Material handling refers to the movement, protection, storage and control of materials and products throughout manufacturing, warehousing, distribution, and the overall supply chain. An optimised material handling system is essential for efficient logistics and operations. This comprehensive guide covers everything you need to know about principles, equipment, best practices and more for effective material handling.
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What is Material Handling and Why is it Important?Material handling incorporates the physical handling, storage, control and movement of raw materials, work-in-process inventory, and finished goods. It plays a fundamental role in the supply chain and impacts:
Productivity
Operational efficiency
Costs and profitability
Inventory management
Storage space utilisation
Safety and ergonomics
Smooth material flow is critical for meeting production and distribution requirements. Material handling solutions affect cycle times, throughput, and on-time delivery across the entire supply chain. Companies invest heavily in material handling systems and equipment to maximise productivity and efficiency while minimising costs.
Types of Material HandlingThere are three primary categories of material handling:
Manual HandlingThis involves moving materials entirely through human labour, without assistive equipment. Manual handling tasks include lifting, lowering, carrying, pushing, pulling, stacking, storing, replenishing, order picking, and more. It is most applicable for handling smaller loads or in isolated tasks.
Mechanical HandlingThis uses equipment to assist workers with handling tasks, while still requiring direct human involvement. Mechanical handling reduces worker strain and enables handling larger, heavier materials. Examples include hand trucks, carts, forklifts, conveyors, lifts, cranes, and other tools that aid material movement.
Automated HandlingThis utilises fully automated equipment and controls to handle materials with minimal human intervention. Automated systems include complex conveyor systems, automated storage and retrieval systems, autonomous mobile robots, robotic pick and place, sorting systems and more. Automating repetitive handling tasks improves consistency, output and reduces labour requirements.
10 Core Principles of Material HandlingStandardised handling methods, storage, equipment and unit loads improves consistency and maximises space.
Design tasks, equipment and workstations to minimise human strain and fatigue.
Maximise effective storage density and optimise layouts for material flow.
Automate material handling tasks through equipment and controls to boost throughput.
Optimise inventory quantities, locations and turnover to balance costs.
Select appropriate handling equipment matched to loads, routing and tasks.
Combine items into standardised units, pallets or containers when beneficial.
Provide proper lighting, safety controls, and ventilation for material handling.
Evaluate equipment and systems based on total cost, not just upfront cost.
Locate storage, equipment and stations for efficient material flow and minimal handling.
Types of Material Handling EquipmentThere is a vast array of material handling equipment available, ranging from simple manual aids to complex automated systems.
Basic Material Handling Equipment&#; Multi-wheeled tools to batch transfer loads
&#; Hold and organise inventory
&#; Access high storage locations
&#; Raise and lower materials
&#; Move loose materials
&#; Transport materials in batches
&#; Lift and transfer pallets and heavy loads
&#; Access high storage for each picking
&#; Operator-driven forklift for short transports
&#; Compact device to move pallets
&#; Tow multiple carts or trailers
&#; Transport materials between process steps
&#; Computerised storage and retrieval
&#; Robots to palletise, depalletise, sort items
&#; Automatically guided vehicles for material transport
&#; Route items based on destination
&#; Direct pickers to inventory locations
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&#; High-density storage and retrieval machine
And many other speciality material handling solutions&#;
Material Handling Process FlowThe material handling process is a systematic method employed to manage the movement of materials and products within a warehouse or between different stages of a supply chain process. This process spans from the initial receipt of materials to their eventual shipment to customers or movement to storage areas. By optimising material movement processes, you can streamline operations, enhance productivity, and ensure the efficient utilisation of available space within the warehouse. Here&#;s a breakdown of the steps involved in the material handling process:
This is the first stage where materials are received, inspected, and sorted. Proper equipment such as forklifts and conveyor systems are utilised to ensure smooth unloading and movement to the designated areas.
Post-reception, materials are moved to storage areas. The storage process should be optimised to ensure easy retrieval and minimal handling, thus reducing handling costs.
This involves selecting and gathering products in the right quantity as per customer orders. Automated equipment and systems like Automated Storage and Retrieval Systems (AS/RS) can be used to enhance picking efficiency.
Once picked, products are then packed and prepared for dispatch. Automated or semi-automated systems can expedite this stage, ensuring products are securely packed and ready for shipment.
The final step involves loading and unloading materials for shipment. Here, the use of equipment like forklifts and conveyor systems is essential to ensure timely and accurate deliveries.
Handling returns efficiently is also a part of the material handling process. Efficient systems should be in place to manage returns, restocking, or disposal.
Each of these stages requires a coordinated effort and the right material handling system in place to ensure that the flow of material is optimised throughout the supply chain. By following the principles of material handling, organisations can create an effective material handling system that caters to their specific operational needs and enhances overall supply chain efficiency.
Key Benefits of Effective Material HandlingOptimising a facility&#;s material handling system provides significant benefits:
Faster processing and order fulfilment
Increased throughput and productivity
Lower operational costs
Reduced labour requirements
Improved inventory control and accuracy
Better space utilisation
Enhanced worker ergonomics and safety
Higher customer service and satisfaction
Given its enormous impacts on supply chain efficiency, material handling deserves significant planning, resources and capital investment. By following proven principles and best practices, companies can achieve smooth, economical material flow.
In Summary: Material Handling Systems in Warehouses and Supply ChainEfficient material handling is vital for manufacturing, warehouse and distribution operations. Manual, mechanical and automated solutions each have advantages depending on the application. Optimising material movement, storage, inventory and costs through ergonomic equipment selection, standardised processes and automation ensures high productivity. Material handling should be a key priority for driving operational excellence.
At Pallite, we specialise in creating materials and warehouse storage solutions that work seamlessly with most material handling systems. Get in touch with our team today to find out how we can improve your warehouse.
Written by David Rose
Frequently Asked Questions about Material MovementMaterial handling refers to the process of moving, storing, controlling, and protecting materials, goods, and products throughout the process of manufacturing, distribution, consumption, and disposal.
Material handling equipment includes a variety of tools and systems used to move, store, control, and protect materials, such as conveyors, forklifts, and automated storage and retrieval systems.
Manual material handling involves the use of human effort for moving and handling materials, while automated material handling utilises machinery and control systems to handle materials with minimal human intervention.
Bulk material handling refers to the process of storing, transporting, and controlling bulk materials such as liquids, minerals, and food in large quantities.
A material handling system encompasses a range of equipment and methods used to move, store, control, and protect materials within a facility or at a site.
Material handling plays a crucial role in logistics by ensuring the efficient movement and storage of goods, which in turn enhances the overall supply chain operations.
Common material handling injuries include strains, sprains, and fractures. They can be prevented by adhering to safety protocols, using the correct equipment, and ensuring workers are properly trained.
The responsibility for safe operation of material handling equipment lies with both the employer and the employees. Employers must provide safe and well-maintained equipment, while employees must adhere to safety guidelines and operating instructions.
Material handling costs can be calculated by considering factors such as equipment acquisition and maintenance, labour, and energy costs, among others.
Factors to consider include the specific needs of your operation, the reliability and reputation of the supplier, the total cost of ownership, and the safety features of the equipment.
Various types of material handling equipment include storage, engineered systems, industrial trucks, and bulk material handling. Conveyors such as belt, screw, and pneumatic conveyors are used for handling bulk materials.
Common hazards include improper lifting techniques, inadequate training, and unsafe equipment or work conditions. Ensuring proper training and adherence to safety protocols can mitigate these risks.
Material handling robots, also known as automated guided vehicles (AGVs), are robots designed to move materials and goods efficiently within a warehouse or factory. They use sensors and navigation systems to transport heavy loads with zero or near-zero human intervention.
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Material handling robots are automated machines designed to move materials and goods efficiently in industrial settings. They rely on integrated technologies to navigate, pick up and place heavy loads with precision.
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Material handling robots come in many shapes and sizes for all sorts of different applications.
Here are the most common types:
These are stationary robots that move materials around a fixed area. They typically work within a rectangular area and move materials on a horizontal plane. Gantry robots are often used for large payloads and precise, repetitive movements.
They&#;re commonly seen in manufacturing facilities moving heavy materials or doing pick-and-place tasks.
SCARA is a nice acronym for Selective Compliance Assembly Robot Arm. These bots have two parallel rotating joints to move horizontally in the &#;X&#; plane. They are fast, precise, and ideal for light assembly work, packaging, and sorting small parts. SCARA robots are compact and take up little floor space.
Delta robots consist of three arms connected at the base that move simultaneously to pick up and maneuver payloads. They&#;re fast, flexible, and energy efficient. Delta robots are used for high-speed assembly, packaging, and sorting. They can handle light payloads at rates of up to 200 picks per minute.
Delta robots require a very small footprint and are often mounted on ceilings or walls.
These robots have three linear axes of motion &#; one vertical, one horizontal, and one lateral. They move very precisely along these three axes. Cartesian robots are typically used for precise, repetitive pick and place work, assembly, and handling of heavy loads. They provide high precision but slower speeds than other robot types.
They&#;re commonly found in factories and warehouses.
There are several other more specialized material handling robots like palletizers, depalletizers, pick and place robots, and autonomous mobile robots.
Robotics technology is rapidly advancing, so new types of robots continue to emerge out of the woodwork. If anything, that trend is set to accelerate in the coming years.
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