MATERIAL HANDLING 2

• Apple (1977) notes that

material handling can
account for up to 80 percent
of production activity.
• Although material
movement does not add
value in the manufacturing
process, half of the
company’s operation costs
are material handling costs
(Meyers 1993).
“keeping the material handling activity at a
minimum is very important”
 Material Handling Devices
MHDS
• There are a number of different types of
material handling devices (MHDs), most of
which move materials via material handling
paths on the shop floor.
• However, there are some MHDs—such as
cranes, hoists, and overhead conveyors—that
utilize the space above the machines.
 Consideration MHDS

• cost, weight, size, and volume of the loads;

space availability; and types of
workstations; Integrated with another
systems
 Types of MHDS
• There are seven basic types of MHDs (Heragu
2008):
conveyors,
palletizers,
trucks,
robots,
automated guided vehicles,
hoists cranes and jibs,
warehouse material handling devices
 MATERIAL HANDLING EQUIPMENT
• Basic Handling Equipment Types
– Conveyors

conveyors should be considered only when the volume of parts or

material to be transported is large and when the transported
material is relatively uniform in size and shape
MATERIAL HANDLING EQUIPMENT
• Basic Handling Equipment Types
– Cranes and Hoists
 MATERIAL HANDLING EQUIPMENT
• Basic Handling Equipment Types
– Industrial Trucks
Trucks are particularly useful
when the material moved
varies frequently in size,
shape, and weight, when the
volume of the parts or
material moved is low,
and when the number of
trips required for each part is
relatively small
MATERIAL HANDLING EQUIPMENT
• AGV
• It can be found in
Autonomous Vehicle
Storage and Retrieval
System AVS/RS
MATERIAL HANDLING EQUIPMENT
• Jibs
 MATERIAL HANDLING EQUIPMENT
• robot
complex repetitive tasks
automatically and they
can work in hazardous
and uncomfortable
environments that a
human operator
cannot work.
MATERIAL HANDLING EQUIPMENT
• Palletizers
MATERIAL HANDLING EQUIPMENT
• Warehouse devices
• E.g : scale, trolley
MATERIAL HANDLING EQUIPMENT
• Equipment is not always required in order to solve a
handling problem
• The equipment selected should:
– Fit into the handling system
– Combine handling with other functions
– Optimize material flow
– Be as simple as is practicable
– Utilize gravity wherever possible
– Require a minimum of space
– Be flexible, adaptable
– etc.
 QUESTION?

• WHICH
MHDS
SHOULD BE
PICKED?
 The Material Handling System Equation

WHY ?

WHAT ? WHERE ? WHEN ? HOW ? WHO ? WHICH ?

MATERIALS + MOVES + METHODS PREFERRED

SYSTEM

Materials + Moves + Methods = Recommended System

 Material Handling Principles
1. Planning Principle 7. System Principle
2. Standardization 8. Automation Principle
Principle 9. Environmental
3. Work Principle Principle
4. Ergonomic Principle 10. Life Cycle Cost
5. Unit Load Principle Principle

6. Space Utilization
 Tautan video
• AGV  Kiva system
• Conveyor overhead & robot  manufacture
BMW
Ongkos Material Handling
 Estimasi Ongkos Material Handling

• Total OMH = Ongkos alat angkut per meter gerakan x

jarak tempuh pengangkutan x frekuensi
pengangkutan dalam 1 hari.
• Kapasitas alat angkut = volume alat angkut/volume
material
• Frekuensi = output (satuan perpindahan/hari)/
kapasitas alat angkut
 Estimasi Ongkos Material Handling

• Total OMH = Biaya mesin + Biaya operator

• Biaya mesin = Biaya perawatan + Biaya Bahan Bakar +
Depresiasi
• Depresiasi adalah biaya penyusutan terhadap umur
mesin/alat selama umur ekonomis alat tersebut.

Depresasi mesin =
Harga alat/umur ekonomis x 1 tahun/ jumlah hari kerja x 1
hari/jam kerja
= Rp / jam
 Ongkos Material handling

z= 
f cd
i j
ij ij ij

dimana : fij = frekwensi perpindahan antara stasiun i dan j

cij = ongkos material handling per-satuan jarak
dij = jarak antara stasiun i dan j

Jarak antar stasiun dapat dihitung setelah ditentukan posisi setiap

stasiun didalam lantai produksi (shopfloor). Jika urutan penempatan
stasiun adalah ABCD, maka :

Jarak stasiun A dan B = 1/ 2 LuasA 1/ 2 LuasB

Jarak stasiun A ke C = 1/ 2 LuasA1/ 2 LuasB1/ 2 LuasC

 contoh
• Gaji operator MH = Rp 800.000 per-bulan, sebulan 25 hari
kerja dan sehari 8 jam kerja. Harga pallet jack = 30 juta
dengan umur ekonomis 10 tahun. Biaya perawatan sebulan
500.000 dan biaya bahan bakar 1.000.000/ bulan . Jarak
tempuh pallet jack per jam 200 meter. Maka OMH :
• Biaya perawatan = 500.000/(25 hari x 8 jam) = Rp 2500/jam
• Biaya B. Bakar = 1.000.000/ (25 x 8 jam) = Rp.5000/ jam
• Depresiasi = 30 juta /(10 tahun x 300hari x 8 jam)
=Rp1.250 / jam
• Biaya operator = 800.000/(25 hari x 8 jam) = Rp 4.000 / jam
• Ongkos peralatan = B. Perawatan + Depresiasi + B. Bahan
bakar
• = 2500 + 1250 + 5000= Rp 8.750 / jam
• OMH = Ongkos peralatan MH + Ongkos operator
• = 8.750 / jam + Rp 4.000 / jam = Rp 12.750 / jam
• = Rp 12.750 / 200 m = Rp 63.75 / m
 contoh
Diketahui volume material A 20X15X15cm,
sedangkan alat angkut forklift volumenya
120x120x120 cm. Output material A (satuan
perpindahan) 300 produk setengah jadi. Biaya
loading/unloading Rp 10.000 sedangkan bahan
bakar untuk forklift selama sebulan Rp
2.000.000 (25 hari kerja, 8 jam sehari) untuk
3000 meter dimana jarak perpindahan sebesar
100 meter Hitung total OMH
• Kapasitas alat angkut = volume alat angkut/volume
material
• C= 120x120x120 cm / 20X15X15cm = 384 unit load
• Frekuensi = output (satuan perpindahan/hari)/
kapasitas alat angkut
• F= 300/384 = 0,78 ~1
• Biaya B. Bakar (OMH/m)= 2.000.000/ (25 x 8 jam)
3000 = Rp 3,33
• OMH= (1x 10.000 )+ (Rp 3,33 x 200 m)= 10.666,67
Selamat Belajar