UPPSC AE Engineering Aptitude By HD Engineering Mantra (Harsh Dahiya)

Handling & Storage of

Products
(Complete Subject Marathon Class for
Civil Electrical Mechanical Agriculture Engineering)

1. Introduction to Handling & Storage of Products

2. Principles of Material Handling
3. Types of Material Handling Equipment
4. Factors Affecting Selection of Material Handling
Equipment
5. Storage of Products
6. Storage Equipment
7. Warehousing
8. Safety in Handling and Storage
9. Inventory Control Techniques
10. Emerging Trends in Handling & Storage
11. Common Handling and Storage Problems

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Chapter 1: Introduction to Handling & Storage of Products

1.1 Introduction
Handling and storage of products involves the safe and efficient movement, storage, control, and
protection of materials throughout the supply chain. This involves two key operations:
• Material Handling:
"It is the art and science of moving, storing, controlling, and protecting materials, goods, and
products throughout the process of manufacturing, distribution, consumption, and disposal."
• Storage:
"Storage refers to the act of keeping materials or goods in a designated space in an organized,
safe, and efficient manner until required for use or distribution."
Together, Material Handling and Storage form the backbone of logistics, inventory management,
and operational workflow in manufacturing, construction, and supply chain systems.

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1.2 Objectives of Handling and Storage

• Minimize material movement and handling time
• Reduce labor cost and fatigue
• Prevent damage or spoilage of products
• Improve safety and ergonomics
• Ensure easy and fast retrieval
• Optimize the use of space and resources
• Enhance production flow and delivery speed

1.3 Importance in Engineering and Industry

• In construction, proper handling and storage of cement, aggregates, steel, and tools prevents
wastage.
• In manufacturing, smooth material flow between machines increases efficiency.
• In logistics, effective storage and inventory reduce delays and costs.

1.4 Types of Materials Handled

• Bulk materials: Sand, gravel, coal
• Unit loads: Boxes, pallets, bags

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• Liquid and gases: Chemicals, oils, fuels

• Fragile items: Glass, electronics

• Perishable goods: Food, pharmaceuticals

1.5 Basic Activities Involved

1. Loading and unloading
2. Lifting and lowering
3. Carrying or conveying
4. Placing in storage
5. Retrieving for use or dispatch

1.6 Handling and Storage Lifecycle

1. Receiving goods
2. Transporting within the site
3. Storing in appropriate space
4. Maintaining inventory records
5. Issuing for use or dispatch

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1.7 Challenges Faced

• Damage due to improper handling
• Overstocking or understocking
• Wastage from poor storage conditions
• Accidents from unsafe handling
• Delays due to poor organization

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Chapter 2: Principles of Material Handling

Material handling is not just about moving things around. It must be planned, efficient, and safe. To
ensure this, engineers and managers follow a set of well-established principles.

2.1 Planning Principle

• All material handling activities must be pre-planned.
• Layouts, routes, equipment, and personnel should be organized in advance.
Example: Deciding conveyor paths during the plant design phase.

2.2 Standardization Principle

• Use standard methods and equipment for handling.
• Reduces cost, improves compatibility and maintenance.
Example: Using standard-sized pallets and containers.

2.3 Work Principle

• Reduce unnecessary movement of material.
• Aim to handle a product only once between two processes.
Example: Directly loading finished products onto trucks instead of moving them to temporary storage.
2.4 Ergonomic Principle
• Design handling systems considering human capabilities.
• Prevent fatigue, injury, and inefficiency.
Example: Adjustable height workbenches to avoid worker bending.

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2.5 Unit Load Principle

• Combine individual items into a single larger load for handling.
Example: Transporting 50 boxes together on a pallet instead of individually.

2.6 Space Utilization Principle

• Use all available space, especially vertical space.
• Helps in reducing storage area footprint.
Example: Use of pallet racks and multi-level shelving.

2.7 System Principle

• Material handling should be a part of the total system, not isolated.
• It must integrate with production, storage, and distribution.
Example: A conveyor system connected to both the packaging and dispatch sections.

2.8 Automation Principle

• Automate repetitive and high-volume handling tasks.
• Increases speed, consistency, and reduces errors.
Example: Using robotic arms to sort or place materials.

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2.9 Safety Principle

• Ensure safety of personnel, equipment, and products.
• Avoid overloading, maintain clear pathways, use guards and warning signs.
Example: Using forklifts with seat belts and warning beepers.

2.10 Environmental Principle (Modern Addition)

• Material handling should consider sustainability.
• Reduce emissions, waste, and energy use.
Example: Using electric forklifts instead of diesel ones.

2.11 Maintenance Principle

• Design systems to require minimal and easy maintenance.
Example: Using sealed bearings in handling machines to avoid frequent lubrication.

2.12 Flexibility Principle

• Equipment and methods should be adaptable to different materials and processes.
Example: Adjustable conveyor belts for different box sizes.

Summary Table of Principles

Principle Key Focus

Planning Pre-defined processes

Standardization Common equipment and methods

Work Minimum movement

Ergonomic Human efficiency and safety

Unit Load Combine items into single load

Space Utilization Efficient use of space

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System Integration with entire process

Automation Technology-driven movement

Safety Protect people and materials

Environmental Eco-friendly practices

Maintenance Ease of servicing equipment

Flexibility Ability to handle various tasks

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Chapter 3: Types of Material Handling Equipment

Material handling equipment (MHE) refers to the mechanical and manual devices used for moving,
lifting, transporting, storing, and controlling materials in industries, warehouses, construction sites,
etc.

3.1 Classification of Material Handling Equipment

Material handling equipment can be broadly classified into the following categories:
A. Manual Handling Equipment
Used for short distances and light loads. Operated by humans without power assistance.
• Hand Trolleys
• Wheelbarrows
• Sack Trucks
• Platform Trolleys
Example: Moving bricks at a construction site using a wheelbarrow.

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B. Mechanical Handling Equipment

Used for medium to heavy loads. Powered by electricity, fuel, or hydraulics.

i. Conveyors
Conveyors are continuous mechanical systems used for transporting materials horizontally, vertically,
or inclined over fixed paths.
• Belt Conveyor: Rubber belts used for smooth transport of unit/bulk materials.
• Roller Conveyor: Series of rollers to transport boxes or packages.
• Screw Conveyor: Helical screw used for powdery or granular materials.
• Chain Conveyor: Chains used for transporting pallets or heavy loads.
Applications: Assembly lines, airports, cement plants.

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ii. Hoists and Cranes

Used to lift and move materials vertically and horizontally in large areas.
• Overhead Crane: Suspended from the ceiling; used in workshops.
• Jib Crane: Has a rotating arm; suitable for workstations.
• Gantry Crane: Mounted on floor rails; used in shipyards and outdoor areas.
• Tower Crane: Tall structure used in multi-storey construction.
• Electric Hoist: Lifting device powered by electricity, mounted on hooks or cranes.

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iii. Industrial Trucks

These are wheeled vehicles used for flexible movement of materials.
• Forklift Truck: Lifts pallets; widely used in warehouses.

• Pallet Jack: Manual or electric tool for lifting pallets..

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• Platform Truck: Flat surface for carrying packages.

• Stackers: Used for stacking goods vertically.

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iv. Lifts and Elevators

Used to transport materials between vertical levels inside buildings or shafts.
• Goods Lift
• Hydraulic Lift
• Scissor Lift

v. Automated Material Handling Equipment

Used in modern warehouses and factories for high speed and precision.
• Automated Guided Vehicles (AGVs): Driverless vehicles that follow markers or lasers.
• Robotic Arms: Used for loading, unloading, sorting.
• Automated Storage and Retrieval Systems (AS/RS)

C. Bulk Material Handling Equipment

Used for handling loose, granular, or powdered materials.
• Bucket Elevators
• Hoppers
• Silos
• Screw Feeders

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• Stackers and Reclaimers

Used in: Power plants, cement plants, grain industries.

3.2 Summary Table

Type Example Use Case

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Manual Equipment Trolley, Wheelbarrow Light material movement

Conveyors Belt, Roller, Screw Assembly lines, warehouses
Cranes and Hoists Overhead, Jib, Gantry Heavy lifting and loading
Industrial Trucks Forklift, Pallet Jack Warehouse logistics
Lifts and Elevators Hydraulic Lift Multi-floor movement
Automated Equipment AGVs, Robots Modern logistics and precision
Bulk Material Equipment Silos, Hoppers, Stackers Powdered and granular handling

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Chapter 4: Factors Affecting Selection of Material Handling Equipment

Selecting the right equipment is critical for operational efficiency, safety, and cost-effectiveness. The
choice depends on multiple technical, economic, and operational factors.

4.1 Nature of the Material

• Shape and Size: Irregular or fragile shapes may require special containers.
• Weight and Volume: Heavy materials need powered equipment.
• Type: Solid, liquid, gas, or semi-fluid. Bulk materials need conveyors or hoppers.
• Fragility: Fragile items require smooth and cushioned handling.
• Toxicity or Reactivity: Hazardous materials require sealed and protected handling systems.

4.2 Distance to be Covered

• Short Distances: Manual or forklift-based handling.
• Long Distances: Conveyor belts or AGVs.
• Vertical Movement: Cranes, hoists, elevators.

4.3 Speed of Operation

• High-speed environments like airports, packaging, or assembly lines require automated or
semi-automated systems.

4.4 Frequency of Handling

• Frequent handling operations justify the use of automated or mechanical systems to save
labor and time.
• Infrequent operations can be handled manually or with basic equipment.

4.5 Layout of the Facility

• Space availability: Limited space may restrict large equipment use.
• Aisle width: isle width refers to the space between rows or shelves in a warehouse, store, or
other space where goods are stored or displayed. Narrow aisles suit pallet jacks over forklifts.

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• Building height: May influence stacking systems or overhead cranes.

4.6 Cost Considerations

• Initial Investment: High for cranes, AGVs, and automated systems.
• Operating Cost: Energy, maintenance, and labor.
• Return on Investment (ROI): Equipment should match the scale of operations.

4.7 Flexibility and Adaptability

• Equipment should be versatile to handle various sizes, weights, and materials.
• Adjustable conveyors, modular racks are preferred in dynamic operations.

4.8 Safety and Ergonomics

• Handling equipment must ensure worker safety and minimize injuries.
• Ergonomic tools reduce fatigue and improve productivity.

4.9 Maintenance and Reliability

• Equipment should be durable and easy to maintain.
• Choose brands with good support and service availability.

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4.10 Legal and Environmental Considerations

• Compliance with safety laws, pollution control, and material handling codes.
• Electric trucks and solar-powered lifts are preferred for eco-friendly operations.

4.11 Summary of Key Factors

Factor Influence on Equipment Choice

Material Type Determines suitable handling mechanism

Weight/Size Affects load capacity and grip type
Distance & Height Conveyor vs Crane vs Lift
Frequency of Use Manual vs Automated
Facility Layout Space restrictions and path design
Cost Budget limits and ROI
Flexibility Suitability for varied materials/tasks
Safety Requirements Protection for workers and goods
Maintenance Needs Availability of service and spare parts
Environmental Laws Use of energy-efficient equipment

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Chapter 5: Storage of Products

Storage refers to the process of safely keeping materials or products until they are needed for further
use, processing, or distribution. Efficient storage ensures material protection, space optimization,
and easy accessibility.

5.1 Objectives of Storage

• Protection of materials from damage, theft, and environmental conditions.
• Preservation of quality, shelf-life, and usability.
• Efficient space utilization.
• Facilitates inventory management.
• Supports continuous production or supply.

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5.2 Types of Storage

A. Based on Duration
1. Temporary Storage
o For short periods between processes.
o Example: Storage between machining and assembly.
2. Long-term Storage
o For products with seasonal demand or reserve stock.
o Example: Grain or cold storage.

B. Based on Temperature Conditions

1. Ambient Storage
o Normal temperature conditions.
o Example: Hardware items, furniture.
2. Cold Storage
o Controlled low temperatures for perishables.
o Example: Fruits, vegetables, meat.
3. Climate-Controlled Storage
o Humidity and temperature-controlled.
o Example: Pharmaceuticals, electronics.

C. Based on Product Type

• Bulk Storage – For loose, unpackaged materials (grains, cement).
• Unit Load Storage – For packaged goods stored in bins or racks.
• Hazardous Storage – Special storage for chemicals or flammable materials.

5.3 Principles of Good Storage

• FIFO or LIFO: Follow First-In-First-Out or Last-In-First-Out as required.
• Easy Accessibility: Items should be easily retrievable.
• Labeling: Clear identification of items.

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• Ventilation: Avoid moisture accumulation.

• Cleanliness and Safety: Prevent contamination or accidents.

5.4 Challenges in Storage

• Risk of deterioration, theft, or overstocking.
• Space congestion.
• Inaccurate stock tracking.
• Need for trained manpower and automated systems.

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Chapter 6: Storage Equipment

Storage equipment helps in organizing, stacking, and securing materials. The choice of equipment
depends on the material type, space, safety, and frequency of access.

6.1 Types of Storage Equipment

A. Shelving and Racks

1. Adjustable Steel Racks

o Modular height adjustment.
o Used in warehouses and libraries.

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2. Pallet Racking System

o Stores palletized goods.
o Allows access by forklifts.

3. Cantilever Racks
o For long items like pipes and timber.

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4. Bin Shelves
o Small compartments for nuts, bolts, and parts.

B. Containers and Bins

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1. Plastic/Metal Bins
o Stackable and reusable.
2. Wire Mesh Containers
o Visibility and ventilation.
3. Drums and Barrels
o Used for liquids or granules.
C. Silos and Hoppers
• For bulk storage of powders, grains, cement.
• Allow gravity-based discharge.

D. Mezzanine Floors
• Intermediate floors installed in warehouses.
• Increase vertical storage space.

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E. Vertical Lift Modules (VLM)

• Automated vertical storage that brings required trays to the operator.

F. Mobile Racking Systems

• Movable racks on rails to save aisle space

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6.2 Material Compatibility

• Corrosion-resistant racks for chemicals.
• Anti-static bins for electronics.
• Food-grade containers for edibles.

6.3 Safety Measures

• Load limits on racks.
• Fireproof materials for high-risk storage.
• Securing top-heavy racks against tipping.

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Chapter 7: Warehousing

Warehousing is the process of storing goods in dedicated buildings (warehouses) until they are
needed for production, sale, or dispatch.

7.1 Importance of Warehousing

• Ensures continuous supply of materials.
• Enables bulk purchasing and cost savings.
• Helps maintain buffer stock.
• Essential for export/import operations.
• Critical for logistics and supply chain operations.

7.2 Functions of a Warehouse

1. Receiving goods from suppliers.
2. Inspecting and sorting materials.
3. Storage under appropriate conditions.

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4. Inventory control and stock keeping.

5. Packing and dispatching for delivery.
6. Providing security and insurance.

7.3 Types of Warehouses

A. Based on Ownership
1. Private Warehouses
o Owned by companies for their own use.
o Example: Reliance, Amazon warehouses.
2. Public Warehouses
o Rented out to businesses; regulated by government.
3. Government Warehouses
o Owned and operated by the government.
o Example: Central Warehousing Corporation (CWC).
4. Co-operative Warehouses
o Operated by farmer co-operatives.

B. Based on Functionality
1. Distribution Centers
o Focus on high-speed goods movement.
2. Cold Storage Warehouses
o Refrigerated for perishable goods.
3. Bonded Warehouses
o For imported goods; customs duty paid later.
4. Smart Warehouses
o Use automation, robotics, sensors, AI.

7.4 Design of a Warehouse

• Location: Near transport facilities.

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• Layout: Clear movement path for forklifts, workers.

• Ventilation: To maintain air quality and temperature.

• Security: CCTV, fire alarms, fencing.
• Loading/Unloading Areas: Docks and ramps.

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7.5 Warehouse Management Systems (WMS)

Software used to manage and automate:
• Inventory tracking
• Barcode scanning
• Storage location optimization
• Order processing

7.6 Key Performance Indicators (KPIs) for Warehousing

• Space utilization
• Order fulfillment time
• Inventory accuracy
• Storage costs per unit
• Loss/damage ratio

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Chapter 8: Safety in Handling and Storage

Safety is a crucial aspect of material handling and storage, as it helps prevent accidents, injuries,
property loss, and downtime in industrial operations.

8.1 Importance of Safety

• Protects workers and equipment
• Prevents material damage

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• Reduces workplace accidents

• Ensures compliance with safety regulations
• Improves productivity and morale

8.2 Common Hazards

1. Manual Handling Injuries – Back strain, muscle injuries from lifting heavy loads.

2. Slips and Falls – Due to wet floors or scattered materials.

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3. Crushing/Impact – From forklifts or falling objects.

4. Fire and Explosions – Especially in chemical and fuel storage.

5. Ergonomic Risks – Poor posture or repetitive motions.

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8.3 Safety Practices in Handling

• Use proper lifting techniques (lift with legs, not the back).
• Use PPE (helmets, gloves, shoes).

• Train workers in safe use of handling equipment.

• Use appropriate tools for weight and shape of the load.
• Avoid overloading forklifts or cranes.

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8.4 Safety in Storage

• Label hazardous materials clearly.
• Store heavier items at lower levels.
• Maintain clear aisles and exits.
• Use fire safety systems (sprinklers, extinguishers).
• Secure racks and shelves to prevent toppling.

8.5 Legal and Regulatory Safety Standards

• Factories Act
• Occupational Safety and Health Administration (OSHA) guidelines
• Material Safety Data Sheets (MSDS)
• National Building Code provisions

8.6 Emergency Preparedness

• First aid kits
• Emergency exits and lighting
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• Fire drills and response teams

• Safety signage

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Chapter 9: Inventory Control Techniques

9.1 Introduction
Inventory control refers to the systematic approach to sourcing, storing, and selling inventory—
both raw materials and finished goods. The goal is to ensure that the right quantity of items is
available at the right time, minimizing costs while avoiding overstock or stockouts.

9.2 Objectives of Inventory Control

• Ensure uninterrupted production and supply
• Minimize inventory carrying costs
• Prevent wastage, pilferage, and obsolescence
• Improve customer service levels
• Optimize ordering and storage decisions
• Maintain accurate stock records

9.3 Types of Inventory

1. Raw Materials – Basic inputs used in manufacturing.
2. Work-In-Progress (WIP) – Semi-finished goods.
3. Finished Goods – Products ready for sale or dispatch.
4. MRO (Maintenance, Repair & Operations) – Tools, lubricants, cleaning supplies, etc.

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9.4 Key Inventory Control Techniques

1. ABC Analysis (Always Better Control)

Classification based on value and usage:

• A Items – High-value, low-quantity (≈10% items, ≈70% value)
Example: Expensive motors, precision tools
• B Items – Moderate value and quantity (≈20% items, ≈20% value)
• C Items – Low-value, high-quantity (≈70% items, ≈10% value)
Example: Nuts, bolts, washers
Purpose: Apply tight control over A items and relaxed control over C items.

2. VED Analysis (Vital, Essential, Desirable)

Primarily used for spare parts and maintenance materials:
• Vital – Essential for operation; non-availability stops production
• Essential – Needed but production may continue for short time
• Desirable – Non-essential items
Objective: Prioritize purchase and stocking of Vital items.

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3. EOQ (Economic Order Quantity)

EOQ determines the optimal quantity to order that minimizes total inventory cost (ordering +
holding).

EOQ Formula:

EOQ=√2𝐷𝑆/𝐻

Where:
• D = Annual Demand
• S = Ordering Cost per Order
• H = Holding Cost per Unit per Year
Benefits:
• Reduces total inventory cost
• Helps in budgeting and planning

4. FSN Analysis (Fast, Slow, Non-Moving)

Based on the rate of consumption or usage:
• Fast Moving (F) – High usage
• Slow Moving (S) – Moderate usage
• Non-Moving (N) – Obsolete or unused for long

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Objective: Identify and dispose of non-moving items to save space and cost.

5. HML Analysis (High, Medium, Low Cost)

Used for pricing-based classification:
• High-Cost Items – Close monitoring
• Medium-Cost Items – Periodic checks
• Low-Cost Items – Simplified controls
Helpful in budgeting and determining stock value.

6. SDE Analysis (Scarce, Difficult, Easy Availability)

Used in procurement planning:
• Scarce – Difficult to source, long lead times
• Difficult – Available but with some effort
• Easily Available – Readily available in the market
Objective: Plan purchasing cycles accordingly to avoid delays.

7. Just-In-Time (JIT)
Inventory is received exactly when needed in production, reducing carrying costs. Use kanban system
Advantages:
• Low inventory levels
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• Reduced storage needs

• Less capital tied up
Disadvantages:
• Risk of stockouts if supply chain is disrupted

8. Two-Bin System
Inventory is divided into two bins:
• First Bin – Regular use
• Second Bin – Reserve stock, triggers reorder when first is empty
Simple and visual system used for small parts and consumables.

9. Minimum-Maximum System
• Maximum Level – Highest quantity to be stored
• Minimum Level – Minimum required to prevent stockout
• Reorder Level – When fresh order should be placed
Helps in maintaining safety stock and preventing overstock.

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10. Perpetual Inventory System

• Real-time inventory record is updated with every issue and receipt.
• Requires barcode/RFID or computerized systems.
• Enables quick stock verification and minimizes theft/pilferage.

11. Cycle Counting

• Periodic physical counting of selected inventory items.
• Items are counted on a rotating schedule rather than all at once.
• Helps maintain inventory accuracy without full shutdown.

9.5 Stock Level Terminologies

Term Description
Reorder Level Stock level at which a new order must be placed
Minimum Level Lowest stock level to avoid production disruption
Maximum Level Maximum permissible stock to avoid excess inventory
Average Stock (Minimum Level + Maximum Level) / 2
Danger Level Critical stock level needing urgent replenishment
Lead Time Time between placing and receiving an order
Safety Stock Extra inventory to cover for uncertainties

9.6 Benefits of Inventory Control

• Reduced working capital
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• Better space utilization

• Improved order fulfillment
• Minimized wastage and losses
• Informed decision-making with real-time data

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Chapter 10: Emerging Trends in Handling & Storage

With technology advancement, handling and storage have evolved toward automation, intelligence,
and sustainability.

10.1 Automation and Robotics

• Automated Guided Vehicles (AGVs)
• Robotic Arms for picking and placing
• Conveyor automation
• Reduce labor and increase accuracy

10.2 Warehouse Management Systems (WMS)

A Warehouse Management System (WMS) is a software application that helps businesses manage and
control all aspects of their warehouse operations, from receiving goods to shipping them out. It
streamlines processes like inventory tracking, order fulfillment, and resource management, ultimately
improving efficiency and reducing costs.

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• Software for:
o Inventory tracking
o Order processing
o Barcode/RFID integration
o Location optimization
10.3 Use of Drones
• For inventory checks, mapping, and surveillance
• Faster and more accurate in large warehouses

10.4 Smart Shelving and IoT

• Shelves equipped with sensors
• Monitor real-time stock level, weight, temperature

10.5 Sustainability in Storage

• Eco-friendly materials for packaging and racks
• Solar-powered warehouses
• Rainwater harvesting and ventilation systems

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Chapter 11: Common Handling and Storage Problems

Despite best practices, industries face several recurring issues in handling and storage.

11.1 Common Handling Problems

• Manual handling errors: Overexertion, wrong lifting posture
• Mishandling by machines: Incorrect programming or overloading
• Delayed movement: Poor layout or equipment unavailability
• Damage during transit: Improper packaging or stacking

11.2 Common Storage Problems

1. Space Congestion
o Inefficient layout or overstocking.
2. Poor Inventory Management
o Leads to expiry, damage, or mismatch.
3. Pest Infestation
o Especially in food or grain storage.
4. Moisture and Corrosion
o Improper ventilation or temperature control.
5. Obsolete Stock
o No FSN or VED analysis performed.
6. Safety Hazards
o Unsecured racks, overloaded shelves.

11.3 Solutions to Handling & Storage Problems

• Regular training of workers
• Routine maintenance of equipment
• Use of WMS software
• Implement FIFO/LIFO systems

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• Redesign warehouse layout for smooth movement

• Adopt preventive safety measures

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