Material handling involves the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal. Over the years, material handling processes have evolved significantly thanks to technological advancements and innovations in automation. Some of the key changes in material handling systems are discussed below.
Manual Material Handling to Mechanization
In the early years of industrialization, all Material Handling Equipment processes were carried out manually which involved physical labour. Workers would carry, lift and transport materials, components and finished products using simple tools like buckets, pallets and conveyor belts. While manual handling was inexpensive, it was inefficient, unsafe and affected productivity. The introduction of mechanized equipment in the late 19th century like hoists, pulleys and conveyor belts reduced some of the labour intensity. However, full automation was still a far reach and processes relied on both manual and mechanized methods.
Growth of Conveyor Systems
Conveyor systems emerged as a mainstream material handling solution in the early 20th century as they provided continuous and synchronized movement of materials. Different types of conveyors were developed for varied materials, speeds and transport requirements. Belt, roller, chain, pneumatic, vibratory conveyors revolutionized in-plant material flows. Factories were designed around conveyor networks to achieve lean production. Standardization of components also made conveyor systems scalable and customizable. Their reliability and throughput capabilities have since established conveyors as the backbone of automated material handling across industries.
Advent of Forklifts and Lift Trucks
As manufacturing plants expanded in size and inventory volumes grew exponentially post World War 2, there was a need for more heavy-duty material handling equipment with powered operation. Forklifts and lift trucks were introduced to efficiently transport pallet loads and bulk materials over short-medium distances within the factory premises and warehouse facilities. Internal combustion engines provided the necessary power-pack. Additional features like sideshifts, boom lifts and order picking attachments made forklifts a versatile asset. Their flexibility to operate in tight spaces accelerated complete mechanization of all material movement work.
March Towards Automation and Robotics
Introduction of programmable logic controllers and microprocessors in industrial automation equipment enabled higher levels of digitization and integration across various material handling and logistic systems. Automated guided vehicles came into prominence in the 1980s, operating on programmed routes to transport loads precisely. Then robotics and collaborative robots took over certain dangerous and ergonomically challenging material handling jobs. Advanced technologies like artificial intelligence, Internet of Things, cloud computing are now augmenting existing automated material handling infrastructure with real-time optimization, predictive maintenance and smart analytics capabilities.
Advent of Automated Storage and Retrieval Systems
Advancements in automated warehousing brought about specialized material handling solutions like automated storage and retrieval systems (ASRS). ASRS utilize computer-controlled storage and retrieval machines/robots along with vertical lift modules to dynamically store and retrieve loads from multi-tiered racks and shelving at high volumes and accuracy. High-rise ASRS maximize storage density while order picking robots expedite e-commerce fulfillment. Voice-directed technologies are also streamlining put-away and picking workflows. Such automated warehousing systems have transformed supply chain responsiveness.
Transition to Sustainability
With rising environmental consciousness, material handling is now embracing sustainable practices. Equipment manufacturers are using lighter yet stronger materials in machine designs. Conveyor belts made from recyclable plastics are common. Demand is growing for electric vehicles and automated guided carts powered by lithium-ion batteries or fuel cells. Some companies have invested in automated packaging lines to reduce waste. Overall, modern material handling systems focus on efficiency, optimized energy consumption, minimum emissions and maximum utilization of equipment lifecycle to lower environmental footprint.
Future Outlook
Integration of advanced technologies with existing material handling infrastructure will be a key priority going forward. Data analytics, predictive maintenance, robots, cobots, AI assistants, 3D printing will have bigger roles to play. Real-time fleet management, autonomous driving, distributed order management are areas attracting R&D. Advances in automation, robotics, virtual reality and brain-computer interfaces will push the boundaries of material handling possibilities. Sustainability will dominate equipment R&D. Overall, future-ready material handling systems will be clean, connected, collaborative and intelligent to handle high-throughput production and distribution demands efficiently.
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Money Singh is a seasoned content writer with over four years of experience in the market research sector. Her expertise spans various industries, including food and beverages, biotechnology, chemical and materials, defense and aerospace, consumer goods, etc. (https://www.linkedin.com/in/money-singh-590844163)