Material Handling Equipments

Firdaus Jamsan, ST, MT

 the term materials
handling is used with
reference to industrial
activity

Material Handling Equipments 2

 Keyword
Perpindahan/Movement

Perpindahan merupakan gerakan yang tidak

produktif, tidak ada value added pada
product kecuali hanya perpindahan
Menurut AMHS (American Material Handling Society
): “Seni dan ilmu yang meliputi penanganan
(handling), pemindahan (moving),
pembungkusan/pengepakan (packaging), penyimpanan
(storing), dan pengendalian/pengawasan
(controlling) dari bahan/ material dengan segala
bentuknya”
Material Handling Equipments 3
UKURAN JARAK
EUCLEDIAN
Horizontal
C= A +B
2 2 Band Saw

C
RECTILINEAR
B
A+B

Surface Grinder

Material Handling Equipments 4

 Kegiatan perpindahan bahan mencapai
50% - 70% dari total waktu produksi
(sumber : Apple,1977)

MATERIAL HANDLING = WASTE

REDUKSI
Material Handling Equipments 5
Importance of Material
Handling
MH
55%
MH
Factory Space

87%
Production
time

Product
70% Cost
15%

Material Handling Equipments 6

 Definitions of Material
Handling Right amount
MH is the art and science Right material
of moving, storing,
protecting, and controlling
Right time
material.

Right condition
PROVIDE

Right place

Right position

Right sequence
Right methods
Right cost

Material Handling Equipments 7

 NEW DEFINITION OF
MATERIAL HANDLING
Material Handling is the Operations
movement, storage, control and
protection of materials, goods Subjects
and products throughout the
process of manufacturing, Business Processes
distribution, consumption and
disposal. The focus is on the
methods, mechanical equipment,
systems and related controls
used to achieve these
functions.

Material Handling Equipments 8

Material Handling as A
System
Material Handling Equipments 9
The essensial requirements of a
good MH systems
Efficient and
safe movement

Timely movement

Supply rate

Space utilization

Lowest cost solution

Material Handling Equipments 10

A well design of MH system, results:

1. Improve efficiency of a production system by

ensuring the right quantity of materials
delivered at the right place at the right time
most economically;
2. Cut down indirect labour cost;
3. Reduce damage of materials during storage and
movement;
4. Maximise space utilization by proper storage of
materials and there by reduce storage and
handling cost;

Material Handling Equipments 11

A well design of MH system, results:

4. Minimise accident during materials handling;

5. Reduce overall cost by improving materials
handling;
6. Improve customer services by supplying materials
in a manner convenient for handlings;
7. Increase efficiency and sale ability of plant and
equipment with integral materials handling
features.

Material Handling Equipments 12

 MATERIAL HANDLING Planning Principle
SYSTEM PRINCIPLES
Standardization Princip

Work Principle

Ergonomic Principle
PRINCIPLES
Unit Load Principle

Space Utilization
Life Cycle Cost Principle
System Principle
Environment Principle
Automation Principle

Material Handling Equipments 13

material handling equation
Yes
WHY WHAT WHERE + WHEN HOW + WHO
?

MAT’L MOVE METHOD

No

A
Q
D
etc.

E
P
C

Type, Sink, Source Flow; Unit

Qty, Direction Flow, Manpower
Characteristics Volume Equipment
Type of Move, etc.

Material Handling Equipments 14

 Work simplification in MH
 Framework for identifying MH solutions

Evaluate each movement:

1. Can the move be eliminated ?
2. Can the move be combined with another or within
Why? an in-transit operation ?
3. Can the move be simplified ?
4. Can the sequence of moves be changed to
advantages ?

Material Handling Equipments 15

Characteristics of Materials
The characteristics of materials affecting handling include the following: size (width, depth,
height); weight (weight per item, or per unit volume); shape (round, square, long, rectangular,
Material Categories
irregular); and other (slippery, fragile, sticky, explosive, frozen).

Table 1. Material Categories

Physical State
Material Category Solid Liquid Gas
Individual units Part, subassembly — —
Containerized items Carton, bag, tote, box, Barrel Cylinder
pallet, bin
Bulk materials Sand, cement, coal, Liquid chemicals, Oxygen, nitrogen, carbon
granular products solvents, gasoline dioxide

The impact of the material category listed in Table 1 on the type of MH equipment is as follows:
• Individual units and containerized items • discrete material flow • unit loads •
unit handling equipment
• Bulk materials • continuous material flow • bulk handling equipment
Figure 1 shows an example of alternate ways of handling a dry bulk material: as containerized
(bagged) items on pallets handled using unit handling equipment (boxcar, pallet, fork truck),
Material Handling Equipments 16
or
as bulk material handled using bulk handling equipment (hopper car, pneumatic conveyor, bulk
the use of standardized material handling equipment.

Individual units and containerized items ⇒ discrete material flow ⇒ unit

loads ⇒ unit handling equipment

Material Handling Equipments 17

 4
Figure 1. Unit vs. bulk handling of material.
Bulk materials ⇒ continuous material flow ⇒ bulk handling equipment

s of unit loads:
ent forming and breaking down the
Material unit
Handling load.
Equipments 18
 Unit load concept
Follows traditional thinking

$/unit

Quantity

The greater the amount moved per

trip,
the less the cost per unit moved

Maximize Unit Load

Material Handling Equipments 19
 Unit Loads
• A unit load is the unit to be moved or handled at one
time.
• A unit load includes the container, carrier, or support
that will be used to move materials.

Unit Load

Stacking Pallet sized by

ANSI (American National
Standard
Institute)
Pallet

Forklift

Material Handling Equipments 20

 Unit Loads
• Examples: tote boxes, “cassette”,
cartons, skids, pallets, pallet boxes,
intermodal container, one unit of
product, etc.
• Most popular: plastic containers and
pallets
• Factors for determining unit load/
container:
– Size of carrier
– Size and weight of items
– Space for storing loaded/unloaded container
– Equipment used for moving
– Cost, supply and maintenance
– Aisle widths, door sizes, and clear stacking
heights Material Handling Equipments 21
 Unit Load and Handling
System
The unit load is an
integral part of the
material handling system
and a “simultaneous”
determination should be
made.

Design the
Handling/Storage
system

Design
the Unit
Load

Material Handling Equipments 22

 Exercise: Unit Load and Cycle Time

We have a system with two Machine 1 Machine 2

machines. Every unit of the

product has to go through 1 min/unit 1 min/unit
Machine 1 first and then
through Machine 2.

We move the product using

forklift trucks. The
company has several of them
going around permanently.
We can use one whenever we
need. The move from Machine
1 to Machine 2 takes two
minutes.
The forklift truck moves a
batch (or a lot) of units
at a time.
How many units should we
move at a time using the
forklift truck to minimize
the time of completion of
an order of 16 units?
In other words, how big
should the unit load be to
minimize completion time?

Material Handling Equipments 23

M1 UL = 16 units
Unit Load and Cycle
MH Time
M2
16 34

Lot size = 16 units

M1 UL = 8 units Machining = 1 min/unit
MH Operations 1 and 2
M2 MH = 2 min/trip
18 26

M1 UL = 2 units Large unit loads: longer

MH cycle times, fewer moves
M2
6 20

Small unit loads: lower

M1 UL = 1 unit cycle time, lower WIP,
MH more frequent handling
M2
4 34

MH time > processing time => MH constrained

Material Handling Equipments 24

Material Handling Equipments 25
Material Handling Equipments 26
 Unit Load Disadvantages
Time spent forming and
breaking down the unit
load.

Empty containers/pallets
may need to be returned
to their point of
origin.

Cost of
containers/pallets and
other load restraining
materials used in the
unit load

Material Handling Equipments 27

 Transport
Equipment

Identificati
on and Positioning
Control Equipment
Equipment
MATERIAL
HANDLING
EQUIPMENT
CATEGORIES

Unit Load
Storage
Formation
Equipment
Equipment

Material Handling Equipments 28

Conveyor Cranes
Transpo
rt
Equipm
ent
Industrial
No Equipment
Truck

Material Handling Equipments 29

 Functional differences
(conveyor; cranes; industrial truck)
• Fixed
Path • Variabel

• Restricted
Area • Unrestricted

Move • Low
Frequency • High

• Yes
Adjacent Move • No

Material Handling Equipments 30

Adjacent move: Yes—move is between adjacent activities
Functional
No—move differences
is between activities that are not adjacent
(conveyor; cranes; industrial truck)
Table 3. Transport Equipment Characteristics

Path Fixed Variable

Area Restricted Restricted Unrestricted
Frequency High Low High Low —
Adjacent — Yes No — — —

Equipment Conveyor Conveyor Industrial Industrial Crane Industrial Truck

Category Truck/Crane Truck

Material Handling Equipments 31

Counter balanced lift truck

Material Handling Equipments 32

 Rated Load Capacity: 1,000–100,000 lbs available; a truck’s rated load capacity is specified
assuming a rated load center of 24 inches (or 500 mm) from the face of the forks of the truck

Counter balanced lift truck

and a lift height of up to 13 ft; attachments and loads with a center of gravity greater than 24
inches reduce the load capacity of the truck. Figure 6 shows the specification sheet for a 3,000 lb
lift truck.

Figure 5. Sit-down counterbalanced lift truck.

acity: A truck’s approximate allowable load capacity W (see Figure 5(a))

W ( F + L0 )
Figure 5. Sit-down counterbalanced lift truck.

GB M
Load Capacity: A truck’s approximate allowable load capacity W (see Figure 5(a)) 0is given by
Load capacity: W = = = ,
Load capacity: W =
GB F M
=
+ L= W ( FF+ L+) L, 0 F +(0.1)
L 0

F+L F+L F+L

Material Handling Equipments 33
A truck’s approximate allowable load capacity W (see Figure 5(a)) is given by

W0 ( F + L0 )
MATERIAL HANDLING EQUIPMENT
GB M
Load capacity: W = = = , (0.1)
F+L F+L F+L
where
G = empty truck weight (lbs)
B = front-axle to truck-load-center
49 distance (in.)
F = front-axle to fork-face distance (in.)
L = actual load center, distance from fork face to load center of gravity (in.)
ULD
= if constant-density rectangular-shaped load
2
ULD = unit load depth
L0 = 24 in. = rated load center
M = load moment (in·lbs)
W0 = rated load capacity (lbs).
Although it might seem preferable, Material Handlingof
in light (0.1), to specify a truck’s load moment
Equipments 34 (M
is specified instead because it is easier to relate to the truck’s maximum allowable load w