Introduction:

This 5-day training course provides in-depth knowledge on material handling and storage solutions, crucial for optimizing logistics and supply chain operations. Participants will explore best practices, technologies, and modern innovations that contribute to safe, efficient, and cost-effective material handling systems. The course covers the entire lifecycle of material handling, from receiving to storage and shipping, with an emphasis on automation, ergonomics, and sustainability in the modern warehouse environment.

Objectives:

By the end of this training course, participants will be able to:

1. Understand the principles of material handling and storage systems and their role in supply chain efficiency.
2. Identify and select the most suitable material handling equipment (MHE) based on specific warehouse needs and challenges.
3. Implement ergonomics and safety best practices in material handling processes.
4. Optimize space utilization through efficient storage systems and layouts.
5. Leverage advanced technologies, including robotics, automation, and AI, to enhance material handling efficiency.
6. Address future challenges in material handling and storage, such as sustainability, automation, and scalability.

Who Should Attend:

This course is designed for professionals working in logistics, supply chain management, and warehouse operations. It is particularly suited for:

• Warehouse Managers and Supervisors
• Logistics and Supply Chain Professionals
• Operations Managers
• Material Handling Equipment (MHE) Supervisors
• Industrial Engineers
• Safety and Ergonomics Specialists
• Anyone involved in optimizing material handling and storage operations

Day 1: Introduction to Material Handling and Storage Systems

Morning Session:

1. Course Overview and Expectations
   • Icebreaker activity
   • Course goals and structure
2. The Importance of Material Handling in Logistics & Supply Chain
   • Defining material handling and its impact on warehouse operations
   • Relationship between material handling and overall supply chain efficiency
3. Types of Material Handling Equipment (MHE)
   • Manual, semi-automated, and fully automated equipment
   • Forklifts, conveyors, cranes, pallet jacks, and automated guided vehicles (AGVs)

Afternoon Session:

1. Principles of Material Handling
   • The 10 principles of material handling (e.g., minimizing handling, standardizing equipment)
   • How material handling systems reduce costs and increase productivity
2. Material Handling System Design
   • Designing an effective material flow system
   • Integrating material handling with warehouse layout and operations

Case Study:

• Analyzing a warehouse with inefficiencies in material handling and proposing solutions

Day 2: Equipment Selection and Ergonomics in Material Handling

Morning Session:

1. Selecting the Right Material Handling Equipment (MHE)
   • Factors to consider: product types, warehouse space, load size, throughput
   • Comparing manual vs. automated systems
2. Automated Material Handling Solutions
   • Automated Storage and Retrieval Systems (AS/RS)
   • Robotics, drones, and conveyor systems

Afternoon Session:

1. Ergonomics in Material Handling
   • The importance of ergonomics in reducing worker injury and improving productivity
   • Designing workstations and handling equipment with ergonomics in mind
2. Safety Standards and Practices
   • OSHA regulations and safety practices in material handling
   • Risk assessment and creating a safety culture in the warehouse

Workshop:

• Ergonomic evaluation of material handling equipment and processes

Day 3: Optimizing Storage Systems for Efficiency

Morning Session:

1. Storage Solutions and Systems
   • Different types of storage systems: shelving, pallet racks, cantilever racks, mezzanine floors
   • Selecting the right storage system for different types of products and operations
2. Optimizing Storage Space and Layout
   • Space utilization: vertical vs. horizontal storage
   • Dynamic storage vs. static storage solutions

Afternoon Session:

1. Automated Storage Systems
   • How automated storage solutions (e.g., AS/RS, automated palletizers) can improve efficiency
   • Benefits of integrating technology into storage solutions
2. Order Picking Systems
   • Types of picking systems: single order picking, batch picking, zone picking, wave picking
   • How to optimize picking efficiency and reduce picking errors

Group Exercise:

• Designing a storage solution for a specific product type with space constraints

Day 4: Leveraging Technology and Innovation in Material Handling

Morning Session:

1. The Role of Robotics and Automation in Material Handling
   • Using robotics for sorting, picking, and packing
   • Introduction to AGVs (Automated Guided Vehicles) and their impact on operations
2. Internet of Things (IoT) and Smart Warehouses
   • Real-time tracking and monitoring of inventory and equipment
   • How IoT enhances material handling efficiency and safety

Afternoon Session:

1. AI and Machine Learning in Material Handling
   • Predictive analytics for inventory management and demand forecasting
   • AI for optimizing routes, picking strategies, and material flow
2. Sustainability and Green Practices in Material Handling
   • Sustainable material handling solutions: energy-efficient equipment, waste reduction
   • Using recycled materials and green technology in storage and handling systems

Hands-on Activity:

• Exploring robotic systems and AI-based tools in material handling simulations

Day 5: Implementing and Managing Material Handling Systems

Morning Session:

1. Implementing Material Handling Systems in the Real World
   • Step-by-step process for integrating material handling systems into existing operations
   • Managing change: overcoming resistance and ensuring successful adoption
2. Performance Metrics and Continuous Improvement
   • Key performance indicators (KPIs) for material handling systems
   • Techniques for measuring and improving material handling efficiency

Afternoon Session:

1. Scalability and Future-Proofing Material Handling Systems
   • Designing systems that can scale with business growth and changing demand
   • Planning for future technology integration, such as drones and autonomous robots
2. Final Project: Design and Present a Material Handling Solution
   • Group project: designing a material handling and storage system for a fictional company

Closing Remarks:

• Review of key concepts and takeaways
• Certification and next steps for continued learning

Certification:

Upon successful completion of the course, participants will receive a Material Handling and Storage Solutions for Logistics & Supply Chain Certification.