01 Pendahuluan Sistem Manufaktur.pdf

SISTEM MANUFAKTUR (SM)

Pengantar Sistem Manufaktur

SISTEM MANUFAKTUR (SM)

Pengantar Sistem Manufaktur Tujuan pmbelajaran: Memahami definisi sistem manufaktur, konsep dasar dan model sistem manufaktur, serta ruang lingkup sistem manufaktur

SISTEM MANUFAKTUR (SM)

Pengantar Sistem Manufaktur Outline: Definis sistem manufaktur Konsep dasar dan model sistem manufaktur Ruang lingkup sistem manufaktur

Definisi Sistem Manufaktur Sistem Manufaktur merupakan penggabungan dari dua suku kata, SISTEM dan MANUFAKTUR.

SISTEM adalah kumpulan elemen yang bekerja bersama untuk mencapai tujuan yang diharapkan (Blanchard, 1991).

Definisi Sistem Manufaktur The word manufacturing is defined from the Latin

manu factus

made by hand manu = hand factus = made

Definisi Sistem Manufaktur Manufaktur melibatkan pembuatan produk dari bahan mentah melalui berbagai proses, mesin, dan operasi,

melalui rencana yang terorganisir dengan baik untuk setiap kegiatan yang diperlukan.

Contoh Sistem Manufaktur

Definisi Sistem Manufaktur Manufakturing menurut Random House Webster’s Dictionary: The making of goods or wares by manual or by machiney, on large scale. Manufaturing menurut Nationa Science Foundation’s Workshop: The creation and integration of informational and physical processes to create economic wealth through the production of artifacts.

Manufakturing menurut Degarmo: Manufacturing is the economic term of making goods and services available to satisfy human wants. Manufakturing menurut International Conference on Production Engineering (1983): A Series of interrelated activities and operations involving the design, materials selection, planning, manufacturing production, quality assurance, management and marketing of products on the manufacturing industries.

Definisi Sistem Manufaktur

Production

Manufacturing

Manufacturing Engineering is the term used widely in the United States to describe this area of industrial activity. Production Engineering is equivalent term to manufacturing Engineering in other countries.

Spring, 2005

Definisi Sistem Manufaktur The manufacturing System is a collection of manufacturing processes used to obtain a desired product(s)

The manufacturing System is the design or arrangement of the manufacturing processes. Control of a manufacturing system applies to overall control of the whole processes or equipment. The entire manufacturing system must be controlled in order to schedule and control production, inventory levels, product quality and so forth. Spring, 2005

Definisi Sistem Manufaktur Manufacturing system can be viewed as an integrated combination of processes, machine systems, people, organizational structures, information flows, control systems and computers, designed and operated in order to properly support a coherent manufacturing strategy. Manufacturing systems engineering is a methodology which is associated with the optimum design, analysis, operation and control of manufacturing systems. *B. Wu, Manufacturing Systems Design and Analysis, Chapman & Hall, 1992.

Definisi Sistem Manufaktur 

Manufacturing engineer  Designs/selects the processes and operations required to produce the product • e.g., fixturing, tooling, feed rates, cutting speeds, etc.



Human factors engineer  Design of the individual human operated workstation • e.g., bench heights, lifting angles, placement of tools, presentation of visual information, etc.

Konsep Dasar & Model Sistem Manufaktur The Economics Transformation System Boundary of system

Inputs Labor, capital, management

Transformation

Economics system transforms inputs to outputs

Feedback loop

Outputs Goods and services

Konsep Dasar & Model Sistem Manufaktur

INPUTS: RAW MATERIAL SUB ASSEMBLIES COMPONENT

RECEIVING

LATHE

BROACH

PAINT

SUB ASSEMBLY

SAW

LATHE

DRILL

FINAL ASSEMBLY

CAST

MILL

GRINDER

PLATING

Sequence of processes

Flow shop manufacturing system Spring, 2005

FINISHED GOODS STORAGE

The manufacturing System takes inputs and produces products for the external customer

OUTPUTS: FINAL PRODUCTS COMPONENTS PARTS SUB ASSEMBLIES

Konsep Dasar & Model Sistem Manufaktur Manufacturing System may produce

Discrete products Individual parts (e.g. nails, gears, engine blocks, ……etc.)

Continuous products May be cut into individual pieces and thus become discrete parts (e.g. metal or plastic sheets, tubes,……etc.)

Spring, 2005

Konsep Dasar & Model Sistem Manufaktur Produksi (production) Istilah ‘produksi’ berasal dari kata latin producere yang berarti lead forward, yaitu membuat sesuatu yang baru (tangible/intangible). Sebuah Sistem produksi adalah sistem yang melakukan proses transformasi atau konversi bahan mentah menjadi produk yang memiliki nilai tambah dan sesuai dengan desain produk yang telah ditetapkan.

Konsep Dasar & Model Sistem Manufaktur Definisi menurut International Conference Production Engineering:

on

Production system is defined as an organization in the industrial sector for the creation of manufacturing goods and commodities and/or providing services

Konsep Dasar & Model Sistem Manufaktur Production Systems A production system, or the enterprise, will refer to the total company and will include with it the manufacturing system.

The production system includes the manufacturing system plus all the other functional areas of the plant for information, design, analysis, and control. These subsystems are connected by various means to each other to produce products(s). Spring, 2005

Konsep Dasar & Model Sistem Manufaktur The Product Transformation System Boundary of system

Inputs Labor, capital, material, machine, man

Transformation

Product Transformastion

Feedback loop

Outputs Product & waste

Konsep Dasar & Model Sistem Manufaktur Production system terdiri dari kumpulan stasiun kerja (workstation) yang melakukan operasi pekerjaan seperti manufaktur, perakitan, inspeksi, finishing, pengujian, dll untuk membuat suatu produk. Workstation Kumpulan mesin/operator yang melakukan operasi pekerjaan untuk set produk yang sama. Sebuah mesin/operator dapat berupa: Mesin yang bekerja secara otomatis Mesin yang dioperasikan oleh manusia Operator melakukan operasi manual

Konsep Dasar & Model Sistem Manufaktur Work station layout Pengaturan workstation, mendikte pola aliran produk, dan kebutuhan sumber daya pada setiap workstation WS5 WS2 WS1

WS3

WS4

Workstation layout

Konsep Dasar & Model Sistem Manufaktur Production system Pada tingkat abstraksi yang disajikan, kinerja sistem produksi dievaluasi dengan menentukan hal-hal berikut: How fast Throughput (e.g., jobs/hour, parts/minute) How long Time-In-System (TIS) Flow Time Cycle Time (CT) How much Work-In-Progress (WIP)

Konsep Dasar & Model Sistem Manufaktur Production Systems

Konsep Dasar & Model Sistem Manufaktur Production Types

Low-quantity production (1 ~ 100 units/yr) Job shop, prototyping. Medium-quantity production (100 ~ 10,000 units/yr) Batch production & cellular manufacturing. High-quantity production (> 10,000 units/yr) Mass production.

Konsep Dasar & Model Sistem Manufaktur Hubungan antara variasi produk dan kuantitas produksi pada manufaktur produk discrete

Variasi Produk

Production Types

Low Medium High 1

100

10.000

Jumlah Produksi

1.000.000

Production System Facilities And Production Quantity And Quality

Production Variety

Fixed position layout

Process layout

Cellular layout

Job Shop

Product layout

Batch Production Cellular Manufacturing

Quantity Flow Line Mass Production

1

100

10.000 Production Quantity

1.0000.000

Information- Processing Cycle In Manufacturing Support Systems

Product design

Customer order

Business functions

Production System Facilities

Manufacturing control

Manufacturing planning

Konsep Dasar & Model Sistem Manufaktur Machine A specific piece of equipment designed to accomplish specific processes, often called a Machine Tool Examples: Milling machine, punch press, ….

Machine tools linked together manufacturing system cell

to

make

a

Konsep Dasar & Model Sistem Manufaktur Operation (Process) A specific action or treatment, often done on a machine, the collection of which makes up the job of a worker. Examples: Drilling, Forming, Welding, assembly, ……

Konsep Dasar & Model Sistem Manufaktur Model VS Flow Manufacturing System

Definition of product needs; marketing information

Material specification; process and equipment selection; safety review

Conceptual design and eavulation; feasibility study

Pilot production

Prototype production; testing and evaluation

Production drawing; instruction manuals

Computer Aided Design (CAD)

Design analysisi; codes/standard review; physical and analytical models

Production

Inspection and quality assurance

Packaging; marketing and sales literature

Product

Computer Aided Manufacturing and Process Planning (CAM) and CAPP Computer Integrated Manufacturing (CIM)

Ruang Lingkup Sistem Manufacturing Model VS Flow Manufacturing System 5. Process planning: Group technology, process selection, process design, process , parameters, tool and dies, part programming, jigs and fixtures, quality control 4. Product preparation: assembly drawing, part drawing, make/buy decision bill of material

6. Process R&D: process choise, optimization, modeling, environmental

Common database

3. Product design, specification development industrial design, product R&D, prototyping 2. Conceptual design, product concept, market forecast, market research

7. Processing: parts manufacturing, sensing and corrective action, storing, moving, handling, assembly 8. Production control, routing, schedulling, production tracking, machine load monitoring, inventory (part materials in processing), purchashing, maintenance, quality assurance 9. Shipping, inventory, sales, invoicing, accounting

1. Customers needs

10. Customers service

Ruang Lingkup Sistem Manufaktur Organizational Charts Manufacturing Operations Facilities Construction; maintenance

Production and inventory control Scheduling; materials control

Quality assurance and control Supply-chain management Manufacturing Tooling; fabrication; assembly

Design Product development and design Detailed product specifications

Industrial engineering Efficient use of machines, space, and personnel

Process analysis Development and installation of production tools and equipment

Finance/ accounting Disbursements/ credits Receivables Payables General ledger Funds Management Money market International exchange Capital requirements Stock issue Bond issue and recall

Marketing Sales promotion Advertising Sales Market research

Ruang Lingkup Sistem Manufaktur Manfaat yang diperoleh dari penerapan sistem pada proses manufaktur, antara lain: Hasil produksi lebih cepat dan tepat waktu karena dalam sistem manufaktur menggunakan seperangkat komputer sebagai alat proses pengendalian produksinya. Aliran informasi lebih cepat, akurat dan terpercaya. Dokumentasi lebih terstruktur karena menggunakan sistem database Kegagalan produksi dapat diminimalisir.

Ruang Lingkup Sistem Manufaktur EXTERNAL INFORMATION

FLOW OF STRATEGIC MANAGEMENT INFORMATION FLOW OF MANAGERIAL INFORMATION FLOW OF TECHNOLOGICAL INFORMATION FLOW OF MATERIALS

MANAGEMENT PLANNING

FACTORY PLANNING

PRODUCTION PLANNING

SALES PLANNING

LAYOUT DESIGN

PRODUCT DESIGN

RESEARCH & DEVELOPMENT

MATERIAL SUPPLIERS

PROCUREMENT/ MATERIAL PLANNING

RAW MATERIAL

PROCESS PLANNING

SCHEDULING

PRODUCTION & ASSEMBLY

QUALITY CONTROL

PROCESS CONTROL

COST CONTROL

Model VS Flow Manufacturing System

PRODUCT

DISTRIBUTION/ SALES

CUSTOMERS

Ruang Lingkup Sistem Manufaktur 



Jika dilihat pada gambar model aliran dalam sistem manufakturing di atas, maka dapat dipetakan ruang lingkup dari sistem manufakturing. Ruang lingkup sistem manufakturing dalam pembahasan matakuliah ini meliputi:  Perencanaan produk dan seleksi proses (Product Design and Process Selection)  Perencanaan produksi (Production Planning)  Perencanaan kebutuhan bahan baku (Material Planning)  Perencanaan penjadwalan produksi (Scheduling)  Pelaksanaan produksi dan assembly

Ruang Lingkup Sistem Manufaktur

Sistem Manufaktur yang dikembangkan oleh Oliver Wight dan Goerge Plossl yang dikenal sebagai Manufacturing Resource Planning (MRP II)

Ruang Lingkup Sistem Manufaktur 





Adalah Oliver Wight dan Goerge Plossl, konsultan yang mengembangkan konsep MRP (Manufacturing Resource Planning). MRP mengintegrasikan semua sistem yang berhubungan dengan semua bagian yang mendukung kegiatan produksi, sehingga antar bagian dalam lingkaran sistem produksi akan saling terhunung satu sama lain. Data-data dari stetiap bagian diintegrasikan melalui jaringan kerja, mulai dari jenis produk pesanan, jumlah permintaan, perencanaan produksinya, kebutuhan material, sampai proses administrasi dan keuanganya.

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