Materi5 Biaya Material Handling
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Transcript of Materi5 Biaya Material Handling
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Materials Handling Analysis
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Material HandlingMaterial handling is the function of moving the
right material to the right place, at the right time, in the right amount, in sequence, and in
the right position or condition to minimize production costs.
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Five Aspects of Material Handling1. Movement2. Quantity3. Time4. Space5. Control
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Goals of Material Handling Maintain or improve products quality,
reduce damage, and protect materials Promote safety and improve working
conditions Promote productivity
Straight flow Automate as required Use gravity! It’s free power
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Goals of Material Handling Promote increased facility use
Cube utilization Versatile equipment Develop a PM program
Reduce tare weight (dead weight) Control inventory
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Material HandlingProper material handling can: Improper Material Handling
accounts for 50% of all work related injuries
Material Handling accounts for 40% of the organization’s operating costs.
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Material HandlingProper material handling can: Improve ergonomics Minimize total costs Improve worker safety Reduce human exertion Minimize physical labor
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Material Handling Examples
Lift tables are available with complete 360-
degree turntables so that the operator can work from one side.
They can also be made to tilt up to 90
degrees so that master cartons can be accessed more easily without bending over
into the carton
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Material Handling Examples
Filled drums can be moved utilizing one
person will the proper material
handling equipment.
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Material Handling Examples
How about combining four trips into one?
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Material Handling Examples
Sheet goods. . .why use more than one worker when you can achieve the same results with less waste of waiting
and risk of injury?
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Material Handling Examples
Odd shapes? No problem. . .
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Material Handling Examples
Roll stock . . .
Heavy coil . . .
Heavy boxes . . .
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Material Handling Examples
Conveyors . . .
Gravity Conveyor
Powered Roller Conveyor
Ball Transfer Table
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Material Handling Examples
Telescoping Conveyors . . .
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Material Handling Examples
Stretchaveyor Systems. . .
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Material Handling Supporting Pull Manufacturing
Custom built for unique products.
Note: Holding slots designed to aid inventory control.
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Material Handling Supporting Pull Manufacturing Container holds
approximately 200 pieces.
Note: Kanban sign
Note: Tare weight for weigh counting
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Material Handling IdealsMaterial Handling Ideals to live
by. . .1. KISS – “keep it simple and sane”2. “the best material handling
system is no material handling system at all”
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Material Handling Basic Questions
What operation are we doing? Why do we need to move this
material? Where is the material going? When and how often are we doing it? How are we currently doing it? Who is performing this function?
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Cost Justification ExampleAn oil remanufacturing company uses clay in its manufacturing process. The clay comes into the plant in 80# bags (only size available) stacked 40/pallet and 50 pallets/boxcar. Two carloads per year are used. Since there is no railroad spur to the dock, the union and company agreed that two part-time workers would be hired for one week, twice a year at the rate of $7.50/hr to unload these cars. You are asked to investigate the process and provided recommendations for improvement.
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Cost Justification ExampleWhy is this done? We need clay, and the railroad is by far the cheapest way to transport it. Let’s look at it like this:
What? = 80# x 40 bags x 50 pallets = 160,000#/boxcar
Where? = From the boxcar to the warehouse (300 feet)
Who? = Two temporary workers
When? = One week, twice a year
How? = Manually unload the pallets then move these pallets into the storeroom with the fork truck that we own.
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Cost Justification Example
What do we know?
4 weeks x 40 hrs/week x $7.50/hr = $1,200/year
1. Is the current method the cheapest in the long run?
2. How could you justify a $2,400 expenditure (2 year ROI) to improve the task that is performed so infrequently?
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Part of Body Affected by Injury
Number of Nonfatal Occupational Injuries & Illnesses
Upper Extremities27%
Back30%
Neck2% Shoulder
6%
Lower Extremities24%
Body Systems1%
Multiple Parts10%
1999 BLS Data
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Cost Justification ExampleWhat do we know now?
1. Consider the worker.
2. Material handling is not a simple cost benefit analysis.
3. Look at the whole approach when asking the questions.
4. Consider the claim rates of the company.
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SECS Study
Eliminate
Combine
Simplify
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Large Vs. Small Unit LoadOne should always try to maximize / optimizemaximize / optimize the quantity, size, and weight of the load handled.
The intent is to reduce the overall number of movements or trips required to move or transport a given quantity of materials. Don’t increase load at the expense of inventory!
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Materials Handling and Cycle Time
Operation A
Lot Size Container Size Cycle Time1
100
100
1
100
1
30 min
3,000 min
1,020 min
Operation B
Move
Operation C
Move
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Cycle Time ExampleRemember the second ideal?“the best material handling system is no material
handling system at all”
How about SECS?Do we really need to move between the operations?
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Material Handling Utopia The best of both worlds combines
manufacturing and shipping containers Prevalent in the auto industry
Stackable / nestable racks Collapsible containers Inexpensive to acquire and retain
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Material Handling with Pallets
The most common unit load is the pallet. Almost anything can be stacked on a pallet, tied with bonding or plastic wrap, and moved around the plant or world as on unit. Pallets are made of a variety of materials with greatly differing costs.
Cardboard pallets @ $1 ea will make one trip
Plastic pallets @ $4 ea will make 20 trips
Wooden pallets @ $20 ea will make 100 trips
Steel skids @ $150 ea will make 2,000 trips
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Material Handling with Pallets
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Collapsible Containers
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Collapsible and Nestable Containers
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Materials Handling Analysis Tools Operation process chart (OPC) is used to analyze
relations between operations and is useful for analyzing assembly operations and layout
Flow process chart is used to identify detailed problems such as delay in time, storage costs and material handling costs
Flow diagram mainly concerns with floor space, traffic congestion and traveling distance
PERT chart is used as a project scheduling tool and concerns with timing objective and costs for major projects
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The Performance Principle
Material Handling Hours
Total Labor HoursPercentage of M.H. =
Know what your material handling costs are and continuously work to reduce them. The process chart provides the form to calculate the unit cost of every move. Tracking this percentage can show the improvements in performance.
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From-To Charts Can indicate both volume and process
flow Constructed like a mileage chart List the process steps in their “natural”
direction Can be computer generated or simple
hash tabulation marks Note both the required sequence and
intensity of materials flow Note the handling difficulty and cost
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From-To Chart Most exact technique
of the three
Considers the importance of the parts
Establishes a relative importance ranking
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From-To Chart Example Step 1-
Establish the Relative ImportanceRelative Importance factor
Part No. Quantity per Day Weight in Pounds Total Weight (lbs) Relative Importance1 2,000 0.5 1,000 1.02 2,000 9.0 18,000 18.03 3,000 15.0 45,000 45.0
Step 2-– Create the from-to matrix
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From-To Chart ExampleR A B C D S Total
R 1 18 45 64
A 1 45 18 64
B 18 1 19
C 18+45 1 64
D 1 45 46
S
Total: 257
FRO
M
To
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From-To Chart Example Step 3- Assign the penalty points
Double P.P.
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From-To Chart Example Step 4- Determine the efficiency and evaluate
Efficiency = 257 / 699
= 37%
Can we do better?
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5 MsFive basic factors affect all moves: Man Materials Methods of handling Moves – distances and elevations Money – cost of materials
movement and handling equipment
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Questions and Comments