MANUFACTURING SYSTEM

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SASARAN

Memahami sistem manufaktur sebagai sistem integral yang menjadi kerangka

acuan dalam pendidikan Teknik Industri baik yang terkait dengan aspek

struktural, aspek fungsional maupun aspek perancangan dan pengoperasiannya serta

permasalahannya yang terkait dengan profesi Teknik Industri

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What Does IE Do ?

Production Management Corporate Operation System Services* Product &Services * Information System * Comprehensive Planning* Manufacturing Process * Financial &Cost System * Policies & Procedures* Facilities * Personnel * Performance Measurement* Work Methods & Standards * Analysis * Production Planning & Control

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Materi

• Concept of Manufacturing System

• Manufacturing System Design

• Operation & Management System

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CONCEPT OF MANUFACTURING SYSTEM

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Sasaran

Memahami manufactring sebagai kerangka acuan dalam pendidikan

teknik industri baik aspek struktural maupun fungsionalnya

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Materi

• Manufacturing as a Production System

• Transformation Process

• Manufacturing Function

• Manufacturing Cycle

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Manufacture as a Production System

Input Transformation Output

ExtractionPhysicalService

Feedback

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Systemic Aspect• Structural Aspect

– Man, Machine, Material

• Functional Aspect– Man-Man, Man-Material, Man-Machine, Feedback

• Boundary• Environment

– Stakeholder and Societal

• Objective– Unitary, pluralist, coercive

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Factor of Production

»Man

»Machine

»Material

»Management

»Modal

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Performance Criteria

• Quality

• Cost(harga/biaya)

• Delivery(pengiriman)

• Flexibility(flexibel)

• Safety(keamanan)

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Competency

»Technnical

»Managerial . Cooperation

. Leadership

. Adaptive

. Creative

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Structural Aspect

MachineMan

Mat

Boundary

Environment

Input Out-put

: Interaction

Feed-back

Transformation

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Transformation System

1. Classical• Project

• Job Shop

• Flow Shop

2. Emerging• Variable Production Line

• Manufacturing Cells

• FMS

• CIM

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Transformation Process

Form: Order:– Manufacturing ( Discrete ) - Job Shop– Process ( Continue) - Flow Shop– Services - Project

Project Job Shop Flow Shop

Volume Skill Worker Equipment General Special Lay Out Fix Process Product

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Product Lay-out

Peletakan Mesin Berdasarkan Atas Urutan Proses Produksi

Potong Obras Jahit Kancing Finishing Packing

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Process Lay-out

Peletakan Mesin Berdasarkan Atas Kesamaan Jenis Mesin

X

Y

A

F

CB

ED

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Fix Lay-out

Benda Kerja Diam Mesin, Peralatan, Material Dan Karyawan Mendatangi

Benda Kerja

Contoh: • Galangan Kapal

• Assembling Pesawat

• Dll

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Automated Lay-Out

Berdasarkan Atas Kesamaan Fungsi Dan Kemampuan Proses Produksi

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Equipment and Physical Layout Characteristics

Project Job Shop Flow ShopSize of Facility Varies Small Large

Process Flow Circumference Num, Pattern Rigid

Equipment General General Specialized

Capital Ints. Varies Low High

Capital Add. Incremental Small Large Chunk

Speed of Process Varies Slow Fast

Control Worker Worker & Process Design

Tech. Change Slow Average Fast

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Direct Labor and Work Force Characteristics

Project Job Shop Flow ShopLabor value added High Average Very Low

Job content scope Large Average Small

Skill level High Average Low

Wage rate High Average Low

Worker training V. High High Low

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Material and Information Control Characteristics

Project Job Shop Flow ShopMaterial Requirement Varies Unpredictable Predictable

Vertical Integration None Limited Back&Forwd

Inv. Raw Material None Small Large

WIP Large Large Small

Finished Goods None Small High

QC Responsibility D. Labor D. labor QC Specialist

Prod/Serv, Information V. High High Low

Scheduling Uncertain Changes Inflexible

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Process Management Characteristic

Project Job Shop Flow ShopChallenges Estimating Lab.Utilization Avoid Downtime

Sequencing Debottlenecking Time Expansion

Pacing Learning Curve Cost Minimizing

Tools PERT/ Load Chart Line Balancing

CPM Optimization

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Product/Service Start-up Growth Stable Decline

Volume Low Increasing High DecliningVariety Unique Inc.Standard Emergence High Standard Dom. Design Process Technology Organization Project Small Batch Line flow Line flow Job shop Assembly AssemblyInnovation High Medium Medium LowIntegration Low Medium Medium High

Industry Structure Small Consolidation Few large Survivor competitor and fallout competitor Competitive Flexibility Quality and Price(cost) Price(cost) Priority Flexibility Delivery

Product/Service and ProcessTechnology Life Cycles

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Variable Production Line

Dedicated High Volume Lines That Are Reconfigured to Permit Some Process

Variation and Thus Several Different Products or Service

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Manufacturing Cell (MC)

Dedicated Subset of Manufacturing System Designed to Process Part

Families or Product Group

Economies of Set-up

Employee Learning

Reduced WIP

Shorter Throughput Time

Improved Responsiveness to Customer

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Flexible Manufacturing System(FMS)

Integrates and Enhances the Flexibility of Manufacturing Cell Through the Use of

Centralized Control Systems

Flexibility Approaching Job Shop With Material Handling Capability of a Flow Lines

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Computer Integrated Manufacturing (CIM)

Application of a computer system to link several separated information systems and

technologies at different functional level

Simplify, Automate and Integrate

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Stage Toward A CIM

Batch/Lot ProcessMRPII/SPC

JIT &MC Focused factoryStable Flow

FMS CAD/CAMRobotics AMH/GT

CIMInformation System

Integration

Traditional Mfg. Variable Line

Stage 3

Stage 1

Stage 2

Stage 4

To CIM

Process Technology Process Control System

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Manufacturing Function

Marketing Engineering

FabricationProduction

Management

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Marketing• Need Identification

• Type of Product/Service• Customer • Specification• Purchasing Power • Volume• Distribution Channel

• Product/Service Delivery• Marketing Mix

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Engineering

Design Product’s Blue Print According To Customer’s Demand

• Product Design

• Process Planning

• Product Planning

• Method Engineering

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Fabrication

Make Product According to the Blue Print From Engineering

Production Control

Process Control

Quality Control

Facilities Control

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Production Management

Support Manufacturing In Order To Fulfill the Customer’s Demand

• Production Planning And Control• Inventory Control

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Manufacturing Cycle

Marketing/ Sales

Product Design Process Design

Inventory Control

Production Planning and

Control

Work Method , Time Standard & Productivity Improvement

Fabrication Receiving

Receiving

Shipping

Suppl i er

Cus tomer

Quality Control

Production Control

Process Control

Facilities Control