materialHandling

Material handling is the discipline concerned with the movement, protection, storage, and control of materials throughout their life cycle, from procurement to final disposition. It encompasses planning and management of the physical handling of goods, equipment, and information, with the aim of improving productivity, safety, and quality while reducing costs and waste.

In manufacturing and logistics, material handling covers inbound receiving, put-away, internal transport, processing, picking and packing, storage, and outbound shipping. It aligns with factory layout and warehouse design to optimize flow, minimize handling steps, and maximize space utilization. Systematic handling supports just-in-time production and accurate inventory control.

Common equipment and methods include storage solutions such as pallets, racks, and shelving; and handling equipment such as forklifts, conveyors, cranes, hoists, and automated guided vehicles. Automated systems, including automated storage and retrieval systems (AS/RS), sorters, and robotics, coordinate movement with warehouse or production software to improve throughput and accuracy.

Safety and ergonomics are central to material handling. Practices focus on stable load design, safe lifting, collision avoidance, and regular maintenance. Standardization of containers and unit loads, along with data capture and traceability, helps minimize damage and misplacement while facilitating planning and continuous improvement.

Modern material handling increasingly relies on digital systems such as warehouse management systems, inventory tracking, and IoT-enabled sensors. Trends include automation, vertical storage, dynamic routing, and analytics to optimize energy use and throughput across manufacturing and distribution networks.