Академический Документы
Профессиональный Документы
Культура Документы
2014/2015
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
2014/2015
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.
2014/2015
Process
Time
C
Theoretical
Actual
Machine
Machine Needed
Machine
Machine Defective Demands Production
Effeciency
Capacity
Capacity
Theoretical Actual
D
E
F
G
H
I
J
K
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
=
Demand
1 (defective looping process)
2014/2015
Demand
Actual Machine Capacity
2. TIME
2014/2015
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:
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
2014/2015
Advantages of conveyor:
Disadvantages of conveyor:
Damaging one part of the conveyor will stop the flow of the
process.
2014/2015
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.
2014/2015
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.
2014/2015
Picture III.7 Pallet Jack, Trolley Box And Mesh Pallet Box
(Source: www.mspe.in)
10
2014/2015
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.
11
2014/2015
12