Selection of material handling Maintenance of material handling equipment Unit-load, palletization & containerization Types of material handling

1. MATERIAL MANAGEMENT
Mr. Kailash Vilegave.
Dept. of Pharmaceutics,
Shivajirao S Jondhle college of
Pharmacy
Asangaon, Thane
9/2/2012 1

2. CONTENTS
 Selection of material handling
 Maintenance of material handling equipment
 Unit-load, palletization & containerization
 Types of material handling
 References
9/2/2012 2

3. Materials Handling
 Material handling is an activity that uses the
right method to provide the right amount of
the right material at the right place, at the
right time, in the right sequence, in the right
position and at the right cost
9/2/2012 3

4. Goals of Material Handling
 The primary goal is to reduce unit costs of
production
 Maintain or improve product quality, reduce damage of materials
 Promote safety and improve working conditions
 Promote productivity
 material should flow in a straight line
 use gravity! It is free power
 move more material at one time
 mechanize material handling
 automate material handling
9/2/2012 4

5. Goals of Material Handling
 Promote increased use of facilities
 Reduce tare weight (dead weight)
 Control inventory
9/2/2012 5

6. Importance of Material management
 Increase in cost of raw materials & finished
products
 Delay in production schedule & long cycle
 Increase in in-process inventories
 Damage or loss of material & employee
safety liabilities
 Employee frustration & reduced morale
 Customers dissatisfaction
9/2/2012 6

7. Applications of material management
equipment in pharmaceutical industry
 Production department
 Stores department
9/2/2012 7

8. Functions of material handling
 Handling of unit load :-the principle of
containerization, unit-load & palletization are
employed for moving an optimum number of pieces
at a time to their ultimate destinations.
 Placement of equipment :-In production operations,
appropriate plant layout & proper placement of
equipment minimizes the movement of materials.
 Appropriate material handling equipment :-
Mechanical aids should be employed in place of
manual handling.
9/2/2012 8

9. Selection of material handling systems
 The best equipment is one that :
Permits smooth & continuous production flow
Involves less number of accidents
Reduces production cycles time
Promotes better working condition
Lessens fatigue to the operators
Brings down total material handling cost
9/2/2012 9

10.  Nature of material to be moved :- the size, weight,
delicacy, nature (solid, liquid, gas) of material &
chances of getting damaged during handling should
be considered.
Plant building & layout :-A multi-storeyed building
facilitates the use of gravity for material flow.
The door locations,sizes,ceiling heights, roof& floor
strenghts,columns,etc..
Production machines :-Different machines have
different outputs per unit time.
9/2/2012 10

11.  Type of material flow patterns :-A vertical flow
pattern requires elevators,conveyors,pipes
etc.,whereas horizontal flow patterns need
trucks, overhead bridges, cranes, conveyors
etc.
 Type of production :-Conveyors are more
suitable for fixed routes for continuous
process & powered trucks are suitable for
batch operation.
9/2/2012 11

12.  Cost of material handling equipment :-The initial cost
of handling equipment are high. when human
contact with product must be minimized, equipment
is the alternative, hence cost does not limit the
installation.
 Handling costs :-Economy in material handling can
be achieved by employing gravity-aided movements
& minimizing the distance of material travel. A
system that allows the product directly fall over the
material handling equipment is more ideal.
9/2/2012 12

13.  Life of equipment :-Proper periodic
insepection,repairs & maintaences of
equipment increases its life. smoothen the
flow of materials & economize the production
system.
9/2/2012 13

14. Maintenance of material handling
equipment
 Inspection :-all parts, open or covered are inspected
for wear & tear. Worn out or unworkable
components such as wire ropes, bearing & bolts, are
identified & remedial measures are taken. Breaks
are adjusted & lubricated wherever & whenever
necessary.
 Repairs :-After inspection, all repairable parts are
corrected & minor defected are rectified. open gear
transmission, coupling, riveted & bolted joints,
trolleys, breaks, guards etc., require frequent
repairs.
9/2/2012 14

15.  Overhaul:-involves dismantling the complete
mechanism & replacing the damage
components. Crane structure, buffers, rails,
open gear transmission, pulley blocks etc.,
may be overhauled & various sub
mechanisms may be aligned & adjusted.
9/2/2012 15

16. Unit-load, palletization & containerization
 It is easier & faster to move a hundred small
parts by grouping them into one unit than
moving them individually one by one. these
are collectively known as unit-load.
 For example, each formulation of tablet
contains a number of ingredients. For a lot
size, ingredients(raw materials) are weighed
& packed individually & loaded onto a pallet.
9/2/2012 16

17.  Pallet is one unit load Unit load & palletizaton
these are moved to the
production department by
suitable handling system.
 Depending on the types
of item to be transferred,
a suitable pallet can be
designed. for example,
items of irregular in shape
are liable to be damaged
by crushing, for such
items, a post pallet is
useful. small items can be
placed in a wire mesh-
box.
9/2/2012 17

18.  Containerization uses  Containerization
the principle of unit
load. in this system, a
big metal container is
filled with a number of
small products. many
such containers are
placed on a truck or
trailer that is pulled by
tractor or truck. such
containers can be
loaded on railway
trailers & transported.
9/2/2012 18

19. Types of material handling systems
 Conveyors:-are employed for transporting
materials in a fixed path, which may be
horizontal, vertical or inclined to different
locations of a factory. these prove
economical, if the flow of material is
continuous.
9/2/2012 19

20. Belt conveyors
 It is used in transporting containers (bottles)
for filling, capping, sealing, labeling, visual
inspection etc.,in production of
injectables,liquid orals, ointments & jellies.
 Several types of other conveyor are
available. example are roller conveyor, slat
conveyor, wheel conveyor, apron conveyor,
pusher bar conveyor, & bucket conveyor.
9/2/2012 20

21.  Belt Conveyors
 Conveys materials
along horizontal, and
slightly inclined paths
 Driven by power
operated roll mounted
underneath the
conveyor or at the one
end of the conveyor.
 supported on either
rollers or on metal
slider pan and we call
them roller conveyor
and slider conveyor
respectively
9/2/2012 21

22. Belt conveyors-advantages
 Belt can be made of asbestos fibers,
neoprene, Teflon, & vinyl polymer. cord belt
are also used.
 Belt conveyors are for general purpose
installation & available in relatively large
sizes. these can travel several kilometers as
in case of coal mines.
 Routine maintenance is easy.
 It is economical.
 Disadvantage-it is expensive.
9/2/2012 22

23. Pneumatic conveyor
 Pneumatic conveyor or pipeline conveyor is one of
the most commonly used handling techniques in
chemical industry. it is employed when the material
is light & bulky, for example, formulation of powder
insufflations.
 This type of conveyor is a closed system, handling
of unpleasant & injurious substance is easy. it is
used for transporting of granular(example,wheat)or
pulverized material(example,salt)through the pipes.
9/2/2012 23

24. Pneumatic Conveyors
 Involves the transportation
of a wide variety of dry
powdered and granular
solids in a gas stream.
 In most cases the gas is
normally air.
 Where special conditions
prevail, different gases are
used.
9/2/2012 24

25. Why Pneumatic Conveying?
 Advantages
 Dust free transportation of a variety of products.
 Flexibility in routing.
 Low maintenance and low manpower costs.
 Multiple use.
 Security.
 Ease of automation and control.
9/2/2012 25

26. Why Pneumatic Conveying?
 Disadvantages
 High power consumption
 Wear and abrasion of equipment
 Incorrect design can result in particle degradation
 Limited distance
 By virtue of the complex flow phenomenon which take
place, there is a requirement for high levels of skill to
design, operate and maintain systems
9/2/2012 26

27. Fork-lift trucks
 It consist of forks attached to a column of the
truck. fork can be lifted upto the desired
height with material(boxes) on them. the
material can be stacked at the proper place
very close to the roof in warehousing &
shinning area. fork-lift trucks are used for
short distance(40 to 70 meters) travel. these
are used for indoor applications.
9/2/2012 27

28.  Platform truck (low-lift)
is used for transporting
the palletised raw
materials of a lot-size
manually from the
warehouse to the
production area.
 Platform trucks (high
lift) is used for loading
the tablet granules into
double cone blender.
9/2/2012 28

29.  Three wheel engine powered
Electric fork-lift fork-lift
9/2/2012 29

30. cranes
 Cranes are employed
for lifting & lowering of
bulky items, packages
& boxes. these find
applications in heavy
engineering industry &
generally in intermittent
type of production.
9/2/2012 30

31. Hoists
 Hoists means lift or pull something up to
higher place (overhead position) with ropes.
this equipment is mounted on single rail fixed
at the height nearer to the roof. hence,
material are transferred along fixed path.
hoists find application in industries employing
chemical cleaning. Cranes are used for
heavy items & hoists are employed for small
items.s
9/2/2012 31

32.  Air-operated hoist electric hoist
9/2/2012 32

33. Slides, chutes & lifts
 Slides can be straight,
spiral & vibrating, &
made up of wood or
steel. these transfer
small jobs that can slide
down under gravity.
vibrating slides
transport material up &
inclined.(example,cigar-
ette factories)
9/2/2012 33

34. chutes
 Chutes have sheet metal or
roller base for transferring
components down the
incline. chutes generally
deliver the feed material
directly onto the conveyor to
reach the destination further.
 Spiral chutes are used for
transporting sealed vials
from aseptic area to packing
section using gravity
principle.
9/2/2012 34

35. Lifts
 Lifts are used to transport
material up in multi-
storeyed plants. it is a fast &
flexible equipment for floor
to floor travel.
 buckets or trays are
mounted on the endless
chain running from the
ground floor to the top floor.
the material can be loaded
into trays automatically.
9/2/2012 35

36. Tractors & trailers
 Three wheeled or four
wheeled tractors are
employed & fitted with an
IC engine drive. these are
used for outdoor
applications.
 Trailers are loaded with
the material & attached to
the tractor. it can be
either uncoupled from the
tractor or the material can
be dumped in respective
stations.
9/2/2012 36

37. References
 Pharmaceutical Production & Management by C.V.S. Subrahmanyam,
Vallabh Prakashan, first edition, pg. no. 260-267.
 Modern business organization & Management systems approach by
Prof.S.A.Sherlekar,V.S.Sherlekar, Himalaya publishing house, 5th
edition,pg.no.5.38–5.58.
 Applied production & operation management by Evans, Anderson,
Sweemey & Williams, 3rd edition, West publishing company ltd.
 Management (Task, responsibility & practices) by Peter F. Ducker,
Allied publication, Bangalore.
 The eastern pharmacist-1993
 www.google.com
9/2/2012 37

38. 9/2/2012 38