Basics of material handling systems MCQs With Answer

Basics of material handling systems MCQs With Answer — This concise guide is crafted for B.Pharm students to master material handling systems used in pharmaceutical production and distribution. Material handling covers storage, internal transport, unit load concepts, conveyors, forklifts, AGVs, cold chain logistics, and cleanroom transfer methods. Emphasis is on GMP/GDP compliance, contamination control, ergonomics, inventory management, barcoding/RFID, packaging, and warehouse layout to preserve drug quality and safety. Learning these fundamentals improves process efficiency, traceability, and regulatory readiness. Practical focus includes equipment selection, validation, safety protocols, and documentation. Now let’s test your knowledge with 50 MCQs on this topic.

Q1. What is the primary objective of material handling in pharmaceutical operations?

• Maximize storage density at all costs
• Ensure safe, efficient, and compliant movement of materials
• Replace manual labor with machines only
• Minimize paperwork regardless of traceability

Correct Answer: Ensure safe, efficient, and compliant movement of materials

Q2. Which of the following is considered a unit load in material handling?

• Single pill in a bottle
• Pallet with multiple cartons
• Individual label roll
• Loose granules in a hopper

Correct Answer: Pallet with multiple cartons

Q3. In pharmaceutical logistics, GDP stands for:

• Good Distribution Practice
• Global Drug Protocol
• General Delivery Process
• Good Development Procedure

Correct Answer: Good Distribution Practice

Q4. Which equipment is commonly used for short horizontal transport in warehouses?

• Conveyor belt
• Centrifuge
• Autoclave
• Tablet press

Correct Answer: Conveyor belt

Q5. What is the main concern when handling sterile products?

• Maximizing throughput only
• Preventing microbial contamination
• Reducing packaging costs only
• Increasing pallet height

Correct Answer: Preventing microbial contamination

Q6. Which system helps track items using radio-frequency identification?

• WMS without scanners
• Barcode-only system
• RFID system
• Manual logbook

Correct Answer: RFID system

Q7. FIFO in inventory management stands for:

• Fast Inventory Flow Operation
• First In, First Out
• Final Inspection For Orders
• First Input, Final Output

Correct Answer: First In, First Out

Q8. What is a primary advantage of automated guided vehicles (AGVs) in pharma plants?

• They eliminate the need for validation
• They reduce manual handling and contamination risk
• They increase paperwork
• They function without maintenance

Correct Answer: They reduce manual handling and contamination risk

Q9. Which handling equipment is most appropriate for lifting heavy pallets vertically?

• Hand truck
• Forklift
• Conveyor roller
• Vacuum sealer

Correct Answer: Forklift

Q10. In cleanroom transfers, which feature is critical for transfer containers?

• Open design to allow airflow
• Material compatible with cleanroom cleaning/sterilization
• Usage of porous materials
• Unsealed lids to ease access

Correct Answer: Material compatible with cleanroom cleaning/sterilization

Q11. Which metric measures the amount of material moved per unit time?

• Throughput
• Lead time
• Inventory turnover only
• Batch size

Correct Answer: Throughput

Q12. What is cross-docking intended to achieve?

• Long-term storage of products
• Direct transfer from inbound to outbound with minimal storage
• Quality testing of raw materials
• Label printing and manual sorting only

Correct Answer: Direct transfer from inbound to outbound with minimal storage

Q13. Which hazard class needs segregated storage and specialized handling in pharma warehouses?

• Non-hazardous office supplies
• Flammable and corrosive chemicals
• Pallets of empty boxes
• Standard glass bottles

Correct Answer: Flammable and corrosive chemicals

Q14. What does validation of material handling equipment ensure?

• That equipment looks new
• Consistent performance meeting predefined requirements
• That operators are unnecessary
• That packaging costs increase

Correct Answer: Consistent performance meeting predefined requirements

Q15. Ergonomics in material handling primarily addresses:

• Packaging aesthetics
• Worker comfort and reduction of injury risk
• Increasing product potency
• Inventory valuation methods

Correct Answer: Worker comfort and reduction of injury risk

Q16. What is the role of a Warehouse Management System (WMS)?

• Manufacture tablets
• Control and optimize warehouse operations and inventory
• Sterilize equipment
• Replace GMP requirements

Correct Answer: Control and optimize warehouse operations and inventory

Q17. Which packaging element is crucial for traceability in pharma supply chain?

• Blank labels
• Unique batch/lot numbers and barcodes
• Opaque cartons with no markings
• Unlabeled shrink wrap

Correct Answer: Unique batch/lot numbers and barcodes

Q18. What is a key consideration for cold chain handling of vaccines?

• Ambient storage is fine
• Maintaining specified temperature throughout transport and storage
• Only visual inspection is required
• Labels can be removed to save costs

Correct Answer: Maintaining specified temperature throughout transport and storage

Q19. Which is a manual material handling method?

• AGV
• Conveyor system
• Hand carrying and manual lifting
• Automated palletizer

Correct Answer: Hand carrying and manual lifting

Q20. What does SOP for material handling typically include?

• Only the cost of equipment
• Step-by-step procedures, safety, documentation, and responsibilities
• Marketing strategies
• Manufacturer warranties only

Correct Answer: Step-by-step procedures, safety, documentation, and responsibilities

Q21. Which control is important to prevent cross-contamination during handling?

• Using same trolley for all materials without cleaning
• Segregation, cleaning protocols, and dedicated equipment
• Ignoring label instructions
• Stacking incompatible products together

Correct Answer: Segregation, cleaning protocols, and dedicated equipment

Q22. How does barcoding improve material handling?

• Makes paperwork optional
• Enables fast, accurate identification and reduces human error
• Eliminates the need for training
• Replaces physical storage

Correct Answer: Enables fast, accurate identification and reduces human error

Q23. What is the purpose of pallet racking in warehouses?

• For aesthetic display only
• Organized vertical storage to maximize space and accessibility
• To store small loose powders
• To replace forklifts

Correct Answer: Organized vertical storage to maximize space and accessibility

Q24. Which is a common conveyor type used for boxes and cartons?

• Bucket elevators only
• Roller conveyor
• Tablet coating pan
• Lyophilizer conveyor

Correct Answer: Roller conveyor

Q25. Which documentation is essential for inbound material traceability?

• Shipping manifest/waybill and batch certificate
• Employee vacation records
• Marketing brochures
• Empty box labels

Correct Answer: Shipping manifest/waybill and batch certificate

Q26. What is load capacity important for in material handling equipment?

• Ensuring operator comfort
• Preventing overloading and equipment failure
• Increasing electricity consumption
• Reducing validation needs

Correct Answer: Preventing overloading and equipment failure

Q27. Which practice helps maintain cleanliness in material handling areas?

• Regular cleaning and scheduled maintenance
• Never inspecting equipment
• Allowing food in handling zones
• Storing materials on the floor permanently

Correct Answer: Regular cleaning and scheduled maintenance

Q28. What role does risk assessment play in material handling?

• Identifies hazards and implements controls to reduce incidents
• Guarantees zero incidents without action
• Only applies to laboratory chemicals
• Is optional in GMP environments

Correct Answer: Identifies hazards and implements controls to reduce incidents

Q29. Which is a feature of kitting in pharmaceutical assembly?

• Random selection of parts
• Pre-assembling component sets to improve production efficiency
• Eliminating quality checks
• Storing all parts in one pile

Correct Answer: Pre-assembling component sets to improve production efficiency

Q30. Which is critical when handling hazardous pharmaceutical waste?

• Mixing it with regular waste
• Segregation, labeling, and compliant disposal
• Unlabeled storage
• Immediate incineration without permits

Correct Answer: Segregation, labeling, and compliant disposal

Q31. What is the importance of buffer zones in material flow?

• They slow down production intentionally
• They provide space to manage variations and prevent blockages
• They are only for aesthetic appeal
• They store expired products

Correct Answer: They provide space to manage variations and prevent blockages

Q32. Why is calibration important for material handling instruments (e.g., scales)?

• To ensure accurate measurements and compliance
• To increase sample contamination
• To delay production schedules
• Because it is optional

Correct Answer: To ensure accurate measurements and compliance

Q33. Which is a typical control for preventing theft and diversion in pharma warehouses?

• Open access to all areas
• Restricted access, CCTV, and inventory reconciliation
• No record keeping
• Using unlabeled shipments

Correct Answer: Restricted access, CCTV, and inventory reconciliation

Q34. What is palletizing?

• Filling tablets into bottles
• Stacking and securing goods on a pallet for transport
• Sterilizing glassware
• Label printing

Correct Answer: Stacking and securing goods on a pallet for transport

Q35. Which transfer method is preferable for delicate sterile components?

• Manual barehand transfer in open air
• Closed transfer systems or pass-throughs
• Throwing components between rooms
• Leaving components on the floor

Correct Answer: Closed transfer systems or pass-throughs

Q36. What does throughput optimization focus on?

• Maximizing storage without regard to flow
• Increasing product flow while minimizing delays and bottlenecks
• Eliminating validation paperwork
• Reducing safety measures

Correct Answer: Increasing product flow while minimizing delays and bottlenecks

Q37. Which PPE is commonly required during manual material handling?

• Lab coat, gloves, and safety shoes
• Swimming goggles only
• Casual clothing
• No PPE ever

Correct Answer: Lab coat, gloves, and safety shoes

Q38. What is the principle of lean material handling?

• Adding inventory to hide inefficiencies
• Eliminating waste, improving flow, and reducing non-value activities
• Prioritizing complex procedures
• Increasing layout complexity unnecessarily

Correct Answer: Eliminating waste, improving flow, and reducing non-value activities

Q39. Which is a sign that a material handling process needs improvement?

• High pick accuracy and low damage rates
• Frequent product damage, delays, and inventory discrepancies
• Short lead times and good traceability
• Low incident rates

Correct Answer: Frequent product damage, delays, and inventory discrepancies

Q40. What is an advantage of automation in material handling?

• Guaranteed zero validation
• Improved consistency, speed, and reduced human errors
• Higher contamination risk always
• No need for maintenance

Correct Answer: Improved consistency, speed, and reduced human errors

Q41. Which practice ensures temperature excursions are detected during transport?

• Using passive containers without monitoring
• Temperature monitoring devices and data loggers
• Ignoring temperature logs
• Relying on driver memory

Correct Answer: Temperature monitoring devices and data loggers

Q42. What is the role of a material handling layout study?

• Designing inefficient workflows
• Optimizing flow paths, storage locations, and equipment placement
• Increasing travel distances
• Making paperwork harder

Correct Answer: Optimizing flow paths, storage locations, and equipment placement

Q43. Which is important when selecting materials of construction for handling equipment?

• Compatibility with cleaning/sterilization and product
• Choosing the cheapest material regardless of compatibility
• Only considering color
• Selecting porous materials for ease

Correct Answer: Compatibility with cleaning/sterilization and product

Q44. What is cycle counting in inventory control?

• Counting inventory intermittently to maintain accuracy
• Never counting inventory
• Counting inventory once every ten years
• Counting only damaged goods

Correct Answer: Counting inventory intermittently to maintain accuracy

Q45. Which equipment is best for moving pallets in narrow aisles?

• Standard forklift with wide turning radius
• Narrow-aisle reach truck or specialized narrow-aisle forklift
• Handheld label printer
• Overhead crane designed for open areas only

Correct Answer: Narrow-aisle reach truck or specialized narrow-aisle forklift

Q46. What is the primary reason for segregation of quarantined materials?

• To hide them from auditors
• To prevent unintended use before quality release
• To mix them with released goods
• To reduce storage costs

Correct Answer: To prevent unintended use before quality release

Q47. Which is a benefit of proper labeling in material handling?

• Increases chances of misplacement
• Enables quick identification, reduces errors, and supports traceability
• Makes inventory slower
• Eliminates need for training

Correct Answer: Enables quick identification, reduces errors, and supports traceability

Q48. During unloading, what is essential to protect temperature-sensitive drugs?

• Leaving them at the dock indefinitely
• Moving immediately into temperature-controlled storage
• Exposing them to sunlight
• Stacking them near heat sources

Correct Answer: Moving immediately into temperature-controlled storage

Q49. What is the function of a hoist or overhead crane in a pharma facility?

• For small package scanning only
• Lifting heavy equipment or materials vertically in production or maintenance
• Replacing sterile filtration
• Printing batch labels

Correct Answer: Lifting heavy equipment or materials vertically in production or maintenance

Q50. Why is documentation of material handling activities critical in pharmaceutical operations?

• Only for accounting purposes
• To ensure traceability, regulatory compliance, and investigation of deviations
• Because it increases workload unnecessarily
• To avoid following GMP

Correct Answer: To ensure traceability, regulatory compliance, and investigation of deviations

G S Sachin

I am a Registered Pharmacist under the Pharmacy Act, 1948, and the founder of PharmacyFreak.com. I hold a Bachelor of Pharmacy degree from Rungta College of Pharmaceutical Science and Research. With a strong academic foundation and practical knowledge, I am committed to providing accurate, easy-to-understand content to support pharmacy students and professionals. My aim is to make complex pharmaceutical concepts accessible and useful for real-world application.

Mail- Sachin@pharmacyfreak.com