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