Material handling is a critical function in organizations across all sectors in Kenya, from hospitals and universities to banks and agricultural cooperatives. Efficient management and organization of material handling equipment ensure smooth operations, reduce waste, and enhance productivity. This chapter explores the fundamental concepts of material handling and the various types of equipment used to facilitate the movement, storage, control, and protection of materials throughout their lifecycle in professional settings.

2.1 Definition of material handling

Material handling is the movement, protection, storage and control of materials and goods throughout receiving, storage, production, dispatch and disposal. It covers every time an item is lifted, carried, loaded, stacked, picked or moved within the organisation's premises, whether by hand or by equipment. Handling adds cost but no value to the goods, so the aim is to move materials the shortest distance, the fewest times, safely and at the lowest cost. Example: in the store of a soft drinks distributor, material handling includes unloading crates from delivery trucks, moving pallets to the racks, picking orders for retailers and loading them onto dispatch vehicles.

2.1.1 Objectives of material handling

The objectives of material handling are the results the organisation wants from the way it moves and stores materials. They guide the choice of methods, equipment and layout.

• Reduce handling costs: Cut the labour, equipment and time spent on each movement by eliminating unnecessary handling and moving goods in larger units.
• Prevent damage and loss: Protect goods from breakage, spillage, contamination and theft while they are moved and stored.
• Improve safety: Reduce accidents and injuries caused by lifting, falling loads and moving equipment.
• Increase productivity: Speed up receiving, storage, picking and dispatch so that users and customers get materials on time.
• Make better use of space: Use floor and vertical space efficiently through stacking, racking and well-planned aisles.
• Improve material flow and control: Keep materials moving smoothly between operations, avoiding bottlenecks and delays, with accurate records of every movement.
• Maintain quality and continuity of supply: Goods reach users undamaged and on time, so production and customer service are not interrupted.
• Improve working conditions: Reduce fatigue and strain on workers by mechanising heavy and repetitive tasks.

2.1.2 Material handling methods

Material handling methods are the ways in which materials are moved, classified mainly by how much human effort and machinery is involved, and by the form in which the materials are moved. The right method depends on the nature, weight and volume of the goods, the distance and frequency of movement, and the cost.

Manual handling

Materials are lifted, carried, pushed or pulled by workers, with or without simple aids such as hand trucks and trolleys. It suits light items, small quantities, short distances and places where machines cannot work. Example: a stationery store issuing reams of paper to departments by trolley.

Mechanical (mechanised) handling

Powered or hydraulic equipment such as pallet trucks, forklifts, conveyors, hoists and cranes moves the materials, with an operator in control. It suits heavy loads, large volumes and frequent movements. Example: a cement distributor moving pallets of bagged cement with forklifts.

Automated handling

Computer-controlled systems such as automated storage and retrieval systems, automated guided vehicles and sortation conveyors move materials with little human involvement. It suits very high volumes of standard loads, where the investment is justified.

Unit load handling

Items are grouped into a single load, on a pallet, in a crate, a cage or a container, and moved as one unit. This reduces the number of movements and protects the goods. Example: cartons of cooking oil shrink-wrapped on a pallet.

Bulk handling

Loose materials such as grain, sand, cement or liquids are moved without packaging, using conveyors, pipes, pumps, chutes, silos or tankers.

Comparison of methods

2.1.3 Principles of material handling

The principles of material handling are guidelines that help design efficient and safe handling systems. They are applied together when planning a store or reviewing how goods move.

• Planning principle: Plan all handling and storage activities in advance, defining what is moved, from where, to where, how often and by what method.
• Standardisation principle: Standardise equipment, containers, pallets and procedures so that they work together and are easier to maintain.
• Work principle: Reduce handling work by shortening distances, combining or eliminating movements, and avoiding double handling.
• Ergonomic principle: Design tasks and equipment to suit human abilities, avoiding heavy lifting, twisting and repetitive strain.
• Unit load principle: Move materials in the largest practical unit load.
• Space utilisation principle: Use the full cubic space, including height, while keeping aisles clear.
• System principle: Integrate receiving, storage, picking and dispatch so that materials flow smoothly from one stage to the next.
• Automation principle: Mechanise or automate where it improves efficiency, safety and accuracy enough to justify the cost.
• Environmental principle: Choose equipment and methods that save energy and reduce waste and pollution, such as electric rather than diesel forklifts indoors.
• Life cycle cost principle: Compare equipment on its whole-life cost: purchase, operation, maintenance and disposal, not the price alone.
• Gravity principle: Use gravity to move materials where possible, for example gravity roller conveyors and chutes.
• Safety principle: Provide safe methods, equipment, training and protective gear for all handling activities.

2.1.4 Materials handling procedures

Materials handling procedures are the step-by-step instructions the organisation follows each time materials are moved, so that every movement is safe, authorised and recorded. A typical procedure for moving goods within a store is:

1. Receive an authorised instruction for the movement, such as a goods received note for putting away or a stores requisition for issue, so that no goods are moved without authority.
2. Identify the materials by code and description, and check their quantity, weight, size and any hazard markings.
3. Assess the load and the route: decide whether the load can be handled manually or needs equipment, and check that the route is clear.
4. Select the right equipment and protective gear, and carry out pre-use checks on the equipment.
5. Prepare the load: stack it securely, wrap or strap it if necessary, and keep within the safe working load of the equipment.
6. Move the load using safe lifting and driving practice, at a safe speed, with good visibility and warnings to others.
7. Place the materials in the correct location, stacked safely, with labels facing out, and following first-in first-out where required.
8. Record the movement on the bin card, stores ledger or inventory system, with the date, quantity, location and the person responsible.
9. Return equipment to its parking area and report any damage to goods or equipment.

Rules for manual lifting

• Plan the lift: Check the weight, the grip and the route before lifting.
• Stable base: Stand close to the load with feet apart.
• Bend the knees: Keep the back straight and lift with the leg muscles.
• Hold close: Keep the load close to the body and avoid twisting.
• Get help: Use team lifting or equipment for heavy or awkward loads.

2.1.5 Components of material handling

Material handling is a system made up of several components that must work together. Weakness in any one of them, such as untrained operators or a cramped layout, lowers the efficiency of the whole system.

• Materials: The goods being handled; their size, weight, shape, fragility, hazard and quantity decide how they are moved.
• Movement: The transfer of materials from one point to another, defined by distance, route, frequency and speed.
• Time: Materials must reach the right place at the right time to avoid delays in production or dispatch.
• Quantity: The amount moved at a time, from single items to full unit loads, which affects the choice of equipment.
• Space: The floor area, height and aisle widths available for movement and storage.
• Equipment: Trolleys, pallet trucks, forklifts, conveyors, hoists, racks and pallets used to move and hold materials.
• Methods and procedures: The agreed ways of moving and storing materials, as set out in 2.1.4.
• Personnel: Trained storekeepers, operators and supervisors who carry out the handling.
• Information and control systems: Records, labels, barcodes and inventory software that track where materials are and authorise each movement.

Chapter Summary

Material handling involves the movement, protection, storage, and control of materials throughout the manufacturing and distribution processes. Its objectives focus on improving efficiency, reducing handling costs, minimizing damage, and ensuring safety. Various methods are employed in material handling, guided by principles that optimize workflow, reduce unnecessary movement, and promote safety. Procedures for handling materials are structured to maintain consistency and protect both the materials and workers, relying on key components such as equipment, personnel, and systems. Different types of material handling equipment are used depending on the nature of the materials and the tasks involved, each requiring adherence to strict safety procedures to prevent accidents and injuries. Regular maintenance of this equipment is essential to ensure operational reliability and extend its service life. Proper documentation for storage equipment supports inventory management, accountability, and compliance with organizational standards.