MATERIAL HANDLING

Definisi
 Seni dan ilmu pengetahuan dari perpindahan,
penyimpanan, perlindungan dan pengawasan
material
 penanganan material dalam jumlah yang tepat dari
material yang sesuai, dalam kondisi yang baik,
pada tempat yang cocok, pada waktu yang tepat,
pada posisi yang benar, dalam urutan yang sesuai,
dengan biaya yang murah dan menggunakan
metode yang benar.
Tujuan (Meyers, 1993)
 Menjaga atau mengembangkan kualitas produk,
mengurangi kerusakan dan memberikan
perlindungan terhdap material.
 Meningkatkan keamanan dan mengembangkan
kondisi kerja
 meningkatkan produktivitas
 Meningkatkan tingkat penggunaan fasilitas
 mengurangi bobot mati
 sebagai pengawasan persediaan
Pertimbangan perancangan
sistem material handling
 Karakteristik material
 tingkat aliran
 tipe tata letak pabrik
1. Karakteristik material
 Sifat fisik
 ukuran
 berat
 bentuk
 kondisi
 resiko keamanan
2.Tingkat aliran material
 Jumlah aliran rendah dan jarak perpindahan
relatif pendek  handtruck
 Jumlah aliran rendah dan jarak perpindahan
sedikit lebih jauh AGV, Forklift
 Jumlah aliran sangat tinggi  conveyor
 Jumlah aliran sangat tinggi dan jarak
perpindahan sedikit lebih jauh  AGV
Train
3. Tipe tata letak
 Fixed position layout  crane, hoist, truck
 process layout  handtruck, forklift, AGV
 product layout  conveyor, truck
Tingkat Mekanisasi
 Manual dengan ketergantungan tenaga fisik
 handtruck
 mekanik  truck, conveyor dan crane
 mekanik dengan bantuan komputer
 Otomatis
 Otomatis penuh
Flow rate, routing and scheduling:
In addition to material characteristics the other factors are
(1) Quantities and flow rates of materials to be moved,
(2) Routing factors, and
(3) Scheduling of the moves.
Quantity of
material
moved

Conveyors Conveyors
High AGV train

Manual handling Powered trucks

Low
Hand trucks Unit load AGV

Short Long Move Distance

Material Transport Equipment
Five categories:
1. Industrial trucks
2. Automated guided vehicles
3. Monorails and other rail guided vehicles
4. Conveyors
5. Cranes and hoists
Material Transport Equipment:
(a) Industrial trucks: Industrial trucks divide into two types:
non-powered and powered.
 Non-powered trucks are platforms or containers with
wheels that are pushed (didorong) or pulled by human
workers to move materials.
 Powered industrial trucks are steered (mengarahkan) by
human workers. They provide mechanized movement of
materials.
Industrial Trucks:
Two basic categories:
1. Non-powered
• Human workers push or pull loads
2. Powered
• Self-propelled, guided or driven by human
• Common example: forklift truck
 Non-powered Industrial Trucks(Hand Trucks)

Quantities of material moved and distances are

relatively low when this type of equipment is used to
transport materials

(a) Two-wheel hand truck, (b) four-wheel dolly,

(c) hand-operated low-lift pallet truck
 Powered Trucks
Three common types are used in
factories and warehouses:
• Walkie trucks,
• Forklift rider trucks,
• Towing tractors.
Walkie trucks:
these are battery powered vehicles equipped with
wheeled forks for insertion into pallet openings but
with no provision for a worker to ride on the vehicle.
 Forklift rider trucks
These arc distinguished from walkie trucks by
the presence of a modest cab for the worker to sit in
and drive the vehicle.

 Capacities from 450

kg up to 4500 kg
 Power sources
include on-board
batteries and
internal combustion
engines
 Towing tractors

 Designed to pull one or more trailing carts in factories and

warehouses, as well as for airport baggage handling
 Powered by on-board batteries or IC engines
AGVs
(b) Automated guided vehicles: (AGVs).
 AGVs are battery-powered, automatically steered
vehicles that follow defined pathways in the floor.
 AGVs are used to move unit loads between load and
unload stations in the facility. Routing variations are
possible, meaning that different loads move between
different stations.
Automated guided vehicle systems:
An Automated Guided Vehicle System (AGVS) is a
material handling system that uses independently
operated, self-propelled vehicles guided along defined
pathways in the facility floor.
The vehicles arc powered by on-board batteries that
allow many hours of operation (8-16 hr is typical)
between recharging.
Types of AGVS:
• Driverless trains
• Pallet trucks
• Unit load AGVs
Driverless Automated Guided Trains:
• A driverless train consists of a towing vehicle (which is the
AGV) that pulls one or more trailers to form a train.

• Common application is moving heavy payloads over long

distances in warehouses and factories without intermediate stops
along the route
 Automated guided pellet trucks:

• 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
 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
 AGVs Applications
• Driverless train operations - movement of large quantities of
material over long distances
• Storage and distribution - movement of pallet loads between
shipping/receiving docks and storage racks
• Assembly line operations - movement of car bodies and major
subassemblies (motors) through the assembly stations
• Flexible manufacturing systems - movement of workparts
between machine tools
• Miscellaneous - mail delivery and hospital supplies
 Vehicle Guidance Technology

• Method by which AGVS pathways are defined and vehicles are

controlled to follow the pathways
• Three main technologies:
• Imbedded guide wires - guide wires in the floor emit
electromagnetic signal that the vehicles follow
• Paint strips - optical sensors on-board vehicles track the white
paint strips
• Self-guided vehicles - vehicles use a combination of
• Dead reckoning - vehicle counts wheel turns in given
direction to move without guidance
• Beacons located throughout facility - vehicle uses
triangulation to compute locations
Rail-Guided Vehicles:
• Self-propelled vehicles that ride on a fixed-rail system
• Vehicles operate independently and are driven by electric
motors that pick up power from an electrified rail
• Fixed rail system
• Overhead monorail - suspended overhead from the ceiling
• On-floor - parallel fixed rails, tracks generally protrude up
from the floor
• Routing variations are possible: switches, turntables, and
other special track sections
(c) Mono rails and other rail guided
vehicles:
 These are self-propelled vehicles that ride on a
fixed rail system that is either on the floor or
suspended from the ceiling.
 The vehicles operate independently and are
usually driven by electric motors that pick up
power from an electrified rail.
 Like AGVS, routing variations are possible in rail-
guided vehicle systems.
Overhead Monorail:
(d) Conveyors:

 These are designed to move materials over fixed

paths, generally in large quantities or volumes.
 Examples include- roller. belt and tow-line
conveyors.
 Conveyors can be either powered or non-
powered.
 Conveyor Systems
Large family of material transport equipment designed to move
materials over fixed paths, usually in large quantities or
volumes
1. Non-powered
• Materials moved by human workers or by gravity
2. Powered
• Power mechanism for transporting materials is contained
in the fixed path, using chains, belts, rollers or other
mechanical devices
Conveyor Types:
• Roller
• Skate-wheel
• Belt
• In-floor towline
• Overhead trolley conveyor
• Cart-on-track conveyor
Roller Conveyor:
• Pathway consists of a series of rollers that are
perpendicular to direction of travel
• Loads must possess a flat bottom to span several
rollers
• Powered rollers rotate to drive the loads forward
• Un-powered roller conveyors also available
Skate-Wheel Conveyor:
• Similar in operation to roller conveyor but use
skate wheels instead of rollers
• Lighter weight and unpowered
• Sometimes built as portable units that can be used
for loading and unloading truck trailers in shipping
and receiving
Belt Conveyor:
• Continuous loop with forward path to move loads
• Belt is made of reinforced elastomer
• Support slider or rollers used to support forward loop
• Two common forms:
• Flat belt (shown)
• V-shaped for bulk materials
In-Floor Tow-Line Conveyor:
• Four-wheel carts powered by moving chains or cables in
trenches in the floor
• Carts use steel pins (or grippers) to project below floor
level and engage the chain (or pulley) for towing
• This allows the carts to be disengaged from towline for
loading and unloading
Overhead Trolley Conveyor:
• A trolley is a wheeled carriage running on an
overhead track from which loads can be suspended
• Trolleys are connected and moved by a chain or
cable that forms a complete loop
• Often used to move parts and assemblies between
major production areas
Cart-On-Track Conveyor:
• Carts ride on a track above floor level
• Carts are driven by a spinning tube
• Forward motion of cart is controlled by a drive
wheel whose angle can be changed from zero (idle)
to 45 degrees (forward)
(e) Cranes and hoists: These are handling devices for lifting,
lowering, and transporting materials, often as very heavy
loads. Hoists accomplish vertical lifting; both manually
operated and powered types are available. Cranes provide
horizontal travel and generally include one or more hoists.
Prinsip-prinsip material handling
(Meyers, 2003)
 Perencanaan
 sistem aliran
 aliran material
 penyederhanaan
 gravitasi
 memanfaatkan ruangan
 ukuran satuan
 mekanisasi
Prinsip-prinsip material handling
(Meyers, 2003)
 Otomasi
 pemilihan peralatan
 standardisasi
 kemampuan adaptasi
 bobot mati
 utilisasi
 perawatan
 keuangan
Prinsip-prinsip material handling
(Meyers, 2003)
 Pengawasan
 kapasitas
 efektivitas
 keamanan
Biaya penanganan material
 Biaya investasi
harga pembelian peralatan, harga komponen alat
bantu dan biaya instalasi
 biaya operasi
biaya perawatan, biaya bahan bakar dan biaya
tenaga kerja
 biaya pembelian muatan
biaya pembelian pallet dan container
 biaya pengepakan dan kerusakan material
Contoh
Sebuah alat angkut forklift dibeli dengan
harga Rp. 50 juta diharapkan umur
ekonomis 5 tahun. Biaya BBM
Rp.20000/hari, biaya perawatan
Rp.5000/jam. Jika forklift berjalan rata-rata
15000 m/hari, tentukan biaya persatuan
jarak. Diasumsikan alat angkut beroperasi
300 hari/tahun dan upah operator
Rp.10000/jam.
Penyelesaian
 Depresiasi (penyusutan) = Rp50.000.000 /(5th x 300 hr x 8
jam) = Rp. 4166/ jam
 Jarak pengangkutan tiap jam =
15000m/hr / 8 jam = 1875 m/jam
 Total biaya = biaya maintenance + biaya BBM + biaya
depresiasi + biaya operator
= 5000+20000/8+4166+10000 = Rp. 21666/jam
 Biaya material handling (OMH/M) =
21666/1875 = Rp.11,55/m
Rasio Produktivitas
 Indeks pekerja penanganan material

l
IPPM =
L
dimana:
l = pekerja yang menangani material
handling
L = jumlah pekerja keseluruhan
Rasio Produktivitas
 Indeks penggunaan peralatan

k
IPP =
K
dimana:
k = komponen yang ditangani
K = kapasitas teoritis
Rasio Produktivitas
 Indeks penggunaan ruang penyimpanan

s
IPRP =
S
dimana
s = luas ruang penyimpanan yang dipakai
S = luas ruangan seluruhnya
Rasio Produktivitas
 Indeks Pergerakan Operasi (IPO)

m
IPO =
M
dimana:
m = jumlah gerakan perpindahan material
M = jumlah operasi produktif
Rasio Produktivitas
 Indeks efisiensi siklus manufacturing

Ta
IESM =
Td
dimana:
Ta = waktu kegiatan produksi/operasi
Td = waktu tersedia
Rasio Produktivitas
 Prosentase area gang

As
PAG =
Ts
dimana:
As = area yang digunakan untuk gang
Ts = jumlah ruangan
Nilai ideal : 0,1 - 0,15
Faktor-faktor untuk Pemilihan
Peralatan Material Handling
 Material yang dipindahkan
jenis, berat, volume, bentuk, ukuran material yang
dipindahkan
 Perpindahan/gerakan
frekuensi, jalur, lebar gang, mekanisme loading&unloading
 Penyimpanan
area, volume, bentuk dan ukuran fasilitas penyimpanan, jarak
antara kolom dll
Faktor-faktor untuk Pemilihan
Peralatan Material Handling
 Biaya
biaya operasi dan investasi peralatan, tingkat suku bunga,
depresiasi, umur ekonomis peralatan
 Faktor-faktor lain
fleksibilitas dalam melakukan pekerjaan ganda dan
pekerjaan atas beberapa produk
Contoh
 Dua peralatan material handling, hand truck dan
forklift digunakan untuk memindahkan produk A
dan B. Pilih dari peralatan tersebut yang lebih
hemat untuk dipakai, jika karakterisasi produk dan
spesifikasi peralatanadalah sbb:

Produk yang Volume Jarak Satuan yang

dipindahkan (cm) perpindahan dipindahkan
A 30x15x15 150m 230/hari
B 60x60x60 150m 260/hari
Peralatan Maksimum Biaya Ongkos material
Volume (cm) loading/unloading handling(OMH/m)
Handtruck 150x90x120 Rp.50000 Rp.1500
Forklift 120x120x120 Rp.25000 Rp.7500
Penyelesaian
 Langkah 1 Menentukan kapasitas peralatan
Produk A:
150 x 90 x120
handtruck =  240 unit
30 x15 x15
120 x120 x120
forklift =  256 unit
30 x15 x15
Produk B:
150 x90 x120
handtruck =  4 unit
60 x 60 x 60

forklift = 120 x120 x120

 8 unit
60 x 60 x 60
Penyelesaian
 Langkah 2 Menentukan frekuensi perpindahan
Produk A dengan handtruck/hari
satuan yang dipindahkan 230
frekuensi    0,958  1
kapasitasalat angkut 240

Produk B dengan handtruck/hari = 260/4= 65 kali

Produk A dengan forklift/hari = 230/256 = 1 kali
Produk B dengan forklift/hari 260/8 =33 kali
Penyelesaian
 Langkah 3 Menentukan biaya pemindahan
Handtruck :
[(frekuensiproduk A x biaya load/unload)+(OMH/m x jarak
perpindahanproduk A)] + [(frekuensiproduk B x biaya
load/unload)+(OMH/m x jarak perpindahanproduk B)] =
[(1 x Rp.50000)+(Rp.1500 x 150m)] +
[(65 x Rp.50000)+(Rp.1500/m x 75m)] = Rp. 3.637.500,-
Forklift :
[(1 x Rp.25000)+(Rp.7500 x 150m)] +
[(33 x Rp.25000)+(Rp.7500/m x 75m)] = Rp.2.537.500,-