Klasifikasi Material Handling
Klasifikasi Material Handling
Klasifikasi Material Handling
edu/~kay/mhetax/
Material Handling Equipment
Material handling equipment (MHE) is used for the movement and storage of material within
a facility or at a site. MHE can be classified into the following five major categories:
I. Transport Equipment. Equipment used to move material from one location to another
(e.g., between workplaces, between a loading dock and a storage area, etc.). The
major subcategories of transport equipment are conveyors, cranes, and industrial
trucks. Material can also be transported manually using no equipment.
II. Positioning Equipment. Equipment used to handle material at a single location so that
it is in the correct position for subsequent handling, machining, transport, or storage.
Unlike transport equipment, positioning equipment is usually used for handling at a
single workplace. Material can also be positioned manually using no equipment.
III. Unit Load Formation Equipment. Equipment used to restrict materials so that they
maintain their integrity when handled a single load during transport and for storage. If
materials are self-restraining (e.g., a single part or interlocking parts), then they can be
formed into a unit load with no equipment.
IV. Storage Equipment. Equipment used for holding or buffering materials over a period
of time. Some storage equipment may include the transport of materials (e.g., the S/R
machines of an AS/RS, or storage carousels). If materials are block stacked directly
on the floor, then no storage equipment is required.
I. Transport Equipment
A. Conveyors
1. Chute conveyor 11. Screw conveyor
2. Wheel conveyor 12. Pneumatic conveyor
3. Roller conveyor 13. Vertical conveyor
4. Chain conveyor 14. Cart-on-track conveyor
5. Slat conveyor 15. Tow conveyor
6. Flat belt conveyor 16. Trolley conveyor
7. Magnetic belt conveyor 17. Power-and-free conveyor
8. Troughed belt conveyor 18. Monorail
9. Bucket conveyor
10. Vibrating conveyor 19. Sortation conveyor
B. Cranes
1. Jib crane
2. Bridge crane
3. Gantry crane
4. Stacker crane
C. Industrial Trucks
1. Hand truck 8. Narrow-aisle reach truck
2. Pallet jack 9. Turret truck
3. Walkie stacker 10. Order picker
4. Pallet truck 11. Sideloader
5. Platform truck 12. Tractor-trailer
6. Counterbalanced lift truck 13. Personnel and burden carrier
7. Narrow-aisle straddle truck 14. Automatic guided vehicle (AGV)
D. No Equipment
.
I. Transport Equipment
Transport equipment is used to move material from one location to another (e.g., between
workplaces, between a loading dock and a storage area, etc.) within a facility or at a site.
I-A. NO EQUIPMENT
I-B. Conveyors
Conveyors are used to move materials over a fixed path. The major types of conveyors are:
1. Chute Conveyor
2. Wheel Conveyor
3. Roller Conveyor
Unit + On-Floor + Accumulate
May be powered (or live) or nonpowered (or gravity)
Materials must have a rigid riding surface
Minimum of three rollers must support smallest loads at all times
Tapered rollers on curves used to maintain load orientation
3(a) Gravity Roller Conveyor
Alternative to wheel conveyor
For heavy-duty applications
Slope for gravity movement depends on load
weight
For accumulating loads
5. Slat Conveyor
Bulk + On-Floor
9. Bucket Conveyor
Bulk + On-Floor
Used to move bulk materials in a vertical or inclined path
Buckets are attached to a cable, chain, or belt
Buckets are automatically unloaded at the end of the conveyor run
10. Vibrating Conveyor
Bulk + On-Floor
Consists of a trough, bed, or tube
Vibrates at a relatively high frequency and small
amplitude in order to convey individual units of
products or bulk material
Can be used to convey almost all granular, free-
flowing materials
An Oscillating Conveyor is similar in construction,
but vibrates at a lower frequency and larger amplitude (not as gentle) in order to convey
larger objects such as hot castings
Bulk + On-Floor
Bulk/Unit + Overhead
Can be used for both bulk and unit movement of materials
Air pressure is used to convey materials through a system of vertical and horizontal tubes
Major advantages are that material is completely enclosed and it is easy to implement turns
and vertical moves
Used for low-frequency intermittent vertical transfers (cf. vertical chain conveyor can be
used for continuous high-frequency vertical transfers
Unit + On-Floor/Overhead
Sortation conveyors are used for merging, identifying, inducting, and separating products to
be conveyed to specific destinations
19(a) Sortation Conveyor: Diverter
Stationary or movable arms that deflect, push, or pull a product to desired destination
Since they do not come in contact with the conveyor, they can be used with almost any flat
surface conveyor
Usually hydraulically or pneumatically operated, but also can be motor driven
Simple and low cost
One or more rows of powered rollers or wheels or chains that pop up above surface of
conveyor to lift product and guide it off conveyor at an angle; wheels are lowered when
products not required to be diverted
Only capable of sorting flat-bottomed items
Pop-up rollers are generally faster than pop-up wheels
19(c) Sortation Conveyor: Sliding Shoe Sorter
Cranes are used to move materials over variable paths within a restricted area. The major
types of cranes are:
1. Jib crane
2. Bridge crane
3. Gantry crane
4. Stacker crane
Used to move loads over variable (horizontal and vertical) paths within a restricted area
Used when there is insufficient (or intermittent) flow volume such that the use of a conveyor
cannot be justified
Provide more flexibility in movement than conveyors
Provide less flexibility in movement than industrial trucks
Loads handled are more varied with respect to their shape and weight than those handled
by a conveyor
Most cranes utilize hoists for vertical movement, although manipulators can be used if
precise positioning of the load is required
1. Jib Crane
Operates like an arm in a work area, where it can function as a manipulator for positioning
tasks
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2. Bridge Crane
Underhung crane can transfer loads and interface with other MHS (e.g., monorail systems)
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3. Gantry Crane
Industrial trucks are used to move materials over variable paths, with no restrictions on the
area covered by the movement. The major types of industrial trucks are:
Industrial trucks:
Used to move materials over variable (horizontal) paths with no restrictions on the area
covered (i.e., unrestricted area)
Provide vertical movement if the truck has lifting capabilities
Used when there is insufficient (or intermittent) flow volume such that the use of a conveyor
cannot be justified
Provide more flexibility in movement than conveyors and cranes
Not licensed to travel on public roads—"commercial trucks" are licensed to travel on public
roads
Characteristics:
Pallet/Non-Pallet: Does the truck have forks for handling pallets, or does the truck have a
flat surface on which to place loads. Non-Pallet => (usually) other means required to load
truck.
Manual/Powered: Does the truck have manual or powered vertical (lifting) and/or
horizontal (travel) movement capabilities. Manual => walk => operator provides the force
needed for lifting loads and/or pushing the vehicle. Powered => on-board power source
(e.g., batteries) used for lifting and/or travel.
Walk/Ride: For non-automated trucks, can the operator ride on the truck (in either a
standing or sitting position) or is the operator required to walk with the truck during travel.
Walk => manual or powered travel possible => powered travel speed limited to a normal
walking pace. Ride => powered => travel speed can be faster than a walking pace.
Stack/No Stack: Can the truck be used to lift loads for stacking purposes. Stack => can also
be used as no stack => more expensive to add stacking capability. No Stack may lift a load a
few inches to clear the floor for subsequent travel (e.g., pallet jack), but the loads cannot be
stacked on top of each other or on shelves.
Narrow Aisle: Is the lift truck designed to have a small turning radius or does it not have to
turn at all in an aisle when loading/unloading. Narrow Aisle => greater cost and (usually)
standing operator => less aisle space required. Counterbalance and/or straddle used for load
support. Small turning radius => load support via straddle or reaching capabilities. No
turning required => even narrower aisle => only one-side loading (sideloaders) or the
capability to rotate the load (turret truck).
Automated: Is the truck automated so that it can transport loads without requiring an
operator. Non-Automated => direct labor cost of operator is by far the largest cost to
operate a non-automated truck. Semi-Automated => operator used to control
loading/unloading, but automated transport control (e.g., the S/R machine of a Man-on-
board AS/RS). Automated => Automated Guided Vehicle (AGV) => no direct labor cost, but
higher equipment costs.
1. Hand Truck
1(b) Dolly
Sometimes referred to as a
"cart" or "(manual) platform
truck"
2. Pallet Jack
4. Pallet Truck
Arm clearance typically provided through the use of load-on-beam rack storage or single-
wing pallets for load-on-floor storage
9. Turret Truck
Greater stacking height compared to other narrow-aisle trucks (40 ft. vs. 25 ft.), but greater
investment cost
Forks rotate to allow for side loading and, since truck itself does not rotate during stacking,
the body of the truck can be longer to increase its counterbalance capability and to allow the
operator to sit
Can function like a sideloader for transporting greater-than-pallet-size load
9(a) Operator-Down Turret Truck
Operator not lifted with the load
5-6 ft. minimum aisle width requirement
11. Sideloader
Positioning equipment is used to handle material at a single location so that the material is in
the correct position for subsequent handling, machining, transport, or storage. Unlike
transport equipment, positioning equipment is usually used for handling at a single
workplace. Material can also be positioned manually using no equipment. The major types of
positioning equipment are:
As compared to manual handling, the use of positioning equipment can provide the following
benefits [Modern Materials Handling, Sept. 1993]:
raise the productivity of each worker when the frequency of handling is high,
improve product quality and limit damage to materials and equipment when the item
handled is heavy or awkward to hold and damage is likely through human error or
inattention, and
reduce fatigue and injuries when the environment is hazardous or inaccessible.
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Under ideal circumstances, maximum recommended weight for manual lifting to avoid back
injuries is 51 lbs.
Recommendation based on NIOSH (National Institute for Occupational Safety and Health)
1994 Lifting Equation, which uses six multipliers to reduce maximum recommended weight
for less than ideal lifting tasks
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2. Lift/Tilt/Turn Table
Pallet load levelers are lift and turn tables used in manual
palletizing to reduce the amount of bending and stooping
involved with manually loading a pallet by combining a
lifting and turning mechanism with a device that lowers the
table as each layer is completed so that loading always takes place at the optimal height of 30
inches
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3. Dock Leveler
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Since loads are pushed on the table, ball friction limits the maximum load weight to 600 lbs.
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5. Rotary Index
Table
Since each part moves between stations at the same time, it is difficult to put buffers between
stations
Different from conveyors used as in-line indexing machines, where linear transfers can take
place between multiple workcenters separated by long distances, since a rotary index table is
restricted to circular transfers with a single compact workcenter
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6. Parts Feeder
Parts feeders can be used to provide inspection capabilities with respect to the shape and
weight of parts (e.g., the coin feeder of a vending machine)
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Can be used in warehousing as the mechanism to convert stationary racks into sliding racks
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8. Hoist
9. Balancer
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10. Manipulator
Manipulators fill the gap between hoists and industrial robots: they can be used for a wider
range of positioning tasks than hoists and are more flexible than industrial robots due to their
use of manual control
10(a) Rigid-Link Manipulator
Unit load formation equipment used to restrict materials so that they maintain their integrity
when handled a single load during transport and for storage. The major types of unit load
formation equipment are ([+] = more info):
More items can be handled at the same time, thereby reducing the number of trips required
and, potentially, reducing handling costs, loading and unloading times, and product damage.
Enables the use of standardized material handling equipment.
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One or more items that can maintain their integrity when handled as a single item (e.g., a
single part or interlocking parts)
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2. Pallets
Platform with enough clearance beneath its top surface (or face) to enable the insertion of
forks for subsequent lifting purposes
48 x 40 in. pallet is most popular in US (27% of all pallets—no other size over 5%) because
its compatibility with railcar and truck trailer dimensions
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3. Skids
Compared to a pallet, a skid is usually used for heavier loads and when stacking is not
required; a metal skid can lift heavier loads than an equal-weight metal pallet because it
enables a platform truck to be used for the lifting, with the platform providing a greater lifting
surface to support the skid as compared to the forks used to support the pallet
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4. Slipsheets
Advantages: usually used in place of a pallet for long-distance shipping because their cost is
10–30% of pallet costs and their weight and volume is 1–5% of a pallet
Disadvantages: slower handling as compared to pallets; greater load damage within the
facility; special lift truck attachment reduces the vehicle’s load capacity
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5. Tote Pans
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6. Pallet
Boxes/Skid
Boxes
Reusable
container
used to
unitize and
protect
loose items for fork/platform truck handling
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7. Bins/Baskets/Racks
Storage equipment that also can be used to unitize and protect loose discrete items
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8. Cartons
Large quantities of finished carton blanks or knocked-down cartons can be stored on pallets
until needed
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9. Bags
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10. Bulk Load Containers
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11. Crates
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13. Strapping/Tape/Glue
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14. Shrink-Wrap/Stretch-Wrap
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15. Palletizers
Used when flexibility is required (e.g., the "Distributor’s Pallet Loading Problem")
Greatest limitation is capacity, typically 6 cycles per minute; capacity is determined by the
number of items handled with each pick operation
Operators arrange items into the desired pattern for each layer of the unit load and a powered
device is used to transfer layers onto a pallet and then lower the load for the next layer
Used when high throughput of identical loads is required (e.g., the "Manufacturer’s Pallet
Loading Problem")
Capacity is typically greater (30–180 items per minute) than pick and place because an entire
layer is placed on the load at one time; not as flexible as pick and place
Preformed layer of items (cases) are indexed onto the stripper plate (or apron); when properly
positioned over the pallet, the apron is pulled out from underneath the layer to deposit the
layer onto the pallet
"In-line" pattern formation (top picture)—flexible patterns are not possible; ideal for high
speed operation (up to 180 items per minute); takes up more room (larger machine) than right
angle
"Right angle" pattern formation (bottom picture)—very flexible patterns are possible; can
handle a wide variety of case sizes and types; limited capacity (up to 80 items per minute);
compact design
Storage equipment used for holding or buffering materials over a period of time. The major
types of storage equipment are:
The most common reason for storing a product allows the other elements of production to
operate more efficiently on a per-unit basis because the fixed costs associated with utilizing
the element can be spread over more products; e.g., storing up to a truckload of product in a
facility reduces the per-unit costs of shipping; and buffering or storage of WIP enables batch
production which reduces the per-unit setup costs.
Other potential reasons for storage include: time bridging—allows product to be available
when it is needed (e.g., storing spare machine parts at the facility); processing—for some
products (e.g., wine), storage can be considered as a processing operation because the product
undergoes a required change during storage; and securing—e.g., nuclear waste storage.
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Bulk storage using block stacking can result in the minimum cost of storage since cube
utilization is high and no storage medium is required, but material accessibility is low since
only the top of the front stack is accessible and loads at bottom of a stack must not require
support
Storage racks are used when support and/or material accessibility is required
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2. Selective Pallet Rack
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3. Drive-Through Rack
Requires similar-width
loads
4. Drive-In
Rack
Same as
drive-
through
rack, except
closed at
one end,
allowing
entry from
only one
end (LIFO)
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5. Flow-Through Rack
6. Push-Back Rack
Same as push-back
rack, except loaded
and unloaded at the
lower end and closed
at the higher end
(LIFO)
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7. Sliding Rack
8. Cantilever Rack
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9. Stacking Frame
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10. Shelves/Bins/Drawers
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12. Automatic Storage/Retrieval Systems (AS/RS)
Storage/retrieval (S/R) machine in an AS/RS operates in narrow aisle, serving rack slots on
both sides of aisle; can travel in horizontal (along the aisle) and vertical (up and down a rack)
directions at same time
Advantages: fewer material handlers, better material control (including security), and more
efficient use of storage space
Stacking heights up to 130 ft. high, with most ranging from 60 to 85 ft. high; 5 to 6 ft. wide
aisles; single- or double-deep storage racks
Used to store/retrieve small parts and tools that can be stored in a storage bin or drawer
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13. Split-Case Order
Picking System
Unlike an AS/RS, a
split-case order picking
system enables fully
automated picking of
individual items
Robotic based systems are similar in construction to robotic pick and place palletizers
Magazine/dispenser based systems are similar to vending machines, but larger in scale
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14. Mezzanine
Identification and control equipment is used to collect and communicate the information that
is used to coordinate the flow of materials within a facility and between a facility and its
suppliers and customers. The major types of identification and communication equipment
are:
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2. Bar Codes
Bar code system consists of bar code label, bar code scanner, and bar code printer
Noncontact bar code scanners include fixed beam, moving beam, and omnidirectional
1-D codes are most common; 2-D codes enable much greater data storage capability
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4. Magnetic Stripe
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5. Machine Vision
Does not require explicit encoding of data since objects can be identified by their physical
appearance
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Electronic data interchange (EDI) provides standards for inter-corporate transfer of purchase
orders, invoices, shipping notices, and other frequently used business documents
Prior to the Internet, EDI required expensive dedicated value added networks (VANs)