11/21/2010

Alat Industri Kimia

Penanganan Bahan Material (Material Handling/MH)

Introduction
•MH includes any or all movements, packaging and storage of
materials, parts, assemblies, and products
•Term materials include raw materials, parts, subassemblies, and
semi-finished goods
• Need of handling of goods between plants (transportation)
•MH includes all such movements of materials from the receipt of
the raw materials to the shipment of finished products.
•MH is a system which forms the various factors of movement,
transfer, warehousing, in-process handling, and shipping into one
interdependent cycle considering the most economical solution
for the respective plant. The next slide demonstrates the material
handling system in the form of flow diagram.

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Materials Flow Diagram

MH system in the form of Flow Diagram:
Raw mat. supplier Transportation Receiving at
store

Manufacturing/fabrication units Storing

Flow of parts to Testing and shipping

assembly line packaging

Disposal/ Warehouse
Dealers/consumers
recycling

Material handling in intermittent and continuous

manufacturing system
— In some operations, MH cost can be reduced by
accumulating parts between operations
— This condition is true for intermittent system where less
automation of MH system.
— Parts can be accumulated and inventoried in to the
boxes or baskets and transported by hand-jack dollies or
forklift trucks more economically than they can be
carried by hand.
— In continuous manufacturing, automated MH system
are designed to reduce overall handling costs, resulting
in less work in process

(Reference: Rverette E. Adam, Ronald J. (2001). Production and Operations

Management, p. 456)

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Functions of material handling

— The movement and positioning of purchased
materials for storage
— Internal transportation of materials from store
to shops or as required
— Movement of materials from one department to
another or from one machine to another
— Movement of finished products to store or sale
— Unloading raw materials
— Loading packed materials to move

Factors to be considered in material handling problem

1 Engineering factors 2 Economic factors
Engineering factors to be considered:
— Nature of materials and products (solid, gas, etc)
— Production process and equipment (sequence of
operation, machine output per unit time)
— Building construction (single or multi-storey)
— Layout (layout and material handling are not
separable)
— Existing material handling equipment
— Production planning and control (sequence for
material flow and timing for processing)
— Packaging (easy handling of packaged products)

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Economic factors to be considered in MH…

— Initial cost of equipment

— Cost of installation
— Rearrangement of present equipment
— Cost of alternation necessary to the building
— Cost of maintenance, repairs, supplies etc
— Cost of power, depreciation
— Cost of labor to operate
— Cost of auxiliary equipment (for example, charging
equipment for truck batteries, etc)
Flexible MH equipment help in reducing operating costs.

Basic principles of MH
— Reduction in handling (minimize MH)
— Reduction in time (waiting, loading, traveling time)
— Principles of unit load (not one piece but optimum
number of pieces as a unit)
— Use of gravity (cheapest source of motive power)
— Safety
— Use of containers
— Stand by facility
— Periodical check up
— Avoid interference with production line
— Flexibility (necessary changes are incorporated)

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Material handling devices

1. Lifting and lowering devices (vertical movement)
2. Transporting devices (horizontal movement)
3. Devices with lift and transport (combination devices)
4. Industrial Robots
5. Automatically guided vehicles

1. Types of Lifting and lowering devices

— Block and tackle (lifting vertically)
— Hand and power winches
— Hoists (lifting load vertically)

— Elevators √
— Pillar crane (stationary or mobile type)
— Overhead bridge crane (used in foundry, power house, steel
industry, etc)

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Elevators
— Group of fixed path handling equipment
— Bucket Elevator (BE) is one of them
— BE –used to convey material vertically
— BE are use to handle free flowing loads
— For example:
— Grain storage
— Food processing
— Chemical plants

2. Types of Transporting Devices

— Wheel barrows
— Hand and power trucks
— Industrial narrow railways (used in mining
and metal working industries before the
development of rubber tire equipment)
— Tractors and trailers
— Pipe lines and Pumps √
— Aerial tram ways (horizontal transportation
system where load carrying vehicle is supported
from the top, by means of a cable –like Aerial
Ropeways)

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Pipe line and pumps in Material Handling

— Pipe lines and pumps are used for transporting horizontal
as well as vertical directions
— Oil
— Water
— Gas
— Concrete pumps in construction industry

3. Devices which lift and transport

— Slides and Chutes (commonly used in railway, air line
terminal, and department store for handling packages and
baggages)
— Hoists with trolleys running on overhead rails

— Fork lift truck √(

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eforpr
ocessl
ayout
)

— Crane trucks √(
appr
opr
iat
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ayout
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— Conveyors √(
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ayout
)
— Spiral rollers
— cranes

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4. Industrial Robots
— A robot is a reprogrammable multifunctional
manipulator designed to move material, parts, tools,
or specialized devices through variable programmed
motions for the performance of a variety of tasks
— Robots are like human workers
— Robot application:
-to pick up hot steel ingots
-handling radioactive rods in nuclear power
plants
-spot welding and arc welding

5. Automated Guided Vehicle Systems (AVGS)

— Battery-powered, automatically steered vehicles designed
to follow defined pathways.
— Capable of automatically loading and unloading unit loads
— Usually interfaced with other automated systems to
achieve full benefits of integrated automation.
— Examples: driverless trains, pallet trucks, unit load carriers

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Relation between plant layout and MH

— Close relation between plant layout and MH
— MH methods influence the layout and factory building
— MH is to be considered as an integral part of plant layout to
design low cost handling system
— Good MH is resulted based on the arrangement of production
equipment, location of departments, logical sequence of
operations, location of stores, tools
— MH system/equipment can be selected only after the
appropriate floor plan
— Plant layout considers the points for material receiving and
shipping of products
— Careful arrangement of work centers and storage areas
— Consider horizontal or vertical material transportation

Process layout and MH system

— Need of flexibilities of path, and flexibility of size, weight and
shape of load
— This requirement is better fulfilled by the MH equipment such
as mobile trucks, tractor trains, cranes, and forklift trucks, etc.
— Loading and unloading time is very important for efficient MH
system
— Quick pick up systems have developed around skids and
pallets
— Material is loaded directly on skid or pallet by worker as S/he
completes his operation on the part
— Heavy parts/loads are handled by overhead cranes

— How much MH equipment is needed? Difficult question

because of random variations on demand for transporting
capacity in process layouts.

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Line layout and MH

— Nature of line layout requires direct means of transportation
between operations
— Arrange the material flow so that each operator places the unit
down in such a position that it can be picked up by the
succeeding worker
— Where possible gravity chutes can be used
— Chutes are common in railway and air line terminal for
handling baggages.
— conveyors to lift all types of parts are available
— These conveyors require a considerable amount of special
design to fit them into an effective overall design of a line
layout
(Reference: M. Mahajan (2002). Industrial engineering and production
management)

Task for self study

— Review the literatures on material handling equipment.
Understand the basic physical construction and
application of major material handling equipment used in
manufacturing and construction sector. Participate
actively in class room discussion and demonstrate your
knowledge and understanding ability on material
handling equipment.

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