Bab-6 Perancangan Produk

Perancangan Produk Product design proses pendefinisian seluruh produk

dan karakteristik perusahaan. Harus diingat Perancangan produk harus didukung oleh proses pabrik. (

(cara termudah dihasilkan di pabrik)

Perancangan produk dapat meliputi; Appearance (pertampakan),

Materials (material),

Dimensions (dimensi),

Tolerances (toleransi), and

performance standards (standar keinerja)

Product design proses pendefinisian seluruh produkdan karakteristik perusahaan. Harus diingat Perancangan produk harus didukung oleh proses pabrik. (

(cara termudah dihasilkan di pabrik)

Perancangan produk dapat meliputi; Appearance (pertampakan),

Materials (material),

Dimensions (dimensi),

Tolerances (toleransi), and

performance standards (standar keinerja)

Perancangan Jasa Vs Barang

Jasa sifatnya unik, sehingga perancanganharus memenuhi: Dirancang meliputi jasa dan konsep

- Unsur fisik, estetika, dan manfaat psikologis.

e.g. kecepatan, keakraban, atmosphere

Produk dan jasa dirancang harus memenuhikebutuhan dan preferensi kelompok pelanggan.

Jasa sifatnya unik, sehingga perancanganharus memenuhi: Dirancang meliputi jasa dan konsep

- Unsur fisik, estetika, dan manfaat psikologis.

e.g. kecepatan, keakraban, atmosphere

Produk dan jasa dirancang harus memenuhikebutuhan dan preferensi kelompok pelanggan.

Perancangan Produk dan Jasa

Perancangan produk dan prosespemilihan mempengaruhi. Kualitas produk

Biaya

Kepuasan pelanggan

Kemampuan pabrikasi dan kemudahan dibidang operasi.

Perancangan produk dan prosespemilihan mempengaruhi. Kualitas produk

Biaya

Kepuasan pelanggan

Kemampuan pabrikasi dan kemudahan dibidang operasi.

Proses Perancangan PRODUK Step 1 Pengembangan Ide

- Someone thinks of a need and a product/service design to satisfy ite.g. customers, marketing, engineering, competitors,

benchmarking, reverse engineering

Step 2 Pemeriksaan Perancangan- Every business needs a formal/structured evaluation process

e.g. fit with facility and labor skills, size of market, contribution margin,break-even analysis, return on sales

Step 3 Perancangan awal dan pengujian- Technical specifications are developed, prototypes built, testing starts

Step 4 Rancangan Final- Final design based on test results, facility, equipment, material, & labor

skills defined, suppliers identified

Step 1 Pengembangan Ide- Someone thinks of a need and a product/service design to satisfy it

e.g. customers, marketing, engineering, competitors,

benchmarking, reverse engineering

Step 2 Pemeriksaan Perancangan- Every business needs a formal/structured evaluation process

e.g. fit with facility and labor skills, size of market, contribution margin,break-even analysis, return on sales

Step 3 Perancangan awal dan pengujian- Technical specifications are developed, prototypes built, testing starts

Step 4 Rancangan Final- Final design based on test results, facility, equipment, material, & labor

skills defined, suppliers identified

Menggunan Break-EvenAnalysis

Computes the quantity of goodscompany needs to sell to cover its costs

QBE = F/ (SP - VC) QBE Break even quantity F Fixed costs SP selling price/unit VC Variable cost

Computes the quantity of goodscompany needs to sell to cover its costs

QBE = F/ (SP - VC) QBE Break even quantity F Fixed costs SP selling price/unit VC Variable cost

Product Screening Tool Break-Even Analysis

Break-even analysis also includes calculating Total cost sum of fixed and variable cost

Total cost = F + (VC)*Q

Revenue amount of money brought in fromsales

Revenue = (SP) * Q

Q = number of units sold

Break-even analysis also includes calculating Total cost sum of fixed and variable cost

Total cost = F + (VC)*Q

Revenue amount of money brought in fromsales

Revenue = (SP) * Q

Q = number of units sold

Break-Even Analysis: Pendekatan Grafik

Compute quantity of goods thatmust be sold to break-even

Compute total revenue at anassumed selling price

Compute fixed cost and variablecost for several quantities

Plot the total revenue line andthe total cost line

Intersection is break-even Sensitivity analysis can be done

to examine changes in all of theassumptions made

Compute quantity of goods thatmust be sold to break-even

Compute total revenue at anassumed selling price

Compute fixed cost and variablecost for several quantities

Plot the total revenue line andthe total cost line

Intersection is break-even Sensitivity analysis can be done

to examine changes in all of theassumptions made

Break-even calculation: A company is planning to establish a chain of movietheaters. It estimates that each new theater will cost approximately $1 Million. Thetheaters will hold 500 people and will have 4 showings each day with average ticketprices at $8. They estimate that concession sales will average $2 per patron. Thevariable costs in labor and material are estimated to be $6 per patron. They will beopen 300 days each year. What must average occupancy be to break-even?

Break-Even PointTotal revenues = Total costs @ break-even point QSelling price*Q = Fixed cost + variable cost*Q

($8+$2)Q= $1,000,000 + $6*QQ = 250,000 patrons (42% occupancy)

What is the gross profit if they sell 300,000 ticketsProfit = Total Revenue Total Costs

P = $10*300,000 (1,000,000 + $6*300,000)P = $200,000

If concessions only average $.50/patron, what is break-even Q now? (sensitivity analysis)

($8.50)Q = 1,000,000 - $6*QQ = 400,000 patrons (67% occupancy)

Break-Even PointTotal revenues = Total costs @ break-even point QSelling price*Q = Fixed cost + variable cost*Q

($8+$2)Q= $1,000,000 + $6*QQ = 250,000 patrons (42% occupancy)

What is the gross profit if they sell 300,000 ticketsProfit = Total Revenue Total Costs

P = $10*300,000 (1,000,000 + $6*300,000)P = $200,000

If concessions only average $.50/patron, what is break-even Q now? (sensitivity analysis)

($8.50)Q = 1,000,000 - $6*QQ = 400,000 patrons (67% occupancy)

Faktor yang berdampak padaPerancangan Produk

Kebutuhan Perancangan Pabrik

Series of guidelines tofollow in order to producea product easily andprofitably Minimilais bentuk produk

Standardisasi Design parts for multiply

applications

Rancangan yangterintegrasi

Sederhanakan operasi

Kebutuhan Perancangan Pabrik

Series of guidelines tofollow in order to producea product easily andprofitably Minimilais bentuk produk

Standardisasi Design parts for multiply

applications

Rancangan yangterintegrasi

Sederhanakan operasi

Faktor Siklus Produk Product life cycle

series of changingproduct demand

Consider productlife cycle stages Introduction Growth Maturity Decline

Facility & processinvestment depends onlife cycle

Product life cycle series of changingproduct demand

Consider productlife cycle stages Introduction Growth Maturity Decline

Facility & processinvestment depends onlife cycle

Pabrikasi Simultan Old over-the wall sequential

design process should not be used Each function did its work and passed it to

the next function

Replace with a ConcurrentEngineering process

All functions form a design team working

together to develop specifications, involve

customers early, solve potential problems,

reduce costs, & shorten time to market

Old over-the wall sequentialdesign process should not be used Each function did its work and passed it to

the next function

Replace with a ConcurrentEngineering process

All functions form a design team working

together to develop specifications, involve

customers early, solve potential problems,

reduce costs, & shorten time to market

Process Selection

Product design considerations mustinclude the process

Klasifikasi meliputi Intermittent operations

menghasilakan berbagai jenis dalamjumlah kecil

Repetitive operations menghasilakansatu atau beberapa dalam jumlahbesar.

Product design considerations mustinclude the process

Klasifikasi meliputi Intermittent operations

menghasilakan berbagai jenis dalamjumlah kecil

Repetitive operations menghasilakansatu atau beberapa dalam jumlahbesar.

Process Selection

Lima Pertimbangan Bentuk proses ; range from intermittent to

continuous Derajat integrasi vertikal Fleksibilitas sumberdaya Bauran antara modal dan sumberdaya

manusia Derajat kontak dengan konsumen

Lima Pertimbangan Bentuk proses ; range from intermittent to

continuous Derajat integrasi vertikal Fleksibilitas sumberdaya Bauran antara modal dan sumberdaya

manusia Derajat kontak dengan konsumen

Process Selection Process types can be: chika

Project process make a one-at-a-time productexactly to customer specifications

Batch process small quantities of product ingroups or batches based on customer orders orspecifications

Line process large quantities of a standardproduct

Continuous process very high volumes of a fullystandard product

Process types exist on a continuum

Process types can be: chika Project process make a one-at-a-time product

exactly to customer specifications Batch process small quantities of product in

groups or batches based on customer orders orspecifications

Line process large quantities of a standardproduct

Continuous process very high volumes of a fullystandard product

Process types exist on a continuum

Underlying Process RelationshipBetween Volume and StandardizationContinuum

Differences between Intermittentand Continuous Operations

Decision Intermittent Operation Continuous Operation

Product variety Great Small

Degree of standardization Low High

Organization of resources Grouped by Function Line flow

Path of products Varied, depends on product Line flow

Factor driving production Customer orders Forecast of demand

Critical resource Labor Capital

Type of equipment General purpose Specialized

Degree of automation Low High

Throughput time Longer Shorter

Work-in-process inventory More Less

Decision Intermittent Operation Continuous Operation

Product variety Great Small

Degree of standardization Low High

Organization of resources Grouped by Function Line flow

Path of products Varied, depends on product Line flow

Factor driving production Customer orders Forecast of demand

Critical resource Labor Capital

Type of equipment General purpose Specialized

Degree of automation Low High

Throughput time Longer Shorter

Work-in-process inventory More Less

Designing Processes

Process design tools include Process flow analysis Process flowchart

Design considerations include Make-to-stock strategy Assemble-to-order strategy Make-to-order strategy

Process design tools include Process flow analysis Process flowchart

Design considerations include Make-to-stock strategy Assemble-to-order strategy Make-to-order strategy

Process Design Tools Process flow analysis is

a tool used to analyze anddocument the sequence ofsteps within a totalprocess. Usually first stepin Process Reengineering.

Process Re-engineering is astructured approachused when majorbusiness changes arerequired as a result of: Major new products Quality improvement

needed Better competitors Inadequate

performance

Process flow analysis isa tool used to analyze anddocument the sequence ofsteps within a totalprocess. Usually first stepin Process Reengineering.

Process Re-engineering is astructured approachused when majorbusiness changes arerequired as a result of: Major new products Quality improvement

needed Better competitors Inadequate

performance

Facility Layout and Process Choice

Process Performance Metrics

Determining if a process is functioningproperly is required

Determination requires measuringperformance Process performance metrics

measurement of different processcharacteristics that tell us how a process isperforming

Determining if a process is functioningproperly is required

Determination requires measuringperformance Process performance metrics

measurement of different processcharacteristics that tell us how a process isperforming

Process Performance Metrics

Linking Product Design &Process Selection Product design and process selection directly

linked Type of product selected defines type of

operation required Type of operation available defines broader

organizational aspects such as Equipment required Facility arrangement Organizational structure

Product design and process selection directlylinked

Type of product selected defines type ofoperation required

Type of operation available defines broaderorganizational aspects such as Equipment required Facility arrangement Organizational structure

Linking Design & Process Selection

Organizational Decisions appropriate for different types of operations

Intermittent VS. Repetitive Layouts

Product and Service Strategy

Type of operation is directly related toproduct and service strategy

Three basic strategies include Make-to-stock; in anticipation of demand Assemble-to-order; built from standard

components on order Make-to-order; produce to customer

specification at time of order

Type of operation is directly related toproduct and service strategy

Three basic strategies include Make-to-stock; in anticipation of demand Assemble-to-order; built from standard

components on order Make-to-order; produce to customer

specification at time of order

Product and Service Strategy Options

Process Decisions-Vertical Integration& Make or Buy

Vertical integration refers to the degree a firm chooses to doprocesses itself- raw material to sales Backward Integration means moving closer to primary operations Forward Integration means moving closer to customers

A firms Make-or-Buy choices should be based on the followingconsiderations: Strategic impact Available capacity Expertise Quality considerations Speed Cost (fixed cost + variable cost)make = Cost (fixed cost + Variable cost)buy

Business are trending toward less backward integration, moreoutsourcing

Vertical integration refers to the degree a firm chooses to doprocesses itself- raw material to sales Backward Integration means moving closer to primary operations Forward Integration means moving closer to customers

A firms Make-or-Buy choices should be based on the followingconsiderations: Strategic impact Available capacity Expertise Quality considerations Speed Cost (fixed cost + variable cost)make = Cost (fixed cost + Variable cost)buy

Business are trending toward less backward integration, moreoutsourcing

Manufacturing Technology Decisions

Simplify first then apply appropriate technology

Information Technology: ERP, GPS, RFID

Automation

Automated Material Handling: Automated guided vehicles (AGV)

Automated storage & retrieval systems (AS/RS)

Flexible Manufacturing Systems (FMS)

Robotics & Numerically-Controlled (NC) equipment

Simplify first then apply appropriate technology

Information Technology: ERP, GPS, RFID

Automation

Automated Material Handling: Automated guided vehicles (AGV)

Automated storage & retrieval systems (AS/RS)

Flexible Manufacturing Systems (FMS)

Robotics & Numerically-Controlled (NC) equipment

E-manufacturing Web-based environment creates numerous

business opportunities to include; Product design collaboration Process design collaboration

Computer-aided design uses computergraphics to design new products

Computer-integrated manufacturing integration of product design, processplanning, and manufacturing using anintegrated computer system

Web-based environment creates numerousbusiness opportunities to include; Product design collaboration Process design collaboration

Computer-aided design uses computergraphics to design new products

Computer-integrated manufacturing integration of product design, processplanning, and manufacturing using anintegrated computer system

How Are Services Differentfrom Manufacturing

Services are different frommanufacturing as they; Produce intangible products Involve a high degree of customer contact

Type of service is classified according todegree of customer contact

Services are different frommanufacturing as they; Produce intangible products Involve a high degree of customer contact

Type of service is classified according todegree of customer contact

Designing Services Service Characteristics

Pure services Quasi-Manufacturing Mixed services

Service Package The physical goods The sensual benefits The psychological benefits

Differing designs Substitute technology for

people Get customer involved High customer attention

Service Characteristics Pure services Quasi-Manufacturing Mixed services

Service Package The physical goods The sensual benefits The psychological benefits

Differing designs Substitute technology for

people Get customer involved High customer attention

Product Design and ProcessSelection Across the Organization

Strategic and financial of product designand process selection mandatesoperations work closely across theorganization Marketing is impacted by product that is

produced Finance is integral to the product design

and process selection issues due tofrequent large financial outlays

Strategic and financial of product designand process selection mandatesoperations work closely across theorganization Marketing is impacted by product that is

produced Finance is integral to the product design

and process selection issues due tofrequent large financial outlays

Product Design and Process SelectionAcross the Organization - continued

Strategic and financial of product design andprocess selection mandates operations workclosely across the organization Information services has to be developed to match

the needs of the production process Human resources provides important input to the

process selection decisions for staffing needs

Strategic and financial of product design andprocess selection mandates operations workclosely across the organization Information services has to be developed to match

the needs of the production process Human resources provides important input to the

process selection decisions for staffing needs

Chapter 3 Highlights Product design is the process of deciding on the unique

characteristics and features of a companys productProcess selection is the development of the processnecessary to produce the product being designed.

Steps in product include idea generation, productscreening, preliminary design and testing, and final design

Break-even analysis is a tool used to compute the amountof goods that have to be sold just to cover costs.

Production processes can be divided into two broadcategories: intermittent and repetitive operation project tobatch to line to continuous

Product design is the process of deciding on the uniquecharacteristics and features of a companys productProcess selection is the development of the processnecessary to produce the product being designed.

Steps in product include idea generation, productscreening, preliminary design and testing, and final design

Break-even analysis is a tool used to compute the amountof goods that have to be sold just to cover costs.

Production processes can be divided into two broadcategories: intermittent and repetitive operation project tobatch to line to continuous

Chapter 3 Highlights Product design and process selection decisions are

linked Process flow charts is used for viewing the flow of

the processes involved in producing the Different types of technologies can significantly

enhance product and process design. These includeautomation, automated material handling devices,CAD, NC, FMS, and CIM

Designing services have more complexities thanmanufacturing, because service produce anintangible product and typically have a high degreeof customer contact.

Product design and process selection decisions arelinked

Process flow charts is used for viewing the flow ofthe processes involved in producing the

Different types of technologies can significantlyenhance product and process design. These includeautomation, automated material handling devices,CAD, NC, FMS, and CIM

Designing services have more complexities thanmanufacturing, because service produce anintangible product and typically have a high degreeof customer contact.

The End Copyright 2007 John Wiley & Sons, Inc. All rights reserved.

Reproduction or translation of this work beyond that permittedin Section 117 of the 1976 United State Copyright Act withoutthe express written permission of the copyright owner isunlawful. Request for further information should be addressedto the Permissions Department, John Wiley & Sons, Inc. Thepurchaser may make back-up copies for his/her own use onlyand not for distribution or resale. The Publisher assumes noresponsibility for errors, omissions, or damages, caused by theuse of these programs or from the use of the informationcontained herein.

Copyright 2007 John Wiley & Sons, Inc. All rights reserved.Reproduction or translation of this work beyond that permittedin Section 117 of the 1976 United State Copyright Act withoutthe express written permission of the copyright owner isunlawful. Request for further information should be addressedto the Permissions Department, John Wiley & Sons, Inc. Thepurchaser may make back-up copies for his/her own use onlyand not for distribution or resale. The Publisher assumes noresponsibility for errors, omissions, or damages, caused by theuse of these programs or from the use of the informationcontained herein.

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