridge crane, jib crane, gantry crane, Pallet, straddle truck, reach trucks, order , picker trucks, storage trucks, platform truck and hand truck,  Conveyor: belt system and roller system, ropes, slings,  Safe working loads and breaking strength, testing and calibration of equipment and gears  Assessment of loads before starting, Inspection for safety work and
Emergency procedure
Chapter 4. Manual handling Equipment Operations:
 Manual Handling , Conditions for manual handling and precautions &safety in manual handling
 Storage system - pallet storage, bin shelving, gravity flow racks and carousels, Overhead handling operations and loading operations on ship ,  Safe handling of chemicals toxic gases, radioactive material and corrosive materials
Chapter 5. Maintenance of Equipments:
Maintenance schedule for loading machineries Daily, weekly, fortnightly, monthly, quarterly, half yearly, yearly maintenance,  Safety keeping and storing of lifting equipments and loading premises,  Preventive maintenance procedures and Procedure to generate
maintenance and service report.,  Diagnose error on MHE and preventive measures taken
Conclusion: The book "Material Handling: Repair and Maintenance of Equipment" by Sanjivan Saini serves as a comprehensive guide for professionals and practitioners involved in the maintenance and repair of material handling equipment. It covers essential topics, including maintenance principles, troubleshooting techniques, safety considerations, and equipment calibration. With its practical insights and systematic approach, the book aims to enhance the knowledge and skills of readers, enabling them to ensure the optimal performance and longevity of material handling equipment in their respective industr
 

• Language: English
• Publisher: SANJIVAN SAINI
• Release date: Sep 14, 2023
• ISBN: 9798223855750

SANJIVAN SAINI

Sanjivan Saini is the author of this book. He holds a Bachelor of Science degree in Mathematics from RRBMU University in Rajasthan, India. He has also a diploma in Logistics Technology from the MSME Technology Centre in Bhiwadi, Alwar, Rajasthan, India. With his academic background and practical experience in the field of logistics and supply chain management, Saini brings a deep understanding of the subject matter to this book.

Book preview

UNIT-1 Material Handling

1.1 Introduction And  Meaning Of Material Handling

Introduction to Material Handling: Material handling refers to the movement, storage, control, and protection of materials and products throughout various stages of manufacturing, distribution, consumption, and disposal. It involves a wide range of activities, equipment, and systems designed to efficiently and safely handle materials in industries such as manufacturing, warehousing, logistics, construction, and mining.

Meaning of Material Handling: Material handling encompasses all the processes and techniques involved in the transportation, storage, control, and protection of materials and goods. It includes activities such as loading, unloading, sorting, packaging, storing, and conveying materials using various equipment and systems like forklifts, conveyors, cranes, automated guided vehicles (AGVs), and robotics. The primary objective of material handling is to ensure the smooth flow of materials, optimize operational efficiency, minimize costs, reduce risks, and enhance workplace safety. Effective material handling plays a crucial role in improving overall productivity, customer satisfaction, and profitability in various industries.

1.2 Definition Of Material Handling

• Materials handling is the movement and storage of materials at the lowest possible cost through the use of proper methods and equipment.

OR

• Materials handling is the moving of materials or product by any means, including storage, and all movements except processing operations and inspection.

OR

• Materials handling is the art and science of conveying, elevating, positioning, transporting, packaging and storing of materials.

1.3 Basis and need of material handling

The basis and need for material handling can be understood by considering the following factors:

Efficiency: Material handling aims to improve efficiency in the movement, storage, and utilization of materials. By implementing effective material handling techniques and equipment, companies can reduce the time and effort required to handle materials, resulting in increased productivity and cost savings.

Safety: Material handling activities can involve heavy lifting, transporting bulky objects, working at heights, and operating machinery. Proper material handling practices prioritize safety to prevent accidents, injuries, and damage to goods or equipment. Implementing ergonomic designs, providing training, and using safety devices are essential for maintaining a safe working environment.

Inventory Management: Efficient material handling plays a crucial role in managing inventory effectively. It helps in organizing, tracking, and controlling the movement of materials, ensuring the right quantity of materials is available at the right time. This reduces inventory holding costs, minimizes stockouts, and improves overall supply chain performance.

Space Utilization: Effective material handling enables optimal utilization of storage space. By employing appropriate storage systems, such as racks, shelves, and automated storage and retrieval systems, companies can maximize their warehouse capacity and streamline material flow. This leads to efficient space utilization, reduced storage costs, and improved accessibility.

Cost Reduction: Material handling directly impacts costs associated with labor, equipment, inventory, and space. By implementing efficient material handling practices, companies can reduce labor requirements, minimize equipment downtime, optimize inventory levels, and utilize storage space more efficiently. This results in cost savings and improved profitability.

Customer Satisfaction: Timely and accurate delivery of products is crucial for customer satisfaction. Effective material handling ensures that goods are available when needed, reducing lead times and improving order fulfillment. This enhances customer satisfaction, builds customer loyalty, and strengthens the company's reputation.

In summary, the need for material handling arises from the desire to improve efficiency, ensure safety, optimize inventory management, utilize space effectively, reduce costs, and meet customer expectations. By implementing proper material handling techniques and systems, companies can enhance productivity, profitability, and overall operational performance.

Negative key factor of materials handling should also not be overlooked. These are:

(i) Additional capital cost involved in any materials handling system.

(ii) Once a materials handling system get implemented, flexibility for further changes gets greatly

reduced.

(iii) With an integrated materials handling system installed, failure/stoppage in any portion of it

leads to increased downtime of the production system.

(iv) Materials handling system needs maintenance, hence any addition to materials handling means

additional maintenance facilities and costs.

The essential requirements of a good materials handling system may be summarized as:

(i) Efficient and safe movement of materials to the desired place.

(ii) Timely movement of the materials when needed.

(iii) Supply of materials at the desired rate.

(iv) Storing of materials utilizing minimum space.

(v) Lowest cost solution to the materials handling activities.

Functional scope of materials handling within an industry covers the following:

(i) Bulk materials as well as unit materials handling. Bulk handling is particularly relevant in the processing, mining and construction industries. Unit materials handling covers handling of

formed materials in the initial, intermediate and final stages of manufacture.

(ii) Industrial packaging of in-process materials, semi finished or finished goods, primarily from the point of view of ease and safety of handling, storage and transportation. However, consumer packaging is not directly related to materials handling.

(iii) Handling of materials for storage or warehousing from raw materials to finished product stage.

1.4 Manual handling

Manual handling refers to the process of physically moving, lifting, carrying, or controlling objects or loads by human effort, without the use of mechanical aids or equipment. It is a common aspect of material handling in various industries and workplaces. Manual handling tasks can include lifting boxes, pushing carts, carrying bags, or manipulating objects.

Functions of Manual Handling:

Load Transportation: Manual handling allows workers to transport objects or loads from one location to another, such as moving boxes from a storage area to a truck for delivery.

Load Placement: Manual handling involves placing or positioning loads in specific areas or on equipment, such as arranging materials on shelves or pallets.

Load Assembly: Manual handling may involve assembling components or parts manually to create a complete load or product.

Load Control: Manual handling tasks require workers to maintain control and stability of loads while moving or manipulating them, ensuring they are secure and do not pose a safety risk.

Challenges of Manual Handling:

Risk of Injuries: Manual handling tasks can put strain on the body, leading to injuries such as strains, sprains, back pain, and musculoskeletal disorders. Lifting heavy loads, repetitive motions, awkward postures, or improper techniques increase the risk of injuries.

Ergonomic Challenges: Manual handling often involves working in awkward postures, bending, twisting, or reaching, which can strain the body and increase the risk of ergonomic-related injuries. Improper body mechanics, such as lifting with the back instead of the legs, can further exacerbate these challenges.

Weight and Size Limitations: Manual handling has limitations on the weight and size of loads that can be safely lifted or carried by individuals. Heavy or bulky loads may require additional assistance or mechanical aids to ensure safe handling.

Lack of Training and Awareness: Inadequate training and awareness regarding proper manual handling techniques can lead to increased risk of injuries. Workers may not be aware of safe lifting practices, load distribution, or body mechanics, which can contribute to accidents and health issues.

Fatigue and Productivity: Manual handling tasks can be physically demanding, leading to fatigue and decreased productivity over time. Workers may experience decreased performance or efficiency due to physical exertion or repetitive motions.

Workplace Design and Layout: Challenges can arise from the layout of the workplace, such as narrow aisles, uneven surfaces, or obstacles that hinder manual handling tasks. Poorly designed workstations or inadequate equipment may further contribute to difficulties in manual handling.

To address these challenges, organizations should focus on implementing ergonomic principles and safe manual handling practices. This includes providing proper training to employees, promoting awareness of ergonomic techniques, assessing and modifying workplace design, and utilizing mechanical aids or equipment when necessary. By prioritizing safety and ergonomics, the risks associated with manual handling can be minimized, enhancing employee well-being and productivity.

1.5 Types of material handling In terms of specifications

In terms of specifications, there are various types of material handling methods and equipment used in different industries. Here are some common types:

Manual Handling: This involves the physical movement of materials by human effort, without the use of mechanical equipment. It includes tasks like lifting, carrying, pushing, and pulling objects. Examples include manually moving boxes, manually stacking items on shelves, or hand-carrying materials.

Conveyors: Conveyors are mechanical systems used to transport materials from one location to another. They use belts, chains, or rollers to move items along a fixed path. Conveyors are commonly used in industries such as manufacturing, distribution, and airports for automated material handling.

Cranes and Hoists: Cranes and hoists are used for lifting and moving heavy loads. They consist of a framework, cables or chains, and a lifting mechanism. Cranes are often used in construction, warehouses, and ports, while hoists are commonly found in manufacturing plants and assembly lines.

Forklifts: Forklifts are powered industrial trucks equipped with forks used to lift and move heavy loads. They are versatile and widely used in warehouses, distribution centers, and construction sites. Forklifts come in various types, such as counterbalance, reach trucks, pallet trucks, and order pickers.

Automated Guided Vehicles (AGVs): AGVs are autonomous or semi-autonomous vehicles used for