Kuliah-1
-
Upload
ozora-yisrael -
Category
Documents
-
view
57 -
download
0
Transcript of Kuliah-1
PRODUCTION PLANNING & PRODUCTION PLANNING & INVENTORY CONTROLINVENTORY CONTROL
E.F. SRI MARYANI SANTOSOE.F. SRI MARYANI SANTOSO
SCOPE OF PPICSCOPE OF PPIC
Planning, execution, and control of Planning, execution, and control of production rates and inventory levels production rates and inventory levels to achieve customer satisfaction at to achieve customer satisfaction at minimum cost.minimum cost.
Good production and inventory Good production and inventory control can be a competitive weaponcontrol can be a competitive weapon
RULE OF CONDUCTRULE OF CONDUCT
Min 80% Present in ClassMin 80% Present in Class
Present in Class Before Starting Present in Class Before Starting the Lecturethe Lecture
Don’t Use Sandal, T shirt and Don’t Use Sandal, T shirt and Hand Phone During the LectureHand Phone During the Lecture
Having Good AttitudeHaving Good Attitude
ASSESSMENTASSESSMENT
Requirements: Requirements: – Min 80% Present in ClassMin 80% Present in Class– Having Good AttitudeHaving Good Attitude
Score/Grade :Score/Grade :– Mid Semester Test (UTS) : 35%Mid Semester Test (UTS) : 35%– Final Test (UAS): 50%Final Test (UAS): 50%– Homework (paper, problems) : Homework (paper, problems) :
15%15%
PRODUCTION SYSTEMPRODUCTION SYSTEMSystem is an assembly of elements or System is an assembly of elements or components or part related in an whole to reach components or part related in an whole to reach an objectivean objective
Production is an activity to improve the values of Production is an activity to improve the values of to input to be outputto input to be output
Production system is to functionalize of Production system is to functionalize of materials, machines, work force, capital, and materials, machines, work force, capital, and methods to produce a product that can meet at a methods to produce a product that can meet at a level of quality, price, and availability.level of quality, price, and availability.
INPUTOPERATION/TRANSFORMATION OUTPUT
CUSTOMER OR CLIENT PARTICIPATION
PERFORMANCE INDICATOR
PRODUCTION SYSTEM
Production system exhibits the following 7 Production system exhibits the following 7 conflicting measures of performance:conflicting measures of performance:
Volume: how much is produced?Volume: how much is produced?Variety: how many different types of products?Variety: how many different types of products?Quality: What percentage of products meet Quality: What percentage of products meet design specifications?design specifications?Timeliness: Are the products available when Timeliness: Are the products available when customer requires them?customer requires them?Place: Are the products available when customer Place: Are the products available when customer requires them?requires them?Satisfaction: are the participants in the Satisfaction: are the participants in the production process satisfied and fulfilled in their production process satisfied and fulfilled in their work?work?Cost: Have the products been created at min. Cost: Have the products been created at min. cost?cost?
KIND OF TRANSFORMATION :KIND OF TRANSFORMATION :
Due to process: Due to process:
1. Fabrication transformation1. Fabrication transformation
2. Process Transformation2. Process Transformation
3. Service Transformation3. Service Transformation
Due to production volumeDue to production volume– Job shopJob shop– Flow shopFlow shop– ProjectProject
Job shopJob shop
Production will be done to meet Production will be done to meet of customer demand not to make of customer demand not to make inventory, inventory,
Starting time was known, but Starting time was known, but finishing time was uncertaintyfinishing time was uncertainty
The role of manpower skill was The role of manpower skill was bigbig
Flow Shop: Flow Shop:
Production will be done to make Production will be done to make inventoryinventory
Manpower as operatorManpower as operator
Project: Special type ofjob shopProject: Special type ofjob shop
The starting and ending time The starting and ending time was knownwas known
Flow Shop terdiri:Flow Shop terdiri:
Flow line/batch: shoes, cloth, Flow line/batch: shoes, cloth,
Assembly line : assembly of Assembly line : assembly of motorcycle, food formulationmotorcycle, food formulation
Continous : sugar factoryContinous : sugar factory
Process Classification:Process Classification:
Change of physical propertiesChange of physical properties
Change of material shapeChange of material shape
Machining processMachining process
Finishing processFinishing process
Assembly processAssembly process
Project Job shopProject Job shop Flow shop Flow shop
1 or 2 volume1 or 2 volume big big
dominant Skill Small dominant Skill Small contrib.contrib.
General Equipment/layout specialGeneral Equipment/layout special
Fix Process Fix Process ProductionProduction
FORECASTING
JIP Eng. Mnfc. database
Perenc, material
Perenc. kapasitas
Shop flow control
Priority Capacity
Raw material
Fabrication plant
Assembly plant
Distribution center
retailer
Customer
Forecasting
Srategic planning
Aggregate production planning
Production schedulling
Shop floor control
Administrativefunctions
Marketing
Product design
Process planning
Manufacturing support
Product flow Prod. Planning & control decision
Related technical & adm. functions
INPUTS PROCESS OUTPUTS
STRATEGICPLANNING
AGGREGATE PRODUCTION PLANNING
DISAGGREGATION
PRODUCTION SCHEDULLING
SHOP FLOOR CONTROL
Long range ec. ForcFinan. choice
Proc. Tech/efficiencyMed. Aggr. productFamily forecastMachine schedules
Production levelsWorkforce levelsCurrent Invent. StatusChangeover Time & MonItem forecast
MPSBoMProcess plan
Production syst. Decision Hierarchy
Labor statusMachine statusJob prioritiesOrder releaseMac. schedule
Operating facilitiesProduct line
Technologies
Production levelWorkforce level
Family inventoris
MPSItem inventories
Job prioritiesOrder Releasea
Machine schedule
Machines prioritiesJob status
Labor reportingMat handling task
Load/price
Dimensions for classifying Dimensions for classifying production schemesproduction schemes
Physical organizationPhysical organizationKey resourcesKey resourcesProduct flow controlProduct flow controlOrder InitiationOrder Initiation
Production AuthorizationProduction AuthorizationProduct varietyProduct varietyProduct volumeProduct volume
Fabrication/assembly Fabrication/assembly structurestructureTime horizonTime horizon
Product vs processProduct vs processLabor intensity vs Capital Labor intensity vs Capital intensityintensityBatch vs Continuous flowBatch vs Continuous flowMake to order vs make to Make to order vs make to stockstockPush vs pullPush vs pullSingle vs multiple productsSingle vs multiple productsCustom job vs rep. mass Custom job vs rep. mass prodprodSingle prod. Stage vs Single prod. Stage vs multiple stagesmultiple stagesSingle planning period Single planning period (static) vs Multiple periods (static) vs Multiple periods 9dynamic)9dynamic)
PRINCIPLES OF PROD. SYSTPRINCIPLES OF PROD. SYSTLearning curveLearning curveThe product demand life cycleThe product demand life cycleProduction setupProduction setupInventory to support productionInventory to support productionCapacity balanchingCapacity balanchingCustomer defined valueCustomer defined valueLarge inventoryLarge inventoryThroughput time≥ cumulative move & Throughput time≥ cumulative move & processing time for a transfer batchprocessing time for a transfer batch
PENGOPERASIAN SISTEM PENGOPERASIAN SISTEM INDUSTRI/PERUSAHAANINDUSTRI/PERUSAHAAN
Perencanaan produksiPerencanaan produksi
pengendalian produksipengendalian produksi
Perencanaan dan pengendalian Perencanaan dan pengendalian produksiproduksi
Rencana penentuan out put produksi Rencana penentuan out put produksi dengan memperhatikan permintaan dengan memperhatikan permintaan dan sumber daya yang dimiliki untuk dan sumber daya yang dimiliki untuk kurun waktu perencanaan tertentukurun waktu perencanaan tertentuBagaimana produksi dapat Bagaimana produksi dapat memenuhi permintaan pasar dalam memenuhi permintaan pasar dalam keterbatasan sumberdaya yang keterbatasan sumberdaya yang dimiliki dengan kinerja yang optimal dimiliki dengan kinerja yang optimal (kualitas, harga, ketersediaan)(kualitas, harga, ketersediaan)
Perencanaan dan pengendalian Perencanaan dan pengendalian produksi berperan sbg pendukung produksi berperan sbg pendukung dalam sistem industri (perusahaan):dalam sistem industri (perusahaan):
Mendukung fungsi marketingMendukung fungsi marketing
Mendukung fungsi fabrikasiMendukung fungsi fabrikasi
Fungsi perencanaan dan pengendalian Fungsi perencanaan dan pengendalian harus mampu menjabarkan target harus mampu menjabarkan target pasar menjadi rencana operasionalpasar menjadi rencana operasional
Perencanaan adalah proses penetapan dan Perencanaan adalah proses penetapan dan penjabaran aktivitastujuanpenjabaran aktivitastujuan
Tujuan yang baik mempunyai Tujuan yang baik mempunyai karakteristik:karakteristik:
1. realistik1. realistik
2. terukur2. terukur
3. berbatas waktu3. berbatas waktu
4. menantang 4. menantang
Aktivitas memerlukan waktu dan Aktivitas memerlukan waktu dan sumberdaya (4 M)sumberdaya (4 M)
Pengendalian adalah aktivitas untuk Pengendalian adalah aktivitas untuk menjamin proses pencapaian tujuan menjamin proses pencapaian tujuan yang telah ditetapkanyang telah ditetapkan
Kerangka dasar Perencanaan dan Kerangka dasar Perencanaan dan PengendalianPengendalian
Pelaksanaan
RencanaStandar Evalua
si
Variabel perencanaan produksi:Variabel perencanaan produksi:Tingkat produksi (PTingkat produksi (Ptt), jumlah produksi ), jumlah produksi yang dihasilkan selama kurun waktu yang dihasilkan selama kurun waktu perencanaan perencanaan
Tingkat tenaga kerja (WTingkat tenaga kerja (Wtt), jumlah TK yang ), jumlah TK yang dibutuhkan untuk menghasilkan produk dibutuhkan untuk menghasilkan produk yang diinginkanyang diinginkan
Tingkat persediaan (ITingkat persediaan (Itt), jumlah persediaan ), jumlah persediaan rata-rata, cadangan pengaman, dan rata-rata, cadangan pengaman, dan jumlah persediaan yang diinginkan untuk jumlah persediaan yang diinginkan untuk periode mendatangperiode mendatang
Jenis perencanaan produksi:Jenis perencanaan produksi:
Perencanaan jangka panjang (long Perencanaan jangka panjang (long term planning), >1 tahunterm planning), >1 tahun
Perencanaan jangka menengah Perencanaan jangka menengah (medium term planning)(medium term planning)
Perencanaan jangka pendek (short Perencanaan jangka pendek (short term planning)term planning)
Pustaka:Pustaka:1.1. Mc.Leavey, D.W, & S.L. Narasimhan, Production Mc.Leavey, D.W, & S.L. Narasimhan, Production
Planning and Inventory ControlPlanning and Inventory Control2.2. Bedworth, D.D & J.E. Bailey, Integrated Production Bedworth, D.D & J.E. Bailey, Integrated Production
Control systems: Management, Analysis, Design 2/EControl systems: Management, Analysis, Design 2/E3.3. Elsayed, E.A. & T.O. Boucher, Analysis and Control of Elsayed, E.A. & T.O. Boucher, Analysis and Control of
Production SystemsProduction Systems4.4. Askin R.G. & J.B. Goldberg, Design and Analysis of Lean Askin R.G. & J.B. Goldberg, Design and Analysis of Lean
Production SystemsProduction Systems5.5. Ballou, R.H., Bussiness Logistic/Supply Chain Ballou, R.H., Bussiness Logistic/Supply Chain
ManagementManagement6.6. Salvendy, G (editor), Handbook of Industrial Salvendy, G (editor), Handbook of Industrial
Engineering (I, II, III)Engineering (I, II, III)7.7. D.Y.Y Leung, 2004, Handbook of SchedullingD.Y.Y Leung, 2004, Handbook of Schedulling8.8. Sule, D.R., 2008, Production Planning and Industrial Sule, D.R., 2008, Production Planning and Industrial
Scheduling: Examples, Case Studies and ApplicationsScheduling: Examples, Case Studies and Applications