Modul 3

MODUL PRAKTIKUM PERANCANGAN TATA LETAK FASILITAS

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MODUL III

DETERMINING MACHINE NEEDS FOR FACTORY LAYOUT

PLANNING AND MATERIAL HANDLING

PRACTICUM OBJECTIVES

1. Practican is able to create routing sheet tables

2. Practican is able to analyze machine needs and calculate the number of

parts to produce the desired product using routing sheet.

3. Practican knows and understands the material handling systems and their

benefits.

4. Practican is able to understand and create material handling systems for

the company

PRACTICUM TOOLS

1. Microsoft excel


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III.1 Routing Sheet

III.1.1 Routing Sheet Definition

Routing sheet is chart that shows the need for materials, engine capacities,

efficient of machine and the others in an attempt to obtain a product desired

(James, 1977). Meanwhile, according to Apple (1990), a routing sheet is the

tabulation steps covered in producing special components and details that

need to be certain of the related things.

The required data in the calculation of the routing sheet is a sequence of

operations of each component, the name or the type of used equipment, the

percentage of scrap and efficiency factory. Sequence of operations on a

routing sheet is based on the sequence of operations that exists on the OPC.

The informations obtained from the routing sheet is able to know theoretical

machine capacities, number of prepared units, and the products with the

efficiency theoretical and the number of machines.

III.1.2 The Purposes of Routing Sheet

Routing sheet is made to streamline and simplify the way how to produce.

There are specific objectives of the routing sheet:

1. Find out the process flow (from preparation to packaging) suffered by

the materials for each type of component to determine the number of

machine.

2. As a basic of determining factory layout.

3. As a tool for improve the ways of work is being done.

4. As a process time guiandce of component for each machine.

5. Disciplining / familiarize operators to work regularly and quickly

according to what has been planned.


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III.1.3 Tabel Routing Sheet

Table IV.1 Routing Sheet

Explanation:

A : Operation name for each process

B : Name of machine that used for each process

C : Time that is needed of machine for doing process

D : Average product can be generated by machine in one day

E : Skill level or measure success of a machine to produce a product

F : The actual machine capacity

G : Process failure and cannot be used again (defective) or residual (scrap)

H : Units produced per day

I : Number of products that are prepared after the defective per day

J : Number of machines required to meet the production

K : Number of machines required according to the condition of existing

Notes:

Time process and defective are given by OPC (previous module)

Demands are according the process flow

Theoritical Machine Capacity

=unit processing time × working hours perday

process time

Actual Machine Capacity

= Theoritical Machine Capacity × Machine Effeciancy

Production = Demand

1 − (defective × looping process)

Theoretical Actual

A B C D E F G H I J K

Actual

Machine

Capacity

Defective Demands ProductionMachine Needed

No Operation MachineProcess

Time

Theoretical

Machine

Capacity

Machine

Effeciency


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Theoritical Machine Needed =Demand

Actual Machine Capacity

III.2 Material Handling System

III.2.1. The Definition of Material Handling and Material Handling

Equipment

There are two definitions of material handling:

Material handling is the art and science of moving, storage, protecting, and

controlling of the material.

Material handling is handle material in the right amount of appropriate

material in good condition at a suitable place, at the right time in the right

position, in order that appropriate and low cost to the correct method.

Meanwhile, Material Handling Equipment (MHE) is equipment used to move

material from one place to another in a short distance, such as the section or

department of the factory, on the accumulation place of materials, construction

sites, storage and unloading place and so on. MHE only moves material in

amount, large, and a certain distance with a displacement of material towards the

vertical, horizontal, or a combination of both.

Material handling systems focus more to discuss about:

1. MOTION : able to move material from one location to another.

2. TIME : able to solve the problem in an industry for any material arrival

time can be fulfilled on time, not too late or too early.

3. QUANTITY : able to bring material in the right amount.

4. SPACE : shape of the flow of material handling systems will affect the

space.


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III.2.2 Purpose of Material Handling

The main purpose of material handling system design is basically to improve the

transfer efficiency of material, so it reduces production cost and affects the

operation and design of the planned facility.

There are some of the objectives of material handling systems:

Maintains or improves the quality of products, reduces damage and provides

protection against materials

Improves security and develops working conditions

Increasing productivity include material moving in a straight line, move a

distance as close as possible, the unit load, increasing the charge with

automatic MHE.

Increases the level of using the facility include the using of the building,

multipurpose building procurement, standardization of MHE, the MHE

integration in a system.

Reduces deadweight

Controls an inventory

III.3 Kinds of Material Handling Equipment

The main of the material handling system is a material handling equipment

(MHE). Most of the existing equipment has characteristics and different

prices. All material handling equipments are classified into three main types:

conveyor, cranes, and trucks.

a. Conveyor

Conveyor is a tool used to move material continuously at a fixed path.

Here are several types of conveyor which is used: belt conveyor, roller

conveyor, screw conveyor, etc.


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Advantages of conveyor:

High capacity making it possible to move large number of

materials.

Fixed speed and it can be adjustable.

Handling is able to be combined with other activities such as

process and inspection.

Can be placed on the operator or on the floor.

Material can be stored temporarily among workstation.

Transportation of goods is done automatically and does not need

operator.

Does not require aisle.

Disadvantages of conveyor:

Following fixed line so transport is limited in that area.

Posible to occour a bottle neck.

Damaging one part of the conveyor will stop the flow of the

process.

There is in fixed place so it would disturb movement of other

machines.

Picture III.4 Belt Conveyor, Roller Conveyor, Screw Conveyor

(Source: www.automatedconveyors.com)


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b. Cranes & Hoists

Cranes and hoists are the equipment used to move material

intermittently with a limited area. There are several types of cranes and

hoists: jib crane, bridge crane, gantry crane, stacker crane, etc.

Advantages of cranes and hoists:

It is possible to lift and move objects.

Little linkage with production work floor.

The work floor can be saved by installing equipment such as cranes.

Disadvantages of crane and hoist:

Need a large investment

Services are limited to the existing area.

Crane only moves in the straight line and cannot use spin/turn.

Picture III.5 Jib Crane, Bridge Crane

(Source: http://www.abuscranes.co.uk/)


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c. Trucks

Trucks are driven by hand or move material with a wide range of

existing lines. Included in this group are forklift, pallet jacks,

automated guide vehicles (AGV) and so on.

Advantages of trucks:

Displacement does not use fixed line so that it can be used

everywhere as long as the room can be passed by trucks.

Be able to loading, unloading, and lifting

Because the movement is not limited, allowing to serve different

places, trucks are able to reach a high level of usage.

Disadvantages of trucks:

Not able to handle heavy loads, such as cranes.

Has limited capacity.

Requires aisle to pass.

Most of the trucks have to be driven by the operator.

Unable to perform double duties/joint venture, such as processing

and inspection like conveyor.

Picture III.6 Forklift and Automated Guide Vehicles (AGV)

(Source: English.chinapost.com.cn)


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Picture III.7 Pallet Jack, Trolley Box And Mesh Pallet Box

(Source: www.mspe.in)

III. 4 Relationship between Materials Handling and Layout

The layout seen from the perspective of production is defined as the

arrangement of production facilities to gain efficiencies in a production.

Layout design should ensure smooth flow of materials, storage of

materials, or raw materials, semi-finished and finished products. Facility

system design, layout design, and design of material handling are

essentially concerned inseparable. What often happens that the design of

the layout and material handling is done first, while the design of the

system to adjust the layout of the facility that has been designed. For the

design of the layout cultivated as flexible as possible. So, one of the

benchmarks in creating an efficient layout is a layout that is able to

minimize material handling compiled by a straight comparison between

the distance of the engine/activity and the frequency of their material

displacement, therefore it need to calculate the material handling

comparisons between the existing layout and the proposal later.


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REFERENCE

1. Tompkins, James A., White, John A., Bozer , Yavuz A., & Tanchoco, J. M

.A.. Facilities Planning Fourth Edition. United States of America: John Wiley

& Sons, Inc. 2010.

2. Wignjosoebroto, Sritomo. Tata Letak Pabrik dan Pemindahan Bahan.

Surabaya: Guna Widya. 2009

3. PFT Laboratory. Modul Praktikum Perancangan Fasilitas Telekomunikasi.

Bandung. Bandung: Telkom University. 2013

4. Purnomo, Hari., Perencanaan dan Perancangan Tata Letak Fasilitas.

Yogykarta : Graha Ilmu. 2004.


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Documents

Modul 3