What is Material Handling, Principle, Factor Affecting, Classification?

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Definition Material Handling:

Material handling is defined as art and science of moving, packaging and sorting of materials in any form.

Material Handling Principles

  • Following are the seven material handling principles which provide a framework for selecting specific materials handling devices/ equipments.

(1) Use simple patterns of material flow:

Materials should move through the workstation in direct flow patterns, minimizing zigzagging or backtracking.

(2) Keep moving:

Related production processes should be kept in line as possible to provide direct material flow there by reducing material movement time.

(3) Eliminate handling:

The number of times each material is handled should be minimized.

(4) Carry full loads:

Mobile equipments should carry full loads all the time.

(5) Mechanized material handling devices:

Should be designed and located so that human effort is minimized.

(6) Heavy and bulky materials:

should be moved to the shortest distance during processing.

(7) System flexibility:

should allow for unexpected breakdown of materials handling equipments or changes in production system technology.

Factors Affecting the selection of material handling equuipments

  • The selection of materials handling equipment requires consideration to and attaining of proper balance between the following factors
  1. Production Related factors
  2. Capabilities of handling equipment
  3. The human element involved

(1) Production Related factors are:

  1. Volume of production to be attained: A high production volume will require handling equipments of larger capacities
  2. Class and type of material to be handled: Liquid or gaseous material will require a different type of material handling equipment than that required by a solid material
  3. The layout of plant and building facilities: A plant layout with multi story building will require lifts and such type of other equipments compared to a plant layout located totally on ground surface.

(2) Equipment factory are:

  1. Adaptability: The load carrying and movement characteristic of equipment should fit the material handling requirement
  2. Flexibility: Wherever possible, the equipment should have flexibility to handle more than one type and size of material
  3. Load Capacity: The equipment should have enough load carrying characteristic to do the job effectively
  4. Power: The equipment should have enough power available to do the job
  5. Speed: The speed of movement of equipment should be within the limits of production process and plant safety
  6. Space requirement: the space required to install or operate materials handling equipment is also an important consideration
  7. Supervision required:The degree of automation in handling equipment decides the amount of supervision required
  8. Ease of maintenance: Equipment selected should be capable of easy maintenance at reasonable cost
  9. Environment: The selected equipment must conform to the environmental regulations
  10. Cost: The cost of equipment is an obvious factor in selection of handling equipment

(3) The Human Factors

Human factors also play an important role of handling equipment and they are 

  1. The capabilities of available manpower to operate the handling equipment
  2. Safety of personnel, those who operate it or come into contact with the equipment

Classification of material handling equipments

  • The various types of material handling equipments can be classified into various ways as follows

(A) Classification on the Basis of material: (Nature of material)

Handling Equipment For Solid Material Like:


  • Hand Carts
  • Cranes
  • Fork Lifts
  • Conveyor Belts

Handling Equipment for Liquids Like:

  • Pipes
  • Barrels
  • Tanks
  • Canals (For Waste Mainly)
Handling Equipment For Gases Like:
  • Cylinders
  • Pipelines
(B) Classification as per path of movement:
  • Movement of material can be of fixed & repetitive nature or it can be variable.0
  • In continuous production systems, when one single item is manufacturing respectively. We have seen that cement, petroleum, fertilizer are such manufacturing systems. In these industries, as processes are standard, movement of material is also of similar type.
  • Because of this reason we see movement of material between two fixed points by fixed path material handling equipments. Elevators, pipe lines, conveyor belts are such examples. Many other type of equipment are variable path handling equipments where path of movement is not fixed.
  • It is needless to say that such equipment are found in intermittent production systems. Wheel mounted cranes, hand carts, fork-lift, are example of variable path equipments. It is understandable that fixed path equipments are more or fully automatic & variable path equipment are not so much automatic.
(C) Classification as per direction of movement:
  • There are separate types of equipments for vertical movement, horizontal movement, & for inclined movements Elevators /& pipes can for vertical movements
  • Hand-carts and fork-lifts are meant for horizontal movement. Pipelines, moving cranes & inclined conveyor belts can facilitate inclined movement also.
(D) Classification as per the starting point & destination of material movements:
  • There can be special equipments for material movement within a department or production area. They are called intra department handling equipments. Other equipments are meant for material movement between two different departments. They are called inter department handlingequipments.
(E) Classification of handling equipments as per degree of automation:

  • Material handling can be fully automatic equipments. Example are robotic systems, automatic storage. Fully automatic systems are usually fixed path handling systems. Some handling equipments are semi-automatic. Elevators and conveyor belts are examples of semi automatic handling systems. Hand carts, fork-lifts are manually controlled equipments. Variable path equipments are usually manually controlled.
(F) Classification as per source of power:

  • All types of handling of material require one or another source of power. Following chart shows the equipment classification as per source of power.
  • Handling Equipments
    • Manually powered Equipments
    • Fuel powered Equipments
    • Electric powered Equipments
      • Battery operated
      • online electric power source
    • Equipments using gravity
  • Examples:
    • Manually powered
      • Hand Carts, movement in cranes
    • Fuel powered
      • Fuel consumming cranes, fork-lifts
    • Gravity as the source of power
      • Down-ward liquid movement by pipelines, gravity chutes, controlled down-ward movement by elevators, conveyors
    • Online electric power source
      • Elevators
    • Battery operated
      • Battery operated fork-lifts

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