ASSIGNMENT ON

MAJOR ASPECTS CONSIDERED IN STORAGE OF

DIFFERENT MATERIALS IN INDUSTRIES

SUBJECT: SAFETY IN INDUSTRIAL OPERATIONS AND DESIGN

SUBMITTED TO: Dr. M. N. KHAN
SUBMITTED BY: VARUN SINGH BISHT (ROLL NO 43/SAP ID 500016265)

INTRODUCTION
Material Handling is the movement, storage, control and protection of materials, goods and
products throughout the process of manufacturing, distribution, consumption and disposal. The
focus is on the methods, mechanical equipment, systems and related controls used to achieve
these functions. The material handling industry manufactures and distributes the equipment and
services required to implement material handling systems. Material handling systems range from
simple pallet rack and shelving projects, to complex conveyor belt and Automated Storage and
Retrieval Systems (AS/RS). Material handling can also consist of sorting and picking as well
as vehicles. Handling and storing materials involve diverse operations such as hoisting tons of
steel with a crane; driving a truck loaded with concrete blocks; carrying bags or materials
manually; and stacking palletized bricks or other materials such as drums, barrels, kegs, and
lumber. The efficient handling and storing of materials are vital to industry. In addition to raw
materials, these operations provide a continuous flow of parts and assemblies through the
workplace and ensure that materials are available when needed. Unfortunately, the improper
handling and storing of materials often result in costly injuries.

DEFINITION AND SCOPE OF MATERIALS HANDLING

Expressed in simple language, materials handling is loading, moving and unloading of
materials.To do it safely and economically, different types of tackles, gadgets and equipment are
used, whenthe materials handling is referred to as mechanical handling of materials.Since
primitive men discovered the use of wheels and levers, they have been moving materials
mechanically.Any human activity involving materials need materials handling. However, in the
field of engineeringand technology, the term materials handling is used with reference to
industrial activity. In anyindustry, be it big or small, involving manufacturing or construction
type work, materials have to behandled as raw materials, intermediate goods or finished products
from the point of receipt and storageof raw materials, through production processes and up to
finished goods storage and dispatch points.Materials handling as such is not a production process
and hence does not add to the value of theproduct. It also costs money; therefore it should be
eliminated or at least reduced as much as possible.
However, the important point in favour of materials handling is that it
helps production. Depending on the weight, volume and throughput of materials, mechanical
handling of materials may become unavoidable.In many cases, mechanical handling reduces the
cost of manual handling of materials, where such materials handling is highly desirable. All these
facts indicate that the type and extent of use of materials handling should be carefully designed
to suit the application and which becomes cost effective. Based on the need to be of optimum
design and application specific to different type of industries, materials handling can be as
diverse as industries themself. As a consequence, unfortunately, there is no universally accepted
definition of materials handling. One of the definition adopted way back by the American
Materials Handling Society is: Materials handling is the art and science involving the moving,
packaging and storing of substances in any form.Some of the other definitions are:

 Materials handling is the movement and storage of materials at the lowest possible cost through
the use of proper methods and equipment.
Materials handling is the moving of materials or product by any means, including storage, and
all movements except processing operations and inspection.
Materials handling is the art and science of conveying, elevating, positioning, transporting,
packaging and storing of materials.
There are other definitions also, but above few jointly bring out the salient features of materials
handling.It is referred to as an art and science because to most of the materials handling problem
no uniquesolution exists and more than one solution may be prescribed. Lot of subjective
considerations of thematerials handling engineer go into it. At the same time many scientific
factors are also considered toarrive at the solution. In one of the definitions, all the functions of
materials handling have been refered to which are conveying, elevating, positioning,
transporting, packaging and storing. Storage or warehousing is very much a part of materials
handling. Materials handling uses different equipment and mechanisms called Materials
Handling Equipment. Though in one of the definitions, processing operations
and inspection have been specifically excluded from scope of materials handling operations, it
is worth mentioning that in specific cases processing or inspection of materials may be
accomplished
simultaneously with handling activity. One definition also covers the important objective of
materials
handling which is lowest cost solution.
The essential requirements of a good materials handling system may be summarized as:
(i) Efficient and safe movement of materials to the desired place.
(ii) Timely movement of the materials when needed.
(iii) Supply of materials at the desired rate.
(iv) Storing of materials utilising minimum space.
(v) Lowest cost solution to the materials handling activities.
Functional scope of materials handling within an industry covers the following:
(i) Bulk materials as well as unit materials handing. Bulk handling is particularly relevant in the
processing, mining and construction industries. Unit materials handling covers handling of
formed materials in the initial, intermediate and final stages of manufacture.
(ii) Industrial packaging of in-process materials, semi finished or finished goods, primarily from
the point of view of ease and safety of handling, storage and transportation. However, consumer
packaging is not directly related to materials handling.
(iii) Handling of materials for storage or warehousing from raw materials to finished product
stage.
Often materials handling extends beyond the boundary of the industry in the form of movement
of raw materials from the sources to the plant or in the form of finished goods from the plant to
the points of consumption. These long distance movements of materials are generally termed as
transportation of materials through various modes of transport like, road, rail, ship or air.
Transportation is generally excluded from the scope of materials handling. However, at each of

the sources and destinations, loading and unloading of materials is necessary and these are
referred to as materials handling of these locations.
Some production equipment are fitted with facilities for handling of the materials being
processed. Such materials handling equipment are generally considered to be an integral part of
the production equipment.
A few typical examples are :
(i)
the feeding mechanism in an automatic machine,
(ii)
coiler and de-coiler in a strip rolling mill or
(iii)
paper feeding and transportation arrangement in a multi-station printing machine.
Essentially these are special material handling devices, but when integrated with
specific production machines, they become specialized parts of those machines. Such special
devices and their functions are generally not considered to be within the scope of materials
handling. However, materials handling at the workplace is an area which is drawing greater
attention after introduction of concepts of machining cells fitted with robotic handling devices.
IMPORTANCE OF MATERIALS HANDLING
The foremost importance of materials handling is that it helps productivity and thereby increases
profitability of an industry. Many enterprises go out of business because of inefficient materials
handling practices. In many instances it is seen that competing industries are using same or
similar production equipment, and one who uses improved materials handling system stays
ahead of their competitors.
A well designed materials handling system attempts to achieve the following:
(i) Improve efficiency of a production system by ensuring the right quantity of materials delivered
at the right place at the right time most economically.
(ii) Cut down indirect labour cost.
(iii) Reduce damage of materials during storage and movement.
(iv) Maximise space utilization by proper storage of materials and thereby reduce storage and
handling cost.
(v) Minimise accident during materials handling.
(vi) Reduce overall cost by improving materials handling.
(vii) Improve customer services by supplying materials in a manner convenient for handlings.
(viii) Increase efficiency and saleability of plant and equipment with integral materials handling
features.
Apart from these, for certain industries, like process industries, heavy manufacturing industries,
construction industries, mining industries, shipbuilding or aircraft industries etc., the materials
are so large and heavy that these industries just can not run without appropriate materials
handling system. All the above points clearly show the importance of materials handling in an
industry or a material transportation system. However, the negative aspects of materials handling
should also not be overlooked.
These are:
(i) Additional capital cost involved in any materials handling system.

(ii) Once a materials handling system get implemented, flexibility for further changes gets
greatly reduced.
(iii) With an integrated materials handling system installed, failure/stoppage in any portion of it
leads to increased downtime of the production system.
(iv) Materials handling system needs maintenance, hence any addition to materials handling
means additional maintenance facilities and costs.

SYSTEMS CONCEPT
In the previous sections materials handling has already been referred to as a system, and it will
be repeated many times in future. It is, therefore, important to understand the systems concept of
materials handling.
The term system has many meaning depending on the field where applied. A general
definition of the term could be: a complex unity formed of many often diverse parts subject to a
common plan or serving a common purpose. The important characteristics of a system is that the
parts, called subsystems, are interrelated and guided by an objective for which the system exists.
In an industry, materials handling is a subsystem (or part) of the production system. Materials
handling itself can also be considered to be a system whose subsystems are
(i)design or method to be adopted,
(ii) types of materials handling equipment to be used,
(iii) different operations like packing /unpacking, movement and storage involved,
(iv) maintenance required for the equipment employed,
(v) mode of transportation by the raw materials suppliers, distributors / customers, waste / scrap
collectors etc.
The common objective by which the different subsystems are guided is the lowest cost solution
of the materials handling system for that industry. In actual practice, the system concept of
materials handling means the different types of materials handling needed at different parts of an
industry and associated suppliers and customers end are to be considered in totality. Only this
approach will ensure an overall cost effective materials handling solution for the industry.
From a traditional point of view, a materials handling engineer may consider the materials
handling problem of a particular area as an individual, isolated case and produces the solution.
He may have produced the most economic solution for that problem alone, but it may not lead to
the overall lowest cost solution for the entire plant. There are many industries who are using
more than hundred sizes of containers/boxes within the same plant! This is the result of solving
materials handling problems of different areas in isolation. From systems point of view, the
materials handling problem of a plant along with its associated suppliers and customers
problems should be considered as one system and the subsystems have to be designed and
operated accordingly. This systems concept is a logical approach which can achieve the objective
of any materials handling scheme which is lowest cost solution.

What should employees know before moving, handling and storing materials?
In addition to training and education, applying general safety principles such as proper work
practices, equipment and controls can help reduce workplace accidents involving the moving,
handling, and storing of materials. Whether moving materials manually or mechanically, your
employees should know and understand the potential hazards associated with the task at hand
and how to control their workplaces to minimize the danger. Because numerous injuries can
result from improperly handling and storing materials, workers should also be aware of accidents
that may result from the unsafe or improper handling of equipment as well as from improper
work practices. In addition, workers should be able to recognize the methods for eliminating or
at least minimizing the occurrence of such accidents. Employers and employees should examine
their workplaces to detect any unsafe or unhealthful conditions, practices, or equipment and take
corrective action.
What are the potential hazards for workers?
Workers frequently cite the weight and bulkiness of objects that they lift as major contributing
factors to their injuries. In 1999, for example, more than 420,000 work place accidents resulted
in back injuries. Bending, followed by twisting and turning, were the more commonly cited
movements that caused back injuries. Other hazards include falling objects, improperly stacked
materials, and various types of equipment. You should make your employees aware of potential
injuries that can occur when manually moving materials, including the following:
Strains and sprains from lifting loads improperly or from carrying loads that are either too
large or too heavy
Fractures and bruises caused by being struck by materials or by being caught in pinch points
Cuts and bruises caused by falling materials that have been improperly stored or by incorrectly
cutting ties or other securing devices.
What precautions should workers take when moving materials manually?
When moving materials manually, workers should attach handles or holders to loads. In addition,
workers should always wear appropriate personal protective equipment and use proper lifting
techniques. To prevent injury from oversize loads, workers should seek help in the following:
When a load is so bulky that employees cannot properly grasp or lift it
When employees cannot see around or over a load
When employees cannot safely handle a load.
Using the following personal protective equipment prevents needless injuries when manually
moving materials:
Hand and forearm protection, such as gloves, for loads with sharp or rough edges.
Eye protection.
Steel-toed safety shoes or boots.

 Metal, fiber or plastic metatarsal guards to protect the instep area from impact or compression.
Employees should use blocking materials to manage loads safely. Workers should also be
cautious when placing blocks under a raised load to ensure that the load is not released before
removing their hands from under the load. Blocking materials and timbers should be large and
strong enough to support the load safely. In addition to materials with cracks, workers should not
use materials with rounded corners, splintered pieces, or dry rot for blocking.
What precautions should workers take when moving materials mechanically?
Using mechanical equipment to move and store materials increases the potential for employee
injuries. Workers must be aware of both manual handling safety concerns and safe equipment
operating techniques. Employees should avoid overloading equipment when moving materials
mechanically by letting the weight, size, and shape of the material being moved dictate the type
of equipment used. All materials handling equipment has rated capacities that determine the
maximum weight the equipment can safely handle and the conditions under which it can handle
that weight. Employers must ensure that the equipment-rated capacity is displayed on each piece
of equipment and is not exceeded except for load testing.
Although workers may be knowledgeable about powered equipment, they should take
precautions when stacking and storing material.
When picking up items with a powered industrial truck, workers must do the following:
Center the load on the forks as close to the mast as possible to minimize the potential for the
truck tipping or the load falling,
Avoid overloading a lift truck because it impairs control and causes tipping over
Do not place extra weight on the rear of a counterbalanced forklift to allow an overload
Adjust the load to the lowest position when traveling,
Follow the truck manufacturers operational requirements, and
Pile and cross-tier all stacked loads correctly when possible.

What precautions must workers take to avoid storage hazards?

Stored materials must not create a hazard for employees. Employers should make workers aware
of such factors as the materials height and weight, how accessible the stored materials are to the
user, and the condition of the containers where the materials are being stored when stacking and
piling materials. To prevent creating hazards when storing materials, employers must do the
following:
Keep storage areas free from accumulated materials that cause tripping, fires, or explosions, or
that may contribute to the harboring of rats and other pests.

 Place stored materials inside buildings that are under construction and at least 6 feet from hoist
ways, or inside floor openings and at least 10 feet away from exterior walls
Separate non compatible material
Equip employees who work on stored grain in silos, hoppers, or tanks, with lifelines and safety
belts.
In addition, workers should consider placing bound material on racks, and secure it by stacking,
blocking or interlocking to prevent it from sliding, falling, or collapsing.
What safeguards must workers follow when stacking materials?
Stacking materials can be dangerous if workers do not follow safety guidelines. Falling materials
and collapsing loads can crush or pin workers, causing injuries or death. To help prevent injuries
when stacking materials, workers must do the following:
Stack lumber no more than 16 feet high if it is handled manually, and no more than 20 feet if
using a forklift
Remove all nails from used lumber before stacking
Stack and level lumber on solidly supported bracing
Ensure that stacks are stable and self-supporting
Do not store pipes and bars in racks that face main aisles to avoid creating a hazard to
passersby when removing supplies
Stack bags and bundles in interlocking rows to keep them secure
Stack bagged material by stepping back the layers and cross-keying the bags at least every ten
layers (to remove bags from the stack, start from the top row first).
During materials stacking activities, workers must also do the following:
Store baled paper and rags inside a building no closer than 18 inches to the walls, partitions, or
sprinkler heads
Band boxed materials or secure them with cross-ties or shrink plastic fiber
Stack drums, barrels, and kegs symmetrically
Block the bottom tiers of drums, barrels, and kegs to keep them from rolling if stored on their
sides
Place planks, sheets of plywood dun age or pallets between each tier of drums, barrels, and
kegs to make a firm, flat, stacking surface when stacking on end;
Chock the bottom tier of drums, barrels, and kegs on each side to prevent shifting in either
direction when stacking two or more tiers high; and

 Stack and block poles as well as structural steel, bar stock and other cylindrical materials to
prevent spreading or tilting unless they are in racks.
In addition, workers should do the following
Paint walls or posts with stripes to indicate maximum stacking heights for quick reference
Observe height limitations when stacking materials
Consider the need for availability of the material
Stack loose bricks no more than 7 feet in height. (When these stacks reach a height of 4 feet,
taper them back 2 inches for every foot of height above the 4-foot level. When masonry blocks
are stacked higher than 6 feet, taper the stacks back one-half block for each tier above the 6-foot
level.)

Important Safety Measures

To reduce the number of accidents associated with workplace equipment, employers must train
employees in the proper use and limitations of the equipment they operate. In addition to
powered industrial trucks, this includes knowing how to safely and effectively use equipment
such as conveyors, cranes, and slings.
What safety measures should employers take regarding conveyors?
When using conveyors, workers may get their hands caught in nip points where the conveyor
medium runs near the frame or over support members or rollers. Workers also
may be struck by material falling off the conveyor, or they may get caught in the conveyor and
drawn into the conveyor path as a result. To prevent or reduce the severity of an injury,
employers must take the following precautions to protect workers:
1. Install an emergency button or pull cord designed to stop the conveyor at the employees
work station.
2. Install emergency stop cables that extend the entire length of continuously accessible
conveyor belts so that the cables can be accessed from any location along the conveyor.
3. Design the emergency stop switch so that it must be reset before the conveyor can be
restarted.
4. Ensure that appropriate personnel inspect the conveyor and clear the stoppage before
restarting a conveyor that has stopped due to an overload.
5. Prohibit employees from riding on a materials-handling conveyor.
6. Provide guards where conveyors pass over work areas or aisles to keep employees from
being struck by falling material.
What safety measures should employers take regarding cranes?
Employers must permit only thoroughly trained and competent workers to operate cranes.
Operators should know what they are lifting and what it weighs. For example, the rated capacity
of mobile cranes varies with the length of the boom and the boom radius. When a crane has a

telescoping boom, a load may be safe to lift at a short boom length or a short boom radius, but
may overload the crane when the boom is extended and the radius increases.
To reduce the severity of an injury, employers must take the following precautions:
1. Equip all cranes that have adjustable booms with boom angle indicators.
2. Provide cranes with telescoping booms with some means to determine boom lengths
unless the load rating is independent of the boom length.
3. Post load rating charts in the cab of cab-operated cranes.(All cranes do not have uniform
capacities for the sameboom length and radius in all directions around the chassisof the
vehicle.)
4. Require workers to always check the cranes load chart to ensure that the crane will not
be overloaded by operating conditions.
5. Instruct workers to plan lifts before starting them to ensure that they are safe.Tell workers
to take additional precautions and exercise extra care when operating around power lines.
6. Teach workers that outriggers on mobile cranes must rest on firm ground, on timbers, or
be sufficiently cribbed to spread the weight of the crane and the load over a large enough
area. (Some mobile cranes cannot operate with outriggers in the traveling position.)
7. Direct workers to always keep hoisting chains and ropes free of kinks or twists and never
wrapped around a load.
8. Train workers to attach loads to the load hook by slings,fixtures, and other devices that
have the capacity to support the load on the hook.
9. Instruct workers to pad sharp edges of loads to prevent cutting slings.
10. Teach workers to maintain proper sling angles so that slings are not loaded in excess of
their capacity.
11. Ensure that all cranes are inspected frequently by persons thoroughly familiar with the
crane, the methods of inspecting the crane, and what can make the crane
unserviceable. Crane activity, the severity of use, and environmental conditions should determine
inspection schedules. Ensure that the critical parts of a cranesuch as crane operating
mechanisms, hooks, air, or hydraulic system components and other load-carrying components
are inspected daily for any maladjustment, deterioration, leakage, deformation, or other damage.
What must employers do to ensure the safe use of slings?
As an employer, you must designate a competent person to conduct inspections of slings before
and during use, especially when service conditions warrant. In addition, you must ensure that
workers observe the following precautions when working with slings:
1. Remove immediately damaged or defective slings from service.
2. Do not shorten slings with knots or bolts or other makeshift devices.
3. Do not kink sling legs.
4. Do not load slings beyond their rated capacity.
5. Keep suspended loads clear of all obstructions.
6. Remain clear of loads about to be lifted and suspended.
7. Do not engage in shock loading.
8. Avoid sudden crane acceleration and deceleration when moving suspended loads.