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MATERIAL MANAGEMENT

Mr. Kailash Vilegave.Dept. of Pharmaceutics,

Shivajirao S Jondhle college of Pharmacy

Asangaon, Thane

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CONTENTS

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

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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

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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

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Goals of Material Handling

Promote increased use of facilities Reduce tare weight (dead weight) Control inventory

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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

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Applications of material management equipment in pharmaceutical industry Production department Stores department

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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.

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Selection of material handling systems The best equipment is one that :

Permits smooth & continuous production flowInvolves less number of accidentsReduces production cycles timePromotes better working conditionLessens fatigue to the operatorsBrings down total material handling cost

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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.

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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.

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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.

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Life of equipment :-Proper periodic insepection,repairs & maintaences of equipment increases its life. smoothen the flow of materials & economize the production system.

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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.

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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.

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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.

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Pallet is one unit load 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.

Unit load & palletizaton

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Containerization uses 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.

Containerization

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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.

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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.

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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

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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.

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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.

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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.

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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.

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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

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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.

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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.

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Three wheel engine powered Electric fork-lift fork-lift

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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.

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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

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Air-operated hoist electric hoist

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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)

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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.

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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.

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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.

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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

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