SISTEM MANUFAKTUR (SM) Pengenalan Sistem Manufaktur Pengenalan Sistem Manufaktur Link materi kuliah http://
SISTEM MANUFAKTUR (SM)
Pengenalan Sistem ManufakturPengenalan Sistem Manufaktur
Link materi kuliah http://
SISTEM MANUFAKTUR SISTEM MANUFAKTUR ((SMSM))
Pengenalan Sistem ManufakturPengenalan Sistem Manufaktur
Tujuan pmbelajaran:Memahami definisi sistem manufaktur, konsep dasar dan
model sistem manufaktur, serta ruang lingkup sistem manufaktur
SISTEM MANUFAKTUR (SM)
Pengenalan Sistem ManufakturPengenalan Sistem Manufaktur
Outline:Definis sistem manufaktur
Konsep dasar dan model sistem manufakturRuang lingkup sistem manufaktur
SISTEM adalah kumpulan elemen yang bekerja bersama untuk mencapai tujuan
yang diharapkan (Blanchard, 1991).
Definisi Sistem ManufakturDefinisi Sistem Manufaktur
Sistem Manufaktur merupakan penggabungan dari dua suku kata, SISTEM dan MANUFAKTUR.
Definisi Sistem ManufakturDefinisi Sistem Manufaktur
The word manufacturing is defined from the Latin
manu factusmanu factus
made by hand
manu = hand
factus = made
Definisi Sistem ManufakturDefinisi Sistem Manufaktur
Manufacturing involves making products from raw
materials by means of various processes, machinery, and
operations, through a well-organized plan for each activity
required.
Definisi Sistem ManufakturDefinisi 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 ManufakturDefinisi 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 ManufakturDefinisi 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 ManufakturDefinisi 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 ManufakturDefinisi 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.
Feedback loop
Outputs
Goods and
services
Transformation
Economics system transforms inputs to outputs
The EconomicThe Economicss Transformation Transformation SystemSystem
Inputs
Labor,capital,
management
Konsep Dasar & Model Sistem Konsep Dasar & Model Sistem ManufakturManufaktur
Boundary of system
Konsep Dasar & Model Sistem Konsep Dasar & Model Sistem ManufakturManufakturThe manufacturing System takes inputs and produces products for the external customer
LATHE BROACH PAINTSUB
ASSEMBLY
SAW LATHE DRILLFINAL
ASSEMBLY
CAST MILL GRINDER PLATING
INPUTS:RAW MATERIALSUB ASSEMBLIESCOMPONENT
OUTPUTS:FINAL PRODUCTSCOMPONENTSPARTSSUB ASSEMBLIES
Sequence of processes
Flow shop manufacturing systemSpring, 2005
Konsep Dasar & Model Sistem Konsep Dasar & Model Sistem ManufakturManufaktur
Manufacturing System may produce
Discrete productsIndividual parts (e.g. nails, gears, engine blocks, ……etc.)
Continuous productsMay be cut into individual pieces and thus become discrete parts (e.g. metal or plastic sheets, tubes,……etc.)
Spring, 2005
Konsep Dasar & Model Sistem Konsep Dasar & Model Sistem ManufakturManufaktur
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 Konsep Dasar & Model Sistem ManufakturManufaktur
Definisi menurut International Conference on Production Engineering:
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 Konsep Dasar & Model Sistem ManufakturManufaktur
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
Feedback loop
Outputs
Product & waste
Transformation
Product Transformastion
The The Product TransformationProduct Transformation SystemSystem
Inputs
Labor,capital,
material, machine, man
Konsep Dasar & Model Sistem Konsep Dasar & Model Sistem ManufakturManufaktur
Boundary of system
Konsep Dasar & Model Sistem Konsep Dasar & Model Sistem ManufakturManufaktur
Production system terdiri dari kumpulan stasiun kerja (workstation) yang melakukan operasi pekerjaan seperti manufaktur, perakitan, inspeksi, finishing, pengujian, dll untuk membuat suatu produk.
WorkstationKumpulan mesin/operator yang melakukan operasi pekerjaan untuk set produk yang sama. Sebuah mesin/operator dapat berupa:Mesin yang bekerja secara otomatisMesin yang dioperasikan oleh manusiaOperator melakukan operasi manual
Work station layout Pengaturan workstation, mendikte pola aliran produk, dan kebutuhan sumber daya pada setiap workstation
WS1
WS5
WS4WS3
WS2
Workstation layout
Konsep Dasar & Model Sistem Konsep Dasar & Model Sistem ManufakturManufaktur
Konsep Dasar & Model Sistem Konsep Dasar & Model Sistem ManufakturManufaktur
Production systemPada tingkat abstraksi yang disajikan, kinerja sistem produksi dievaluasi dengan menentukan hal-hal berikut:
How fastThroughput (e.g., jobs/hour, parts/minute)How longTime-In-System (TIS)Flow TimeCycle Time (CT)How muchWork-In-Progress (WIP)
Konsep Dasar & Model Sistem Konsep Dasar & Model Sistem ManufakturManufakturProduction Systems
Konsep Dasar & Model Sistem Konsep Dasar & Model Sistem ManufakturManufakturProduction 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 Konsep Dasar & Model Sistem ManufakturManufakturMachine
A specific piece of equipment designed to accomplish specific processes, often called a Machine Tool
Examples: Milling machine, punch press, ….
Machine tools linked together to make a manufacturing system cell
Konsep Dasar & Model Sistem Konsep Dasar & Model Sistem ManufakturManufakturOperation (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 Konsep Dasar & Model Sistem ManufakturManufakturModel VS Flow Manufacturing System
Definition of product needs; marketing information
Conceptual design and eavulation;feasibility study
Design analysisi; codes/standard review;physical and analytical models
Prototype production;testing and evaluation
Production drawing;instruction manuals
Material specification; process and equipment selection; safety
review
Pilot production
Production
Inspection and quality assurance
Packaging; marketing and sales literature
Product
Computer Integrated Manufacturing (CIM)
Com
pute
r Aid
ed
Des
ign
(CAD
)
Computer Aided Manufacturing and Process Panning (CAM) and CAPP
Ruang Lingkup Sistem ManufacturingRuang Lingkup Sistem ManufacturingModel VS Flow Manufacturing System
1. Customers needs
7. Processing: parts manufacturing, sensing and corrective action, storing,
moving, handling, assembly
6. Process R&D: process choise, optimization,
modeling, environmental
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
10. Customers service2. Conceptual design, product
concept, market forecast, market research
3. Product design, specification development industrial design,
product R&D, prototyping
4. Product preparation: assembly drawing, part drawing, make/buy
decision bill of material
5. Process planning: Group technology, process selection,
process design, process , parameters, tool and dies, part programming, jigs and fixtures,
quality control
Common database
Ruang Lingkup Sistem ManufakturRuang Lingkup Sistem Manufaktur
MarketingSales promotionAdvertisingSalesMarket research
Organizational ChartsOrganizational Charts
OperationsFacilities Construction; maintenanceProduction and inventory control Scheduling; materials control
Quality assurance and controlSupply-chain managementManufacturing Tooling; fabrication; assemblyDesign Product development and design Detailed product specificationsIndustrial engineering Efficient use of machines, space, and personnelProcess analysis Development and installation of production tools and equipment
Finance/ accountingDisbursements/ credits Receivables Payables General ledgerFunds Management Money market International exchangeCapital requirements Stock issue Bond issue and recall
Manufacturing
Ruang Lingkup Sistem ManufakturRuang 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
databaseKegagalan produksi dapat diminimalisir.
Ruang Lingkup Sistem Ruang Lingkup Sistem ManufakturManufaktur
Model VS Flow Manufacturing System
PRODUCTIONPLANNING
SALES PLANNING
FACTORY PLANNING
LAYOUT DESIGN
PRODUCT DESIGN
PROCESS PLANNING SCHEDULING
PRODUCTION & ASSEMBLY
QUALITY CONTROL
PROCESS CONTROL
COST CONTROL
RAW MATERIAL PRODUCT
CUSTOMERS
MATERIAL SUPPLIERS
EXTERNALINFORMATION
RESEARCH & DEVELOPMENT
PROCUREMENT/MATERIAL PLANNING
DISTRIBUTION/SALES
MANAGEMENT PLANNING
FLOW OF STRATEGIC MANAGEMENT INFORMATIONFLOW OF MANAGERIAL INFORMATIONFLOW OF TECHNOLOGICAL INFORMATIONFLOW OF MATERIALS
Ruang Lingkup Sistem Ruang Lingkup Sistem ManufakturManufaktur
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 Perencanaan produk dan seleksi proses (Product Design and
Process Selection) Process Selection) Perencanaan produksi (Production Planning)Perencanaan produksi (Production Planning) Perencanaan kebutuhan bahan baku (Material Planning)Perencanaan kebutuhan bahan baku (Material Planning) Perencanaan penjadwalan produksi (Scheduling)Perencanaan penjadwalan produksi (Scheduling) Pelaksanaan produksi dan assemblyPelaksanaan produksi dan assembly
Ruang Lingkup Sistem Ruang Lingkup Sistem ManufakturManufaktur
Sistem Manufaktur yang dikembangkan oleh Oliver Wight dan Goerge Plosslyang dikenal sebagai Manufacturing Resource Planning (MRP II)
Ruang Lingkup Sistem Ruang Lingkup Sistem ManufakturManufaktur 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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