What is Mechanical Material Handling? How do they classified? Explain different risk factors in Mechanical Material Handling.

Mechanical material handling refers to the use of machinery and equipment to move, lift, transport, and store materials in industrial and commercial settings. Unlike manual material handling, which relies on human labor, mechanical material handling utilizes various types of powered equipment to perform tasks efficiently and safely. These mechanical handling systems can range from simple conveyors to complex automated robotic systems, depending on the specific requirements of the operation. Mechanical material handling systems are classified into several categories based on their function and design:

1. Conveyors: Conveyors are one of the most common types of mechanical material handling systems. They consist of a continuous belt, chain, or rollers that move materials along a predetermined path. Conveyors can transport materials horizontally, vertically, or at inclines, and they are used in various industries such as manufacturing, distribution, and logistics.

2. Cranes and Hoists: Cranes and hoists are used for lifting and moving heavy loads in industrial settings. Cranes are typically stationary or mobile structures with a hoisting mechanism and a lifting hook or other attachment. Hoists, on the other hand, are smaller lifting devices that can be mounted on overhead beams or attached to a trolley for horizontal movement.

3. Forklift Trucks: Forklift trucks, also known as lift trucks or forklifts, are powered vehicles equipped with forks or other attachments for lifting and carrying loads. They are commonly used in warehouses, distribution centers, and manufacturing facilities to transport palletized goods and other materials over short distances.

4. Automated Guided Vehicles (AGVs): AGVs are self-guided, driverless vehicles equipped with sensors, navigation systems, and onboard computers. They are programmed to transport materials autonomously along predefined routes within a facility. AGVs are used in a wide range of applications, including material handling, assembly, and warehousing.

5. Robotic Material Handling Systems: Robotic material handling systems utilize industrial robots to perform various material handling tasks, such as picking, packing, sorting, and palletizing. These systems are highly versatile and can be customized to meet specific production requirements.

6. Storage and Retrieval Systems: Storage and retrieval systems are designed to store and organize materials efficiently within a warehouse or distribution center. They include automated storage and retrieval systems (AS/RS), pallet racking systems, shelving systems, and mezzanine storage platforms.

Mechanical material handling systems offer several advantages over manual handling, including increased productivity, improved efficiency, reduced labor costs, and enhanced safety. However, they also pose certain risk factors that must be carefully managed to ensure worker safety. Some of the common risk factors associated with mechanical material handling include:

1. Equipment Malfunction: Mechanical handling equipment such as conveyors, cranes, and forklifts can malfunction due to mechanical failures, electrical issues, or software glitches. Equipment malfunctions can result in accidents, injuries, and damage to materials or property.

2. Overloading: Overloading mechanical handling equipment beyond its rated capacity can lead to structural failure, tipping, or collapse. It is essential to adhere to weight limits and load capacities specified by equipment manufacturers to prevent accidents and injuries.

3. Collision Hazards: Mechanical handling equipment operating in confined spaces or congested areas may collide with stationary objects, other equipment, or pedestrians. Collisions can cause damage to equipment, injuries to workers, and disruptions to workflow.

4. Falls from Height: Workers operating cranes, hoists, or elevated platforms are at risk of falling from height if proper fall protection measures are not in place. Falls from height can result in serious injuries or fatalities and should be prevented through the use of guardrails, safety harnesses, and other fall protection equipment.

5. Caught-in or Caught-between Accidents: Workers can get caught in or between moving parts of mechanical handling equipment, such as conveyor belts, gears, or pinch points. These accidents can cause crush injuries, amputations, or fatalities if proper safeguards are not implemented.

6. Noise and Vibration Exposure: Operating noisy or vibrating mechanical handling equipment for extended periods can lead to hearing loss, hand-arm vibration syndrome (HAVS), and other occupational health problems. Workers should be provided with appropriate hearing protection and ergonomic controls to mitigate these risks.

7. Maintenance Hazards: Performing maintenance or repairs on mechanical handling equipment exposes workers to various hazards, including electrical shock, entanglement, and falling objects. Proper lockout/tagout procedures, personal protective equipment, and training are essential to prevent accidents during maintenance activities.

To mitigate these risk factors, employers should implement comprehensive safety programs that include hazard assessments, engineering controls, administrative controls, training, and personal protective equipment. Regular inspections, maintenance, and monitoring of mechanical handling equipment are also essential to ensure safe operation and prevent accidents in the workplace.