Module 5 Material Handling and Warehouse safety
What is Material Handling?
Material handling means moving, lifting, storing, and controlling materials and products in
factories, warehouses, and other industrial places. This could be done manually or using
machines like forklifts, cranes, conveyors, or automated systems.
Why is Material Handling Important?
1. It improves how smoothly things run in a factory or warehouse.
2. Keeps the flow of materials under control, so nothing gets lost or delayed.
3. Faster service to customers, by speeding up delivery and reducing delays.
4. Safer working conditions, by using the right tools and techniques.
Example: In car manufacturing (like Maruti), parts move along a conveyor belt, and workers
assemble them at different points until a full car is ready.
Key Benefits of Good Material Handling
● Reduces total costs – can make up 25% of manufacturing costs.
● Handles parts many times – some parts are moved 50 times before the product is
ready!
● Improves safety – lowers the risk of accidents.
● Reduces damage – parts are moved carefully to avoid breakage.
● Shortens delivery times – faster handling leads to quicker deliveries.
● Better customer service – products reach on time, in good condition.
● Controls inventory – prevents overstocking or running out of items.
Four Dimensions of Material Handling
1. Movement – moving materials in and out of storage areas.
2. Time – making sure materials are ready when needed.
3. Quantity – moving the right amount to avoid waste or shortages.
4. Space – using warehouse or factory space wisely.
Types of Material Handling
1. Manual Handling
● Done by workers using hands or simple tools.
● Examples: lifting, carrying, filling boxes.
● Risk: can cause injuries if not done safely.
● Improvement: Use equipment like lifting tables or carts to reduce bending and lifting.
2. Automated Handling
● Uses machines or robots.
● Examples: conveyor belts, robotic arms, automated forklifts.
● Often still needs a human for loading/unloading.
● Saves time, reduces injuries, and improves accuracy.
Principles of Material Handling
These are the rules to follow for good material handling:
Principle What It Means
Planning Have a plan involving all departments and needs.
Unitization Group items into one package or unit for easy movement.
Systems Connect handling with storage and production efficiently.
Simplification Remove unnecessary steps to make handling faster and easier.
Ergonomics Design jobs and tools that are safe and comfortable for workers.
Standardization Use the same methods and tools across the facility where
possible.
Space Use Keep areas organized and make the best use of space.
Automation Use machines and technology to save time and effort.
Environment Design systems that are eco-friendly and reduce waste.
Safety Follow safety rules and use safe equipment to prevent accidents.
Main Goals of Material Handling Systems
1. Lower the cost per unit produced.
2. Reduce production time – faster processes.
3. Avoid delays and damage to materials.
4. Improve safety and working conditions.
5. Maintain or improve product quality.
6. Boost productivity by:
○ Keeping material flow straight and simple.
○ Reducing the distance materials travel.
○ Moving materials efficiently in fewer steps.
7. Use automation where possible.
8. Keep inventory under control.
What is Material Handling Equipment?
Material handling equipment includes all the tools, machines, and systems used to move,
store, protect, and control materials at any stage—whether it's during production, shipping,
storage, or disposal.
These are classified into four main categories:
1. Storage Equipment
Used to store materials when they are not being moved. These help save floor space and
organize items.
Examples:
● Racks: Hold pallets or goods neatly.
○ Types: Pallet racks, sliding racks, push-back racks.
● Stacking Frames: Stack items like containers without damaging them.
● Shelves, Bins & Drawers: Store small items neatly.
● Mezzanines: Platforms built inside buildings to create extra storage space above
ground.
2. Engineered Systems
These are automated systems designed to work together for efficient storage and
movement.
Examples:
● Conveyors: Move materials from one place to another—horizontally or vertically.
● AGVs (Automated Guided Vehicles): Computer-controlled vehicles that follow a
path and avoid obstacles using sensors.
● AS/RS (Automated Storage and Retrieval Systems): Large systems that
automatically pick and store items using machines like robotic arms or shuttles.
3. Industrial Trucks
These are vehicles used for moving materials either manually or with power.
Types include:
● Stack Trucks: Used for stacking goods.
● Non-Stack Trucks: Used just for moving goods.
● AGVs: Repeated here, as they are also a type of truck.
● Automated Electrified Monorails & Storage Transfer Vehicles: Used in large
warehouses to move goods efficiently.
4. Bulk Handling Equipment
Used for handling large quantities of materials—especially loose items like grains,
powders, liquids, or small packaged goods.
Examples:
● Conveyors: Different types are used based on material type.
● Stackers: Automatically pile bulk materials.
● Reclaimers: Retrieve bulk materials from storage piles using wheels or scrapers.
● Bucket Elevators: Buckets on a chain carry material upwards.
● Grain Elevators: Tall buildings that store and move grain.
● Hoppers: Funnel-shaped containers for pouring or dumping materials.
● Silos: Large storage structures (like for cement or grain), but without built-in lifting
equipment.
1. Product Movement in Material Handling
What is it?
It’s the movement of goods from one place to another inside a facility or across supply
chain stages.
Types of Product Movement:
Type Description
Inbound Receiving raw materials or finished goods from suppliers.
Internal Moving items within the same facility (e.g., storage → line).
Outbound Sending products to customers or distributors.
Return (Reverse) Handling returns, repairs, or recycling.
Methods of Movement:
Method Examples
Manual Handling Hand-carrying, using carts, dollies.
Mechanical Forklifts, cranes, hoists, conveyors, AGVs.
Automated Robots, conveyor belts, drones, AS/RS.
2. Cost in Material Handling
A. Types of Costs:
1. Direct Costs (Easily measurable):
● Labor: Salaries, training, overtime.
● Equipment: Purchase, fuel, maintenance.
● Energy: Power for machines.
● Storage/Warehousing: Rent, utilities.
● Packaging: Pallets, wraps, boxes.
● Transportation: Fuel, shipping, truck repair.
2. Indirect Costs (Hidden but important):
● Product Damage/Waste: Poor handling losses.
● Time Delays: Loading/unloading inefficiencies.
● Injuries: Compensation, medical costs.
● Shrinkage: Theft, spoilage, misplacement.
B. How to Reduce These Costs?
Strategy Category Key Techniques
1. Process Optimization Reduce manual touchpoints, smart layout, cross-docking.
2. Automation & Tech AS/RS, RFID/barcode scanners, AGVs, robotics.
3. Equipment Management Maintain machines, optimize routes, energy-efficient tools.
4. Workforce Management Train staff, plan shifts based on demand.
3. Product Load Activity in Material Handling
What is it?
It’s the process of preparing and placing goods onto transport (e.g., trucks, pallets,
containers).
Key Steps:
1. Preparation – Check orders & documents.
2. Sorting/Staging – Group goods by weight, size, and destination.
3. Packaging/Securing – Wrap and tie goods safely.
4. Loading – Use forklifts or manpower to load.
5. Final Inspection – Check weight balance and paperwork.
Types of Loading:
Type Description
Manual Loading For small/light items. Risk of injury, more time needed.
Mechanical Uses forklifts, conveyors. Faster, less manual effort.
Automated Robotic arms, AGVs. High investment but very efficient.
Challenges in Product Loading:
Challenge Impact
Load Imbalance Risk of vehicle tipping or product damage.
Time Delays Labor costs go up; delivery delays.
Product Damage Poor stacking or weak packaging causes losses.
Space Wastage Poor layout reduces truck/container capacity.
Efficiency Tips:
● Use Load Planning Software – Better space and weight balance.
● Standardize Packaging – Uniform sizes = easy stacking.
● Cross-Docking – Avoid storage; move goods directly from receiving to shipping.
● Train Staff – Fewer errors and safer loading.
● Invest in Equipment – Forklifts, automation = faster loading.
Dispatch Activity in Material Handling
Definition:
Dispatch activity is the process of managing the shipment of goods from a warehouse or
distribution center to their final destination. It ensures on-time delivery, cost control, and
efficient supply chain flow.
Key Steps in Dispatch Activity
Step Description
1. Order Processing Confirm orders, prepare invoices and shipping
documents.
2. Picking & Packing Locate items from storage and securely pack
them.
3. Labeling & Documentation Attach barcodes, shipping labels, and RFID tags.
4. Vehicle Allocation & Route Choose the right vehicle and route for delivery.
Planning
5. Loading & Final Checks Ensure cargo is secure and verify all paperwork.
6. Shipment & Tracking Monitor delivery using GPS or tracking software.
Types of Dispatch Systems
System Type Features Best For
Manual Dispatch Paper-based, manual entries. Prone to Small businesses.
human error.
Semi-Automated Uses WMS, barcode scanners. Less Medium-sized operations.
paperwork, better tracking.
Fully Automated AI logistics, real-time tracking, Large-scale and tech-ready
auto-route planning. operations.
Challenges in Dispatch
Challenge Impact
Order Processing Late shipments, unhappy customers.
Delays
Incorrect Shipments Returns, extra costs, inefficiency.
Poor Route Planning More fuel used, longer delivery times.
Load Imbalance Risk to vehicle safety and product
damage.
Compliance Issues Legal penalties and shipment delays.
Cost Optimization & Efficiency Tips
Strategy Benefit
Use Transportation Management System Automates routing and scheduling.
(TMS)
Real-Time GPS Tracking Better monitoring and quicker response to
delays.
Optimize Vehicle Loading Better space and weight use = fewer trips.
Cross-Docking Bypass storage and send items directly to
delivery.
Leverage AI/Data Analytics Predict demand, allocate fleet smartly, cut
waste.
Packaging in Material Handling
What is Packaging?
Packaging involves enclosing or protecting goods for:
● Storage
● Transportation
● Sale
● Use
Modern packaging also focuses on sustainability, consumer communication, and
handling convenience.
Purposes of Packaging
Function Description
1. Protection Prevents damage, contamination, and exposure to
weather.
2. Containment Keeps items secure, avoids leakage or spills.
3. Communication Displays product info, usage instructions, warnings,
branding.
4. Convenience Easy to handle, store, transport, and use.
5. Sustainability Uses eco-friendly materials to reduce environmental
harm.
Types of Packaging
Type Description Example
Primary Direct contact with the product. Bottle of juice, blister
Packaging pack of tablets.
Secondary Groups primary packs. Carton of toothpaste
Packaging tubes.
Tertiary For bulk handling/logistics. Pallets, shrink-wrapped
Packaging crates.
Specialized For special conditions like temperature or Insulated box for
Packaging hazardous goods. vaccines.
Sustainable Packaging Practices
Practice Details
1. Eco-Friendly Materials Use of recycled, biodegradable, or renewable materials.
2. Design for Use simple materials and clear recycling labels.
Recyclability
3. Lightweighting Use less material while keeping strength.
4. Reusability Design for reuse (e.g., refillable containers).
5. Innovation Use edible, plant-based, or water-soluble materials.
6. Sustainable Printing Non-toxic inks, minimal printing, waterless methods.
7. Certifications E.g., FSC label, Extended Producer Responsibility
(EPR).
8. Lifecycle Assessment Measure impact from production to disposal.
Innovations in Packaging
Innovation Type Description Example
1. Edible Packaging Can be eaten safely. Seaweed snack wraps.
2. Water-Soluble Dissolves in water. Detergent pods.
Packaging
3. Plant-Based Plastics From corn, sugarcane, Compostable cups.
algae.
4. Smart Packaging Has tech (sensors/QR Temperature sensors for food.
codes).
5. Mushroom Packaging From mycelium, Electronics protection.
biodegradable.
6. Air-Inclusive Designs Uses air instead of fillers. Air pillows in boxes.
7. Reusable/Returnable Designed for reuse. Steel containers, glass bottles.
8. Minimalist Packaging Only essential material Paper sleeve on box.
used.
9. Ink-Free Packaging No harmful printing. Embossed cardboard logo.
10. Multi-Functional Has a second use. Pasta box becomes
measuring tool.
WAREHOUSE SAFETY
1. History of Warehouse Safety
● Before 1970: No strict safety rules; focus was only on speed.
● Injuries were common due to:
○ Dangerous substances
○ Improper lifting
○ Poor equipment handling
● 1970: U.S. government established OSHA – Occupational Safety and Health
Administration – to enforce workplace safety rules.
2. Role of OSHA in Warehouse Safety
● OSHA ensures safe working environments by regulating hazards.
● Applies to:
○ Warehouses
○ Factories
○ Fulfillment centers
Top 10 OSHA Warehouse Safety Standards
1. Forklifts
2. Hazard Communication
3. Electrical – Wiring methods
4. Electrical – System design
5. Floor & Wall opening guards
6. Exits
7. Mechanical power transmission
8. Respiratory protection
9. Lockout / Tagout (LOTO)
10.Portable fire extinguishers
3. Why Warehouse Safety is Important
1. Protects Employees
● Ensures health and safety of workers.
● Prevents shutdowns and accidents.
● Was especially critical during the COVID-19 pandemic.
2. Increases Productivity
● Clean, organized spaces reduce clutter and improve movement.
● Smart layout (e.g., one-way workflows) boosts efficiency and safety.
3. Reduces Inventory Damage
● Proper storage prevents falling or breaking items.
● Helps protect both stock and employees.
4. Extends Equipment Life
● Correct use and maintenance prevent breakdowns.
● Training and certification reduce misuse.
● Automation tools also help — but require training to avoid new risks.
Best Practices for Warehouse Safety
● Conduct regular training & safety drills.
● Keep work areas clean and organized.
● Use safety signs and label hazardous areas.
● Perform routine maintenance of equipment.
● Ensure PPE (Personal Protective Equipment) is available and used.
COMMON WAREHOUSE SAFETY HAZARDS &
INJURIES
1. Manual Handling
● Involves lifting, stooping, twisting, reaching, etc.
● Can lead to muscle strain, back injuries, and fatigue.
Safety Tips:
● Don’t lift beyond your strength.
● Lift with your legs, not your back.
● Keep load close to your body.
2. Hazardous Chemicals
● Includes acids, flammables, toxins, oxidizers, etc.
● Can cause burns, poisoning, or respiratory issues.
Safety Tips:
● Use PPE (gloves, masks, goggles).
● Store in ventilated, marked areas.
● Provide proper handling training.
3. Heavy Equipment (e.g., forklifts)
● Risk of collisions, crushing injuries, and falls.
Safety Tips:
● Train operators.
● Maintain equipment.
● Use communication protocols & PPE.
4. Machine Entanglement
● Clothing, jewelry, or hair caught in machinery.
Safety Tips:
● Enforce dress code.
● Train employees on safe machine use.
● Inspect machines regularly.
5. Conveyor Belts
● Risk of crushed hands, finger injuries, or entanglement.
Safety Tips:
● Keep belt speed moderate.
● Don’t overload belts.
● Train workers and do regular maintenance.
WAREHOUSE SAFETY CHECKLIST
# Action Purpose
1 Set site-specific safety Based on layout, products, staff size.
standards
2 Schedule audits To ensure OSHA compliance & prevent
(daily/weekly/yearly) accidents.
3 Train employees regularly Initial + ongoing, especially after equipment
changes.
4 Install safety signage For exits, hazards, equipment use.
5 Check floors & walkways Keep clean, clutter-free, and mark lanes.
6 Audit warehouse layout Ensure safe movement, avoid congestion.
7 Provide PPE Hard hats, gloves, boots, glasses, etc.
8 Ensure good lighting Prevents visibility-related injuries.
9 Keep warehouse clean Reduces infection and injury risk.
10 Test fire safety equipment Ensure fire alarms and extinguishers work.
11 Label hazardous materials Prevents mishandling and accidents.
12 Follow proper storage Safe stacking of heavy or hazardous items.
protocols
13 Inspect loading docks 25% of warehouse injuries happen here.
14 Mark emergency exits clearly For safe and fast evacuation.
15 Designate forklift pathways Prevents collisions and chaos.