Lecture 6:

Overview of Material
Handling & Management
(Part II)
Lecture by: Dr Suryani Ahmad
Prepared by:
Assoc. Prof. Dr Siti Akhtar Mahayuddin
MATERIAL PLANNING AND CONTROL

Material planning:
• A scientific technique of determining in advance the requirements
• Raw materials
• Ancillary parts and components,
• Spares etc. as directed by the production program.
• A sub-system in the overall planning activity.
• Factors of material planning can be classified as macro and micro systems.
• Macro factors: Some of the micro factors which affect material planning, are price trends, business cycles
Govt. import policy etc.
• Micro factors: Some of the micro factors that affect material planning are plant capacity utilization,
rejection rates, lead times, inventory levels, working capital, delegation of powers and communication.
MATERIAL PLANNING
Example of one technique of material planning is Bill of Materials
Example of explosion chart of BOM
MATERIAL PLANNING & CONTROL
Related to Production Flow

The production flow in circulation plants is split up into the following

working stations:
1.Preparation of contact faces
2.Formwork Example:
3.Reinforcement 1. Pallet Circulating System by INDIAPRECAST
http://www.indiaprecast.com/pallet-circulating-ca
4.Casting rrousel-system.html
5.Compacting 2. Please watch this video (pallet system) https://
6.Turning www.youtube.com/watch?v=lNQwLmBYBZM
7.Finishing works (New 2016 Video - Concrete Machinery to Build
the Future Together)
8.Hardening
9.Lifting of elements and storage
10.
Lifting and cleaning of shuttering
Material planning and control
Pallet circulation plants in the production of precast elements for prefabricated buildings.

•Pallet circulation systems to produce wall panels, double walls, solid walls and sandwich walls from
standard and light-weight concrete are in use all over the world to the complete satisfaction of their
users.

•Performances of 200 up to 3.000 m2 can be realized.

•This production method enables a production process which can be controlled the whole way from the
CAD system to the construction site. 

•The automation degree of the plants can be adapted with regards to the aimed capacity and the local
conditions. The plants consist of modules and can be adapted to almost all market requirements.
 
MATERIAL CONTROL
Material control is a management activity that administers how the
inventory employed in the production process is procured, acquired,
handled, stored and utilized (use of materials).
A process that requires planning, organization an auditing of all the
elements employed in certain productive activity.
Objectives - to minimise wastage and losses, derive maximum economy
and establish responsibility for various operations through physical
checks, record keeping, accounting and other devices.
MATERIAL CONTROL – inventory control technology
Systematic solutions for production
Further reading: https://precast.org/2011/05/inventory-control-comes-of-age-2/
BAR CODE
• Barcode technology offer systematic solutions for the
precast producer.
• Barcode technology in the precast industry works just like
it does in retail stores: A scanner reads a barcode label
attached to a cured concrete product, which then
accesses a computer database for information. It is an
easy and cost-effective way to implement product and
data tracking into your everyday inventory.
• Compared with stencils, printed barcode labels are much
more legible, durable and professional looking
• Barcode technology allows to more accurately and
effectively manage our business processes from beginning
to end
• Sample: http://www.infosight.com
/products/metal-tags/136-embed-a-tag-concrete-casting-i
d-tags
RFID
• RFID tags are small chips that can be cast directly
into the concrete product; not only can information
be accessed with a scanner data can be transferred
to the chips at any time during or after production
and can even communicate via telephone.
• RFID allows us to know precisely what stage a piece
is in and what pieces are finished and ready to be
delivered. The dispatcher can easily determine that
• RFID allows not only capture all the product data
accurately and rapidly, but to analyze it to the plant
advantage with the software system that comes
with RFID technology
 VIDEOS
https://www.youtube.com/watch?v=NfAzn50oIvs Behind The Scenes Of A Precast Concrete Plant | Oldcastle Precast

Machine used
Concrete batching & mixing
Quality control

https://www.youtube.com/watch?v=M-o8WZIDldg Turn-Key Precast Concrete Plant by Weckenmann

Circulation plant
Battery formwork

https://www.youtube.com/watch?v=lNQwLmBYBZM (New 2016 Video - Concrete Machinery to Build the Future Together)
Machine used
Material handling