Pengertian Pengertian Umum Sistem Umum Sistem Manufaktur Manufaktur D0394 D0394 Perancangan Perancangan Sistem Sistem Manufaktur Manufaktur Pertemuan I - II Pertemuan I - II
Pengertian Umum Sistem ManufakturD0394 Perancangan Sistem Manufaktur Pertemuan I - II
Definisi Manufaktur
Manufacturing Suatu kumpulan operasi dan aktifitas yang berkorelasi untuk menghasilkan produk, seperti perancangan produk, pemilihan bahan baku, perencanaan, pemrosesan, inspeksi, dan manajemen. Manufacturing process Aktifitas manufaktur merubah bentuk suatu produk dengan mesin-mesin seperti, milling, drilling dll. Assembly Kumpulan dari semua proses dengan mana bermacam komponen dan sub perakitan dibentuk bersamaan untuk membentuk rancangan rakitan atau produk secara geometris secara lengkap. Manufacturing System Suatu pengorganisasian beberapa proses manufaktur dan perakitan yang saling berinteraksi. Tujuannya adalah untuk menjembatani dengan diluar fungsi produksi berkenaan dengan mengoptimasikan produktifitas kinerja sistem.
Manufacturing Historical Perspective
English system (1800s) Memperkenalkan mesin-mesin yang digunakan secara umum yang dapat digunakan untuk produk yang bervariasi. American system (1850s) Menekankan pada presisi dan kemampuan untuk saling bertukar proses. Berubah dari best fit fokus kepada greatest clearance without loss of functionality. Scientific management (1900s) Prespecified worker motions - Moved the control totally into the hands of management. Process improvement (SPC) (1950s) Identical procedures produce different results on same machine at different times. Emphasized outliers instead of mean performance.
Manufacturing Historical Perspective
Numerical control (1970s) Combining the versatility of general purpose machines with the precision and control of special-purpose machines. Computer integrated manufacturing (1980s) Pervasive use of computers to design products, plan production, control operations, and perform various business-related functions. Agile Manufacturing / Mass Customization (1990s) Creation of highly flexible organizational structures that allow systems to produce highly customized product
Manufacturing SystemMachinesRaw Material Finished Products
Characterized by: Number of machines Number of part types Part routes through the system Processing times Machine setups Demand patterns Raw material/component availability Equipment layout/configuration Operator availability
Manufacturing SystemMachinesRaw Material Finished Products
Interested in: Lead time for products Cost of processing
Decisions include: System configuration Scheduling methods
Manufacturing System Configurations
Job Shop Process layout that groups functionally similar machines
Flow Line Product layout that groups machines based on a products flow
Cellular Manufacturing System Hybrid layout that groups similar parts and the corresponding processing machines Flexible Manufacturing System is an automated application
Project Shop Product is fixed and people and equipment brought to it
Continuous Process
Manufacturing System ConfigurationsT T T T D DG G G
TM G
TM G M D
M M M
Job Shop Configuration
Flow Line Configurations
Manufacturing System ConfigurationsCell 1 Cell 2
Cell 4 Cell 3
Cellular Configuration
Product Volume vs. Product VarietyHighContinuous Flow Line / Transfer Line
Volume
Cellular / Flexible Mfg. Sys.
Low
Job Shop
LowVariety
High
Manufacturing System DesignManufacturing System Design
Resource Requirement
Resource Lay Out
Material Flow
Buffer Capacity
Manufacturing System Operation
Operation Decomposition Planning Deciding what to do
Scheduling Deciding when to do what you planned
Execution Carrying out the planned tasks according to the schedule
Hierarchical System Structure Shop Workstation Equipment
Principles of Manufacturing Systems
Littles Law WIP = Production Rate Throughput Time (L= W)
Matter is conserved Larger scope implies reduced reliability Objects decay Exponential growth in complexity
M components, N states ==> NM possible system states
Principles of Manufacturing SystemsTechnology advances System components appear to behave randomly Limits of (Human) rationality Combining, simplifying, and eliminating save time, money, and energy
Manufacturing Systems OverviewProduct Design Process Planning Production System Design Production Planning Operational Planning Shop Floor Control Execution
Product Design
Idea Understanding and identifying customer needs Initial Design Feasibility study to determine initial
Idea Generation (Product Design)
Feasibility Study (Performance Specification)
functionality
Prototype Market Research Market potential, economic analysis,
Preleminary Design (Prototype)
strategic assessment
Design Refinement Functional specifications
Final Design (Final Design Specification)
Detailed Specifications Detailed design considering functions,
Process Planning (Manufacturing Specication)
quality/reliability, manufacturing, etc.
Product Design (Cont.)
Functional analysis Customer specifications Product reliability Design for X Manufacture or Assembly Simplification, standardization, modularization Testing Repair Robustness to variations Concurrent engineering Consider how product will be manufactured (process and production planning) during design phase Reduce cost and time to market
Product Design (Cont.)
Computer-Aided Design Use of computer graphics to assist in the creation, modification, and analysis of a design Common uses Geometric modeling Automated drafting and documentation Engineering analysis Design analysis
CAD/CAM Generation of manufacturing instructions directly from CAD design data
Product Life Cycle
Product (Consumer) Perspective Inception Design Production Use Maintenance and repair
Production System (Manufacturer) Perspective
Disposal Reuse, recycle, scrapSale
Design Ramp-up Maturity Decline
Time
Production System Life Cycle
Lifecycle Inception Design Construction Startup Use Closure
Relationship to product lifecycle Typically production system lifecycle is longer than an individual products lifecycle Production system will revert to earlier stages in its lifecycle when new products are introduced Extent and cost depends on system flexibility