Materials Handling Systems

Definition of Materials Handling Systems

• Materials Handling Systems refer to the methods, equipment, tools, and systems used to move, store, control, and protect materials and products throughout the process of manufacturing.
• It encompasses a variety of systems including conveyor belts, forklifts, automated guided vehicles (AGVs), and warehouse management systems.
• An effective material handling system is crucial for efficient operations and plays a significant role in reducing costs and maximising productivity.
• They not only ensure the safe and timely transport of materials but also that the right quantity of materials is moved to the right place at the right time.

Importance of Materials Handling Systems

• Materials Handling Systems can significantly reduce labour costs, as fewer workers are needed to manually move materials.
• It helps in reducing the risk of injury associated with manual handling of heavy or awkward goods.
• Effective materials handling can lead to less waste, as items are less likely to be damaged during transit.
• By improving the speed and efficiency of the manufacturing process, it can lead to increased company profitability.
• Proper materials handling is key to effective inventory management, ensuring the right stock levels and improving delivery times.

Types of Materials Handling Systems

• Unit load formation equipment such as pallets and skids are used to hold and secure goods in standard sizes for efficient handling.
• Transport equipment such as conveyors, trucks, and cranes are used for moving goods over short distances within a facility.
• Storage equipment includes racks, shelving, and bins used for holding goods over a period of time.
• Identification and control equipment like barcodes, RFID tags, and warehouse management systems are used to manage the flow and location of materials.

Challenges and Issues with Materials Handling Systems

• Implementing new material handling systems can involve high initial costs and significant changes to existing processes.
• The operation and maintenance of these systems can require specialised skills or training.
• Automated systems can be vulnerable to breakdowns or malfunctions, which can disrupt the manufacturing process.
• There can also be safety risks associated with heavy machinery or automated systems if not appropriately managed.

Materials Handling Systems in Practice

• Industries like manufacturing, logistics, and warehousing make extensive use of materials handling systems for efficient operations.
• Modern warehouses now utilise automated guided vehicles (AGVs) and drones for picking and moving goods, reducing the need for human labour.
• Many companies are now implementing the Internet of Things (IoT) to enhance their materials handling, using sensors and data analytics for improved efficiency and predictive maintenance.