UNIT SIX
MATERIALS HANDLING
UNIT 6: MATERIALS HANDLING
6.1. Definition and Scope
6.2. Benefits of Proper Materials Handling
6.3. Influencing Factors and Control
6.4. Materials Handling Codes and Specifications
6.5. Materials Handling Equipment and Guidelines
6.6. Evaluation of Materials Handling
6.7. Materials Disposal Procedures and Practice in
Ethiopia
At the end of this unit students will be able to:
• Define materials handling
• Know Benefits of proper materials handling
• Identify Influencing factors of materials
handling
• Discuss Materials handling codes and
specifications
• Identify Materials handling equipment and
guidelines
6.1. Definition and Scope
Materials handling is:
• the movement and storage of materials
at the lowest possible cost through the
use of proper methods and equipment.
• the movement, protection, storage and
control of materials and products
throughout manufacturing, warehousing,
distribution, consumption and disposal.
As a process, material handling incorporates a
wide range of manual, semi-automated and
automated equipment and systems that support
logistics and make the supply chain work
Materials handling is the art and science of :
• conveying,
• elevating,
• positioning,
• transporting,
• packaging and
• storing of materials.
6.2. Benefits of Proper Materials Handling
The essential requirements of a good materials
handling system may be summarized as:
• Efficient and safe movement of materials to the
desired place.
• Timely movement of the materials when needed.
• Supply of materials at the desired rate.
• Storing of materials utilizing minimum space.
• Lowest cost solution to the materials handling
activities.
Functional scope of materials handling within
an industry covers the following:
1. Bulk handling is particularly relevant in the
processing, mining and construction
industries.
2. Unit materials handling covers handling of
formed materials in the initial,
intermediate & final stages of manufacture
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.
Handling of materials for storage or
warehousing from raw materials to finished
product stage.
6.3. Influencing Factors and Control
• Material handling management is
influenced by factors like the nature of the
material, facility layout, production flow,
and cost.
• Effective control involves optimizing
material flow, selecting appropriate
equipment, & implementing principles like
minimizing movement & standardization
Influencing Factors:
• Material Properties • Selecting Appropriate
• Facility Layout Equipment
• Production Flow • Implementing Material
• Cost Handling Principles
• Engineering Factors • Preventive Maintenance
• Material Flow • Automation and System
Integration
• Optimizing Material
Flow • Ergonomics
• Safety
• Material Properties: The type of material
(size, weight, fragility) significantly impacts
the selection of handling equipment and
methods.
• Facility Layout: The layout, including space,
ceiling height, and floor capacity, dictates the
suitability of equipment and routing.
• Production Flow: Whether production flow is
constant or variable between workstations
influences the need for automation and
system integration.
• Cost: Initial investment, operating costs, and
maintenance costs are crucial considerations
in selecting cost-effective equipment and
methods.
• Engineering Factors: Door and ceiling
dimensions, floor space, and structural
strength of the facility impact the selection of
equipment.
• Material Flow: The type of movement and
method selection (e.g., manual, automated,
conveyors) must be optimized for efficiency.
• Optimizing Material Flow: Efficient routing,
minimizing movement, and using appropriate
equipment ensure smooth material movement
through the facility.
• Selecting Appropriate Equipment: Choosing the
right equipment (e.g., forklifts, conveyors,
automated guided vehicles) based on material
properties, facility layout, and production flow.
• Implementing Material Handling Principles:
Principles like planning, standardization, work
simplification, and ergonomic considerations
contribute to an efficient system.
• Preventive Maintenance: Regular maintenance
and upgrades of equipment ensure reliability
and prevent downtime.
• Automation and System Integration: Using
automation and integrating systems (e.g.,
automated storage and retrieval systems) can
streamline operations and improve efficiency.
• Ergonomics: Prioritizing ergonomics in material
handling to reduce strain and injuries on
workers.
• Safety: Implementing safety measures and
providing personal protective equipment (PPE)
to ensure a safe working environment.
Material handling is a complex process that can
lead to injuries and costly medical costs. To
ensure a safer workplace, organizations should
consider six tips.
1. Minimize ergonomic risk factors
2. Provide personal protective equipment
3. Upgrade equipment
4. Reduce noise and vibration
5. Respond to reports of employee fatigue
6. Use the right equipment
1. Minimize ergonomic risk factors, such as
stressful postures, repetitive motions, and
forceful exertions. Implement control
measures to limit exposure to these risks.
2. Provide personal protective equipment, such
as eye protection, helmets, gloves, steel-toed
safety boots, and metatarsal guards.
3. Upgrade equipment, such as conveyor belts
and forklifts, to increase productivity and
profitability.
4. Reduce noise and vibration by using wheel
materials and shock-dampening casters.
5. Respond to reports of employee fatigue, as
cumulative fatigue can lead to
musculoskeletal disorders.
6. Use the right equipment, such as conveyor
belt systems, storage equipment, and bulk
material equipment, to make the process
safer, faster, and more efficient. Ensure that
only authorized and trained individuals
operate the equipment, regardless of its size
or simplicity.
6.4. Materials Handling Codes and
Specifications
Codification: the code numbers can identify the
various materials used in any organization.
• The codification is defined as giving a symbol or a
numerical code to a particular item.
• This number or symbol is the unique code
number of the item.
After classification of different items in the store in
to sub-groups and groups according to their
characteristics and use for exact identification of
that material or item a code is allotted.
• This code can be a number or symbol consisting
alphabets and numbers together.
Material handling codes are specific codes or
labels used to categorize and identify the
movement, storage, and loading/unloading of
materials within a supply chain. These codes
help streamline processes, improve efficiency,
and minimize costs. Here are some examples of
how material handling codes can be used:
• EAW and EAP: These are special handling
codes used in air cargo to indicate the
presence or absence of a document pouch
with a shipment.
• Fixed and Variable Path Equipment Codes:
Material handling equipment can be
categorized into fixed path (conveyors, chutes)
and variable path (forklifts) systems, and these
categories can be coded for record-keeping
and system optimization.
• Standardization Principle: Material handling
practices should be standardized wherever
possible, and this can be reflected in coding
systems for efficiency.
• Ergonomic Principle: Material handling
equipment should be designed with
ergonomics in mind, and this can be coded
into systems to ensure safe and efficient
interaction with the equipment.
• Energy Principle: Material handling processes
should consider energy consumption, and this
can be included in codes or labels for
efficiency.
In essence, material handling codes are a way to
organize and categorize the different types of
materials, equipment, and processes used in
material handling activities.
• These codes help optimize workflows, reduce
costs, and ensure that materials are handled
safely and efficiently.
Material Handling Coding
For example, the blue color for painting iron
parts is used and its code number can be
MACA2054.
• The suppliers or manufacturers also use their
trade names and numbers for the items,
which they sell.
• But these trade names or brand names of
companies are many a time confusing.
• They supply various items in the trade names.
For example, Bajaj company sell large variety
of goods by its trade name and symbol.
• Therefore, to avoid the confusion and to
purchase, store and supply to production
department a specific item of required
quality and characteristics the materials
management identify every item by a
unique code.
• All the organizations follow some method
of standard coding system.
There are different types of coding systems used
to suit different firms depending upon the type
of materials they are using and selling.
• Whichever method is used for coding, it
should be flexible and simple to adopt.
• It should not be confusing.
Advantages of Codification
• The long names and description of items need
not to be repeated every time when an item is
referred by code.
• It helps in accurate identification of a
particular item.
• Duplication of material is avoided.
• It helps in standardization of materials and
products and reduces variety of them.
• The storing of materials, sorting and
documentation becomes easier.
• It helps in location of materials.
• It helps in accounting and costing.
• It is useful for purchase department to select
suppliers.
• It is useful for communication of information
about materials.
Disadvantages of Codification
• The mistakes may be there in writing codes
and it is difficult to find out correct codes.
• Codes may be misunderstood.
• When large number of codes is used for
different materials, there may be confusion
• and it may be difficult to locate the materials
without knowing the codes.
Criteria for Effective Material
Handling Coding System
• Simplicity • Logical Structure
• Uniqueness • Standardized
• Conciseness • Material Identification
• Consistency • Inventory
• Flexibility Management
• Readability • Accurate Tracking
• Scalability • Reduced Errors
• Efficient Operations
• Simplicity: Easier to understand and use,
reducing training time and errors.
• Uniqueness: Each item or material should
have a unique code for accurate tracking.
• Conciseness: Codes should be compact and
easy to record and read.
• Consistency: The system should be consistent
across all items and departments.
• Flexibility: The system should adapt to
inventory changes without complete overhaul.
• Readability: Codes should be easily readable
by both humans and automated systems.
• Scalability: The system should accommodate
inventory growth without extensive changes.
• Logical Structure: The system should reflect
relationships between items.
• Standardized: Coding should follow industry
practices or company-specific standards.
• Material Identification: The code should
accurately and efficiently identify the material.
• Inventory Management: The coding system
should enable accurate tracking, control, and
reporting of materials.
• Accurate Tracking: The system should facilitate
accurate tracking of material movement.
• Reduced Errors: A well-designed coding
system can significantly reduce errors.
• Efficient Operations: An effective coding
system streamlines operations.
CODIFICATION SYSTEMS
The various types of systems of codification used
in the materials management are as follows.
(i) Numerical system
– Alpha-numeric system
– Decimal system
(ii) Alphabetical system
(iii) Mnemonic system
1. Numerical system:
• The numerical system of codification uses only
numbers as codes of various materials kept in the
stores.
• It is a simple method and most of the
organizations use this system of codification. It is
also easily understood.
• To represent different groups of items, simple
numbers are used.
The block numbers are used to represent materials
belonging to each of these items as sub-groups and
a dash (-) or stroke (/) symbol is used in between
the numbers to represent particular material in the
subgroup.
• Simple number: Either one number 0 to 9 is
allotted to each item of a group. If total items in a
group are more than 10, then two numbers 00 to
99 are allotted and so on.
• Block number: The material of same
characteristics or having similarities are sub-
grouped as one item. These materials of sub-
groups will be coded as block number. The block
can be of three or more numbers for example 1–
1000 or 1001–2000 etc.
• Symbol Dash (-) or stroke (/): It is used in
between numbers to represent the material
belonging to sub-group.
1.1. Alpha-numeric system:
• The alphabets and numbers together are used
in this system of coding.
• The group of items is coded by alphabets and
subgroups and items of these groups are
coded by numbers to identify the exact item.
• This system has advantage of both alphabetic
and numeric system.
• The numbers used also give specifications like
size, length, breadth, thickness, height,
volume and weight etc.
1.2. Decimal system:
This system of codification is similar to numeric system.
• In this system, 10 units of decimal numbers 0-9 are
used. Some significance is attached to every digit.
• Normally 7-8 digits are sufficient to give all
characteristics of items.
For example, first, second and third digits give class,
group and sub-group of items. Fourth to eighth digits
specify type, size, grade, shape and condition.
• The number before the decimal point represents sub-
assembly or class of items.
• If for any particular class characteristics more than 10
sub divisions are required then one digit decimal
system can be substituted by two-digit decimal system.
For example, for type, size and grade, more than 10
divisions are required then decimal is used after
every two digits for type, size and grade to codify
100 items in each from 00-99.
• The decimal codification system is flexible to
extend it but becomes complicated by using
decimal points at various places.
If the decimal point is wrongly inserted or omitted
in the code, the whole system will give wrong codes
and confusion will create for other departments.
• Therefore, it is necessary to put decimal at
correct place by understanding its significance by
stores person.
Method to be adopted and choice of equipment for
a materials handling system primarily depends on
the type of material/s to be handled.
• It is, therefore, very important to know about
different types of materials and their
characteristics which are related to methods and
equipment used for their handling.
• As innumerable different materials are used and
need to be handled in industries, they are
classified based on specific characteristics
relevant to their handling.
2. Alphabetical system:
• In alphabetical system the Alphabets‘ are used
as symbols or codes to identify the items of
stores.
• Group of items according to their nature and
use are allotted an alphabetical starting code
and other alphabets are used to identify exact
items.
• This system will be suitable when the number
of items in the store will be less.
• While coding by alphabets, the duplication of
symbols should be avoided. (A,B,C,D)
3. Mnemonic system:
• This coding system also uses alphabets but the
group of items according to their nature and
use are allotted an alphabetical starting code
from their names and other alphabets are
used to identify exact item.
• This is given below. Use of starting alphabets
as codes helps in memorizing the codes.
EXAMPLE: Raw Material, wood can be coded as
(RM-WD)
Material Handling Equipment Specification
Basic classification of material is made on
the basis of forms, which are Gases,
Liquids, Semi Liquids, Solids …
States of Matter
6.5. Materials Handling
Equipment and Guidelines
Material handling is a crucial aspect of industries
and factories, as it is the main units of
businesses that manufacture products.
Nowadays, there are numerous material
handling devices and applications that make the
handling process easier. These devices include:
• Transportation equipment and applications,
• Positioning applications,
• Applications to form unit loads properly, and
• Storage equipment.
• Transportation equipment and applications
are used to move products from one place to
another, with various types
Such as conveyors, cranes, industrial trucks,
hoists, balancers, manipulators, and industrial
robots.
Cranes are used when loads are too heavy to
move with conveyors, while industrial trucks can
carry more loads than conveyors.
• Positioning applications ensure that the
material is placed in the right way, enhancing
product quality and limiting damage.
Hoists are common for lifting heavy weights and
loads, while balancers help maintain product
quality during storage.
• Industrial robots can perform functions as
humans and have high capacities, making
them beneficial in handling and positioning
products.
• Unit loading equipment, such as pallets and
slip-sheets, is essential for maintaining
product integrity during transportation.
Pallets are made of wood, plastic, metal, and
rubber, while slip-sheets have multiple tabs for
safe and compact storage.
• Storage equipment is another important
factor to consider after manufacturing, with
options like double-deep racks and automatic
storage or retrieval systems.
• These systems provide additional safety and
accuracy, making the material handling
process more efficient and effective.
Material Handling Equipment covers various
• types,
• categories,
• functionalities, and
• applications.
Understanding the right equipment is crucial for
optimizing productivity and efficiency in various
industries.
• We offer customized solutions to meet specific
needs & enhance the material handling experience
• Forklifts: are essential for material handling,
lifting, and transporting heavy loads efficiently in
warehouses, distribution centers, and
manufacturing facilities. Load Mate offers a range
of forklifts tailored to different weight capacities,
ensuring smooth operations and safety
• Pallet Jacks: Pallet jacks, or pallet trucks, are
crucial for moving palletized goods and navigating
confined spaces. Load Mate offers high-quality
pallet jacks with precision control for streamlined
material handling processes.
• Conveyor Systems: We offer customized conveyor
solutions for facility layouts and material handling
needs, automating goods movement, reducing
manual labor, and enhancing material flow.
• Cranes: LOADMATE offers various crane types,
including overhead, gantry, and jib, for lifting and
moving heavy materials in construction and
manufacturing units, ensuring exceptional
performance and operational efficiency.
• Industrial Robots: Industrial robots revolutionize
material handling by automating tasks like
palletizing, sorting, and order fulfillment,
improving accuracy, speed, and productivity.
• Automated Guided Vehicles (AGVs): AGVs are
driverless vehicles that transport materials
autonomously, optimizing material flow and
minimizing human intervention. LOADMATE
offers customized AGVs for seamless
integration into operations.
• Hoists and Lifts: We offer various hoists and
lifts for vertical material and equipment
lifting, ensuring safety and efficiency in
material handling operations.
Choosing the right material handling equipment
is crucial for optimizing operations and
increasing productivity.
• We offer top-quality solutions for loading
equipment and material handling systems,
focusing on customer satisfaction.
• Elevate your material handling experience by
contacting us to find tailored solutions
Broadly material handling equipment’s can be
classified into two categories, namely:
• Fixed Path Equipment
• Variable Path Equipment
Fixed path equipment
• Fixed path equipment which move in a fixed path.
• Conveyors, monorail devices, chutes and pulley
drive equipment belong to this category.
A slight variation in this category is provided by the
overhead crane, which though restricted, can move
materials in any manner within a restricted area by
virtue of its design.
• Overhead cranes have a very good range in terms
of hauling tonnage and are used for handling bulky
raw materials, stacking and at times palletizing.
Variable Path Equipment
• Variable path equipment have no restrictions
in the direction of movement although their
size is a factor to be given due consideration
trucks, forklifts mobile cranes and industrial
tractors belong to this category.
• Forklifts are available in many ranges, they are
maneuverable and various attachments are
provided to increase their versatility.
Guidelines for effective utilization of
material Handling equipment
The following guidelines are invaluable in the
design and cost reduction of the materials
handling system:
• As material handling adds no value but
increases the production cycle time, eliminate
handling wherever possible. Ideally there
should not be any handling at all!
• Sequence the operations in logical manner so
that handling is unidirectional and smooth.
• Use gravity wherever possible as it results in
conservation of power and fuel.
• Standardize the handling equipment to the
extent possible as it means interchangeable
usage, better utilization of handling
equipment, and lesser spares holding.
• Install a regular preventive maintenance
program for material handling equipment so
that downtime is minimum
• In selection of handling equipment, criteria of
versatility and adaptability must be the
governing factor. This will ensure that
investments in special purpose handling
equipment are kept at a minimum.
• Weight of unit load must be maximum so that
each ‘handling trip’ is productive.
• Work study aspects, such as elimination of
unnecessary movements and combination of
processes should be considered while installing a
material handling system.
• Non-productive operations in handling, such as
slinging, loading, etc., should be kept at a
minimum through appropriate design of
handling equipment. Magnetic cranes for scrap
movement and loading in furnaces combination
of excavators and tippers for ores loading and
unloading in mines are examples in this respect.
• Location of stores should be as close as possible
to the plant which uses the materials. This avoids
handling and minimizing investment in material
handling system.
• Application of OR techniques such as queuing can
be very effective in optimal utilization of
materials handling equipment. A very important
aspect in the design of a material handling system
is the safety aspect.
• The system designed should be simple and safe
to operate.
• Avoid any wasteful movements-method study
can be conducted for this purpose.
• Ensure proper coordination through judicious
selection of equipment and training of workmen.
6.6. Evaluation of Materials Handling
The cost factors include investment cost, labor
cost, and anticipated service hours per year,
utilization, and unit load carrying ability, loading
and unloading characteristics,
• operating costs and the size requirements are
the factors for evaluation of material handling
equipment.
Other factors to be considered are source of
power, conditions where the equipment has to
operate and such other technical aspects.
Therefore, choices of equipment in organization
will improve the material handling system
through work study techniques.
• They usually result in improving the ratio of
operating time to loading time through
palletizing, avoiding duplicative movements,
etc.
• Obsolete handling systems can be replaced
with more efficient equipment.
• The effectiveness of the material handling
system can be measured in terms of the ratio
of the time spent in the handling to the total
time spent in production.
• This will cover the time element.
• The cost effectiveness can be measured by the
expenses incurred per unit weight handled.
• It can be safely said that very few organizations
try to collate the expenses and time in this
manner so as to objectively view the
performance and to take remedial measures.
READING ASSIGNMENT
6.7. Materials Disposal Procedures and
Practice in Ethiopia
In Ethiopia, materials disposal procedures and
practices generally involve a mix of informal
and formal systems.
• While some materials are disposed of
through open dump grounds, there are also
efforts towards waste-to-energy facilities and
recycling initiatives, particularly in urban
areas like Addis Ababa.
• The government also plays a role in
managing public property disposal through
the Public Procurement and Property
Disposal Service (PPPDS). Elaboration:
• Open Dumping: Many landfills in Ethiopia,
including those in Addis Ababa, are open
dump sites with limited waste management
systems.
• Waste-to-Energy: A portion of Addis Ababa's
waste is processed at a waste-to-energy
facility like Reppie, demonstrating efforts
towards energy recovery from waste.
• Recycling and Reuse: Some waste is
collected and sold to recycling companies,
creating a system of informal and formal
recycling.
• Public Property Disposal: The PPPDS
handles the disposal of public property,
including sales, transfers, and other
methods like burial or dismantling for
scrap.
• Challenges: Challenges in waste
management include inadequate
infrastructure, limited capacity for landfills,
and insufficient awareness and education
about proper disposal practices.
• Legal Framework: Ethiopia has legal
frameworks, like Proclamation 300/2002,
addressing environmental pollution control
and the need for environmental impact
assessments before development projects.
• Hazardous Waste: There are regulations for
handling hazardous waste, including proper
packaging, labeling, and storage.
• Households and Medicines: Households
often dispose of expired medicines, but
there's a lack of awareness about proper
disposal methods.