PERANCANGAN SISTEM

MANUFAKTUR

Material Handling & Storage Systems

(3)

M. Zainuddin Fathoni
 Material Handling
Yang memiliki arti menggerakkan dan menyimpan material antar proses
atau operasi perakitan

• Material transport
– Kendaraan (Vehicles), Contoh, forklift, Automated Guided Vehicles
(AGVs), monorails
– Conveyors
– Hoists and cranes
• Storage systems
• Unitizing equipment
• Automatic identification and data capture (AIDC)
– Bar codes
– RFID
– Other AIDC equipment
Time Spent in Material Handling
 Definisi Material Handling
• Pergerakan, penyimpanan, perlindungan dan kontrol dari
material sepanjang jalur manufaktur dan proses distribusi
termasuk kebutuhannya dan pembuangannya (The Material
Handling Industry of America)
• Di USA, Diestimasikan sekitar 20-25% dari total biaya
tenaga kerja manufaktur
• Proporsi bervariasi tergantung tipe produksi dan tingkat
automatisasinya
 Kriteria Material Handling
• Safely
• Efficiently
• At low cost
• In a timely manner
• Accurately (the right materials in the right
quantities to the right locations)
• Without damage to the materials
 Logistics
Menyangkut mengenai masalah perolehan, pergerakan,
penyimpanan, dan distribusi dari material dan produk untuk
memenuhi kebutuhan/permintaan konsumen

Dua kategori dari logistik:

• External logistik - transportasi dan aktivitas berkaitan yang
terjadi diluar dari fasilitas (Antar lokasi yang secara geografis
berbeda)
– Lima tradisional mode dari transportasi : rail truck, air, ship, and
pipeline
• Internal logistics - material handling dan storage dalam
fasilitas
External logistik
Internal logistik
 Kategori
Peralatan Material Handling
1. Peralatan Pemindahan Material - Untuk mengerakkan
material di dalam pabrik, gudang, atau fasilitas lainnya.
2. Penyimpanan (Storage) – untuk menyimpan material dan
memberikan akses ke material tersebut jika dibutuhkan.
3. Peralatan Unitizing - mengacu pada (1) containers untuk
menyimpan (hold) material dan (2) peralatan yang digunakan
untuk loading dan membungkus/mengepak container.
4. Identifikasi dan Sistem pelacakan - untuk mengidentifikasi
dan menunjukan/mengarahkan jalur dari material yang akan
digerakkan atau disimpan.
Perhatian dalam mendesain Material Handling

• Karakteristik Material
• Flow rate, routing, and scheduling
• Plant layout
• Prinsip Unit load
 Karakteristik Material
Karakteristik Material berakibat pada tipe alat
transportasi dan peralatan penyimpanan yang
dibutuhkan
• Solid, liquid atau gas
• Size (panjang, Lebar, Tinggi)
• Weight
• Shape : long, flat, bulky
• Condition : hot, cold, wet, dirty
• Resiko kerusakan : fragile, brittle, sturdy
• Safety risk : explosive, flammable, toxic, corrosive
 Flow Rate, Routing, and Scheduling

• Flow rate – jumlah material yang dipindahkan perunit waktu

- contoh: pieces/hr, pallet loads/hr, tons/hr.
- material yang harus dipindahkan dapat berupa individual
unit, dalam bentuk lot, atau kontinyu.
• Routing – lokasi pengambilan dan peletakan, jarak pergerakan,
variasi rute, kondisi sepanjang rute.
• Penjadwalan (Scheduling)
-Waktu dari setiap pengiriman
- tepat pengiriman ketika diperlukan
- Mengunakan stok pengaman untuk mengatasi keterlambatan
pengiriman.
 Plant Layout
• Peralatan Material handling harus memperhatikan
problem tentang desain tata letak fasilitasnya
• Hubungan antara tata letak fasilitas dengan peralatan
material handling :

Tipe tata letak fasilitas Peralatan Material handling

• Fixed-position : Cranes, hoists, industrial trucks.
• Process : Hand trucks, forklift trucks, AGVS.
• Product : Conveyors for product flow,
Trucks to deliver parts to stations.
 Prinsip Unit Load
Pada Umumnya, unit load seharusnya sebanyak mungkin
sehingga menjadikan praktis sistem material handling dan
penyimpanan
• unit load adalah jumlah yang akan dipindahkan atau ditangani
dalam bentuk lainnya dalam satuan waktu

Alasan menggunakan unit load dalam material handling:

• Banyak Item yang ditangani secara simultan
• Mengurangi waktu pergerakan
• Mengurangi waktu Loading/unloading.
• Mengurangi produk yang rusak.
 Unit Load Containers

(a) Wooden pallet, (b) pallet box, (c) tote box

 Peralatan Material Transport
Lima Kategori:
1. Industrial trucks
2. Automated guided vehicles (AGVs)
3. Monorails and other rail guided vehicles
4. Conveyors
5. Cranes and hoists
 Industrial Trucks

Terdapat dua jenis :

1. Non-powered
• Digerakkan oleh manusia; didorong atau ditarik
2. Powered
• Self-propelled, guided or driven by human
• Contoh umum: forklift truck
Non-powered
Powered
Powered
 Automated Guided Vehicles
Automated Guided Sistem Kendaraan (AGVs)
adalah sistem penanganan material yang
dioperasikan secara mandiri, kendaraan self-
propelled dipandu sepanjang jalur yang telah
ditentukan dalam lantai fasilitas

Tipe AGV:
Driverless trains
Pallet trucks
Unit load AGVs
AGV Driverless Automated Guided Train
• Common application is moving heavy
payloads over long distances in
warehouses and factories without
intermediate stops along the route
AGV Pallet Truck
• Used to move palletized loads along
predetermined routes
• Vehicle is backed into loaded pallet
by worker; pallet is then elevated
from floor
• Worker drives pallet truck to AGV
guide path and programs destination
AGV Unit Load Carrier
• Used to move unit loads from station to station
• Often equipped for automatic loading/unloading of
pallets and tote pans using roller conveyors, moving
belts, or mechanized lift platforms
Overhead Monorail
 Conveyor Systems
Termasuk dalam kategori peralatan transportasi bahan
yang dirancang untuk memindahkan bahan pada jalur
tetap, biasanya dalam jumlah besar atau volume

1.Non powered. Bahan digerakkan oleh tenaga manusia

atau oleh gravitasi. Mekanisme Daya
2.Powered untuk mengangkut bahan yang terkandung di
jalur tetap, menggunakan rantai, belt, rol atau perangkat
mekanis lainnya
 Tipe Conveyor
Roller
Skate-wheel
Belt
In-floor towline
Overhead trolley conveyor
Cart-on-track conveyor
Roller conveyor

Belt
In-floor towline conveyor

Overhead trolley conveyor

Cart-on-track conveyor
Single-Direction & Continuous Loop
Conveyor

Single-Direction Conveyor

Continuous Loop Conveyor

 Cranes and Hoists
• Handling devices for lifting, lowering and transporting materials,
often as heavy loads

Cranes
Used for horizontal movement of materials

Hoists
Used for vertical lifting of materials

Cranes usually include hoists so that the crane-and-hoist combination

provides Horizontal transport & Vertical lifting and lowering
Hoist
Bridge Crane
 Gantry Crane :
A half-gantry crane
Jib Crane
 Storage Systems
Function–to store materials (e.g., parts, work-
in-process, finished goods) for a period of time
and permit retrieval when required

• Used in factories, warehouses, distribution

centers, wholesale dealerships, and retail stores
• Important supply chain component
• Automation available to improve efficiency
 Storage System Performance
Performance measures for storage systems:
• Storage capacity -two measures:
- Total volumetric space
- Total number of storage compartments (e.g., unit loads)
• Storage density -volumetric space available for storage
relative to total volumetric space in facility
• Accessibility -capability to access any item in storage
• System throughput -hourly rate of storage/retrieval
transactions
• Utilization and availability (reliability)
 Storage Location Strategies

Randomized storage -incoming items are stored in any

available location
• Usually means nearest available open location

Dedicated storage -incoming items are assigned to

specific locations in the storage facility
• Typical bases for deciding locations:
• Items stored in item number sequence
• Items stored according to activity level
• Items stored according to activity-to-space ratios
 Conventional Storage Methods
• Bulk storage -storage in an open floor area
Problem: achieving proper balance between storage density
and accessibility

• Rack systems -structure with racks for pallet loads

Permits vertical stacking of materials

• Drawer storage -entire contents of each drawer can be viewed

Bulk storage arrangements: (a) high-density bulk storage provides low
accessibility, (b) bulk storage with loads forming rows and blocks for
improved accessibility
• Pallet Rack System : Pallet loads placed on racks
in multi-rack structure
 Automated Storage Systems
• Mechanized and automated storage equipment to reduce the
human resources required to operate a storage facility

• Significant investment
• Level of automation varies
• In mechanized systems, an operator participates in each
storage/retrieval transaction
• In highly automated systems, loads are entered or retrieved
under computer control
 Objectives and Reasons for Automating Storage
Operations
• To increase storage capacity
• To increase storage density
• To recover factory floor space currently used for WIP
• To improve security and reduce pilferage
• To reduce labor cost and/or increase productivity
• To improve safety
• To improve inventory control
• To improve stock rotation
• To improve customer service
 Types of Automated Storage System

1.Automated Storage/Retrieval System (AS/RS)

Rack system with mechanized or automated crane to store/retrieve loads
2.Carousel Storage System
Oval conveyor system to contain individual items
 AS/R
Unit load AS/RS with one aisle
Horizontal Carousel Storage System
Manually operated horizontal carousel storage
system