Handling of Materials

This is the first of a series concerning the handling of materials in a plant.

The handling of materials starts at the receiving door. Is there a system in place that accounts for the materials coming in and or do you place your own part numbers on the materials that are now stored into your facility.  Is the receiving person aware of the materials and the requirements for said materials? Do they understand that when the
forklift damages a bag of carbon filled PEEK that its dollars that are spreading on the floor and not just pellets? Is there a system for handling samples that arrive, or are addressed to the engineer or other persons in the plant?
The current system worked with three machines and 10 employees but you now have 20 machines and 35 employees. Ever been waiting for the sample to test the mold with, only to find out you had it on the dock for a week but no one knew what it was.

When we bring it into our warehouse how are we stacking and storing the materials?  Is the storage of materials 3 or 4 partial pallets high and, are the rows of materials all the same or mixed? Is it a first in last out system where you find 2-year-old nylon and wonder whether it is dry or can ever be dry?

Some suggestions or ideas for your raw materials:

1- Record the incoming materials and include: Type, Grade, Color number, lot numbers, box numbers, amount and any other info for your system.
2- Use any system you find that works well for your operation and personnel for inventory management. This could be as simple as a cardex type that is manual with inventory in and out system to a piece of software using bar codes.
3- Store your materials so that there is a constant rotation of stock, or have procedures in place to where you do rotate stock.
4- Educate the personnel about materials/products they are handling. Education would not only include the MSDS, Prop. 65 (usually listed on the MSDS), but also procedures for broken bags, boxes, about what to do and how to do it, with materials on hand to take care of it.
5- Have procedures in place for accepting and rejecting shipments and or broken bags, boxes etc. If the plant is on JIT than have the variance procedures in place.
6- Make sure that housekeeping practices are adhered too. Have a "Save the Pellet" program in place for the warehouse and the whole of the plant and grounds.
7- If stacking materials check for safety, if storing in pallet racks the units need be anchored. Any material placed in the rack should be secure on its own. ( given the earth's chance of rocking on occasion)

The list is not complete but a start, look around and see what is there and not.

Thanks for the time.

Steven L Silvey
Sr. Technical Service
General Polymers Division
Ashland Distribution