Bagian 4 PTI

1. MANUFACTURING SYSTEM

2. 2
SASARAN
Memahami sistem manufaktur sebagai
sistem integral yang menjadi kerangka
acuan dalam pendidikan Teknik Industri
baik yang terkait dengan aspek
struktural, aspek fungsional maupun
aspek perancangan dan
pengoperasiannya serta
permasalahannya yang terkait dengan
profesi Teknik Industri

3. 3
What Does IE Do ?
Production Management Corporate
Operation System Services
* Product &Services * Information System * Comprehensive Planning
* Manufacturing Process * Financial &Cost System * Policies & Procedures
* Facilities * Personnel * Performance Measurement
* Work Methods & Standards * Analysis
* Production Planning & Control

4. 4
Materi
• Concept of Manufacturing System
• Manufacturing System Design
• Operation & Management System

5. 5
CONCEPT OF
MANUFACTURING SYSTEM

6. 6
Sasaran
Memahami manufactring sebagai
kerangka acuan dalam pendidikan
teknik industri baik aspek struktural
maupun fungsionalnya

7. 7
Materi
• Manufacturing as a Production System
• Transformation Process
• Manufacturing Function
• Manufacturing Cycle

8. 8
Manufacture as a Production
System
Input Transformation Output
Extraction
Physical
Service
Feedback

9. 9
Systemic Aspect
• Structural Aspect
– Man, Machine, Material
• Functional Aspect
– Man-Man, Man-Material, Man-Machine, Feedback
• Boundary
• Environment
– Stakeholder and Societal
• Objective
– Unitary, pluralist, coercive

10. 10
Factor of Production
»Man
»Machine
»Material
»Management
»Modal

11. 11
Performance Criteria
• Quality
• Cost(harga/biaya)
• Delivery(pengiriman)
• Flexibility(flexibel)
• Safety(keamanan)

12. 12
Competency
»Technnical
»Managerial
. Cooperation
. Leadership
. Adaptive
. Creative

13. 13
Structural Aspect
MachineMan
Mat
Boundary
Environment
Input Out-put
: Interaction
Feed-back
Transformation

14. 14
Transformation System
1. Classical
• Project
• Job Shop
• Flow Shop
2. Emerging
• Variable Production Line
• Manufacturing Cells
• FMS
• CIM

15. 15
Transformation Process
Form: Order:
– Manufacturing ( Discrete ) - Job Shop
– Process ( Continue) - Flow Shop
– Services - Project
Project Job Shop Flow Shop
Volume
Skill Worker
Equipment
General Special
Lay Out
Fix Process Product

16. 16
Product Lay-out
Peletakan Mesin Berdasarkan Atas
Urutan Proses Produksi
Potong Obras Jahit Kancing Finishing Packing

17. 17
Process Lay-out
Peletakan Mesin Berdasarkan Atas
Kesamaan Jenis Mesin
X
Y
A
F
CB
ED

18. 18
Fix Lay-out
Benda Kerja Diam Mesin, Peralatan,
Material Dan Karyawan Mendatangi
Benda Kerja
Contoh:
• Galangan Kapal
• Assembling Pesawat
• Dll

19. 19
Automated Lay-Out
Berdasarkan Atas Kesamaan Fungsi Dan
Kemampuan Proses Produksi

20. 20
Equipment and Physical Layout
Characteristics
Project Job Shop Flow Shop
Size of Facility Varies Small Large
Process Flow Circumference Num, Pattern Rigid
Equipment General General Specialized
Capital Ints. Varies Low High
Capital Add. Incremental Small Large Chunk
Speed of Process Varies Slow Fast
Control Worker Worker & Process Design
Tech. Change Slow Average Fast

21. 21
Direct Labor and Work Force
Characteristics
Project Job Shop Flow Shop
Labor value added High Average Very Low
Job content scope Large Average Small
Skill level High Average Low
Wage rate High Average Low
Worker training V. High High Low

22. 22
Material and Information Control
Characteristics
Project Job Shop Flow Shop
Material Requirement Varies Unpredictable Predictable
Vertical Integration None Limited Back&Forwd
Inv. Raw Material None Small Large
WIP Large Large Small
Finished Goods None Small High
QC Responsibility D. Labor D. labor QC Specialist
Prod/Serv, Information V. High High Low
Scheduling Uncertain Changes Inflexible

23. 23
Process Management
Characteristic
Project Job Shop Flow Shop
Challenges Estimating Lab.Utilization Avoid Downtime
Sequencing Debottlenecking Time Expansion
Pacing Learning Curve Cost Minimizing
Tools PERT/ Load Chart Line Balancing
CPM Optimization

24. 24
Product/Service Start-up Growth Stable Decline
Volume Low Increasing High Declining
Variety Unique Inc.Standard Emergence HighStandard
Dom. Design
Process Technology
Organization Project Small Batch Line flow Line flow
Job shop Assembly Assembly
Innovation High Medium Medium Low
Integration Low Medium Medium High
Industry
Structure Small Consolidation Few large Survivor
competitor and fallout competitor
Competitive Flexibility Quality and Price(cost) Price(cost)
Priority Flexibility Delivery
Product/Service and Process
Technology Life Cycles

25. 25
Variable Production Line
Dedicated High Volume Lines That Are
Reconfigured to Permit Some Process
Variation and Thus Several Different Products
or Service

26. 26
Manufacturing Cell (MC)
Dedicated Subset of Manufacturing
System Designed to Process Part
Families or Product Group
Economies of Set-up
Employee Learning
Reduced WIP
Shorter Throughput Time
Improved Responsiveness to Customer

27. 27
Flexible Manufacturing System
(FMS)
Integrates and Enhances the Flexibility of
Manufacturing Cell Through the Use of
Centralized Control Systems
Flexibility Approaching Job Shop With Material
Handling Capability of a Flow Lines

28. 28
Computer Integrated
Manufacturing (CIM)
Application of a computer system to link several
separated information systems and
technologies at different functional level
Simplify, Automate and Integrate

29. 29
Stage Toward A CIM
Batch/Lot Process
MRPII/SPC
JIT &MC
Focused factory
Stable Flow
FMS
CAD/CAM
Robotics AMH/GT
CIM
Information System
Integration
Traditional Mfg.
Variable Line
Stage
3
Stage 1
Stage 2
Stage 4
To CIM
Process Technology Process Control System

30. 30
Manufacturing Function
Marketing Engineering
Fabrication
Production
Management

31. 31
Marketing
• Need Identification
• Type of Product/Service
• Customer
• Specification
• Purchasing Power
• Volume
• Distribution Channel
• Product/Service Delivery
• Marketing Mix

32. 32
Engineering
Design Product’s Blue Print According To
Customer’s Demand
• Product Design
• Process Planning
• Product Planning
• Method Engineering

33. 33
Fabrication
Make Product According to the Blue Print
From Engineering
Production Control
Process Control
Quality Control
Facilities Control

34. 34
Production Management
Support Manufacturing In Order To
Fulfill the Customer’s Demand
• Production Planning And Control
• Inventory Control

35. 35
Manufacturing Cycle
Marketing/
Sales
Product Design Process
Design
Inventory
Control
Production
Planning and
Control
Work Method ,
Time Standard
& Productivity
Improvement
Fabrication Receiving
Receiving
Shipping
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Quality
Control
Production
Control
Process
Control
Facilities
Control