Pengertian Umum Pengertian Umum Sistem Sistem

ManufakturManufaktur

D0394 Perancangan D0394 Perancangan Sistem ManufakturSistem Manufaktur

Pertemuan I - IIPertemuan I - II

Definisi ManufakturDefinisi Manufaktur Manufacturing Manufacturing – – Suatu kumpulan operasi dan aktifitas yang berkorelasi Suatu kumpulan operasi dan aktifitas yang berkorelasi

untuk menghasilkan produk, seperti perancangan produk, pemilihan bahan untuk menghasilkan produk, seperti perancangan produk, pemilihan bahan baku, perencanaan, pemrosesan, inspeksi, dan manajemen. baku, perencanaan, pemrosesan, inspeksi, dan manajemen.

Manufacturing process Manufacturing process – – Aktifitas manufaktur merubah bentuk suatu produk Aktifitas manufaktur merubah bentuk suatu produk dengan mesin-mesin seperti, milling, drilling dll. dengan mesin-mesin seperti, milling, drilling dll.

Assembly Assembly – – Kumpulan dari semua proses dengan mana bermacam komponen Kumpulan dari semua proses dengan mana bermacam komponen dan sub perakitan dibentuk bersamaan untuk membentuk rancangan rakitan dan sub perakitan dibentuk bersamaan untuk membentuk rancangan rakitan atau produk secara geometris secara lengkap.atau produk secara geometris secara lengkap.

Manufacturing System Manufacturing System – – Suatu pengorganisasian beberapa proses Suatu pengorganisasian beberapa proses manufaktur dan perakitan yang saling berinteraksi. Tujuannya adalah untuk manufaktur dan perakitan yang saling berinteraksi. Tujuannya adalah untuk menjembatani dengan diluar fungsi produksi berkenaan dengan menjembatani dengan diluar fungsi produksi berkenaan dengan mengoptimasikan produktifitas kinerja sistem. mengoptimasikan produktifitas kinerja sistem.

Manufacturing – Historical PerspectiveManufacturing – 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 PerspectiveManufacturing – Historical Perspective

Numerical control (1970s)Numerical control (1970s)– Combining the versatility of general purpose machines

with the precision and control of special-purpose machines.

Computer integrated manufacturing (1980s)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)Agile Manufacturing / Mass Customization (1990s)– Creation of highly flexible organizational structures

that allow systems to produce highly customized product

Manufacturing SystemManufacturing System

Characterized byCharacterized by::– Number of machinesNumber of machines– Number of part typesNumber of part types– Part routes through the Part routes through the

systemsystem– Processing timesProcessing times– Machine setupsMachine setups

– Demand patternsDemand patterns

– Raw material/component Raw material/component availabilityavailability

– Equipment Equipment layout/configurationlayout/configuration

– Operator availabilityOperator availability

Machines

Raw Material

“Finished”Products

Manufacturing SystemManufacturing System

Interested inInterested in::– Lead time for productsLead time for products– Cost of processingCost of processing

Decisions include:Decisions include:– System configurationSystem configuration– Scheduling methodsScheduling methods

Machines

Raw Material

“Finished”Products

Manufacturing System Manufacturing System ConfigurationsConfigurations

Job ShopJob Shop– Process layout that groups functionally similar machinesProcess layout that groups functionally similar machines

Flow LineFlow Line– Product layout that groups machines based on a product’s flowProduct layout that groups machines based on a product’s flow

Cellular Manufacturing SystemCellular Manufacturing System– Hybrid layout that groups similar parts and the corresponding Hybrid layout that groups similar parts and the corresponding

processing machinesprocessing machines– Flexible Manufacturing System is an automated applicationFlexible Manufacturing System is an automated application

Project ShopProject Shop– Product is fixed and people and equipment brought to itProduct is fixed and people and equipment brought to it

Continuous Process Continuous Process

Manufacturing System Manufacturing System ConfigurationsConfigurations

MG

DTTT

T

M M

D

G G

T

M

G D

M

T

M

G

Job Shop ConfigurationFlow Line

Configurations

Manufacturing System Manufacturing System ConfigurationsConfigurations

Cellular Configuration

Cell 1Cell

2

Cell 3

Cell 4

Product Volume vs. Product Product Volume vs. Product VarietyVariety

Volume

VarietyLow High

Low

High

ContinuousFlow Line / Transfer Line

Cellular / Flexible Mfg. Sys.

Job Shop

Manufacturing System DesignManufacturing System Design

Manufacturing System Design

Resource Requirement

Buffer Capacity

Material Flow

Resource Lay Out

Manufacturing System Manufacturing System OperationOperation

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 Principles of Manufacturing SystemsSystems

Little’s Law– WIP = Production Rate ⋅ Throughput Time

(L=λW) 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 Principles of Manufacturing SystemsSystems

Technology advances System components appear to behave

randomly Limits of (Human) rationality Combining, simplifying, and eliminating

save time, money, and energy

Manufacturing Systems Manufacturing Systems OverviewOverview

Product Design Process Planning Production System Design Production Planning Operational Planning Shop Floor Control Execution

Product DesigProduct Designn Idea

» Understanding and identifyingcustomer needs

» Initial Design» Feasibility study to determine initial

functionality Prototype Market Research

» Market potential, economic analysis,

strategic assessment Design Refinement

» Functional specifications

Detailed Specifications» Detailed design considering functions,

quality/reliability, manufacturing, etc.

Idea Generation (Product Design)

Feasibility Study (Performance Specification)

Preleminary Design (Prototype)

Final Design (Final Design Specification)

Process Planning (Manufacturing Specication)

Product DesigProduct Design n (Cont.)(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 DesigProduct Design n (Cont.)(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 CycleProduct Life Cycle Product (Consumer) Perspective

– Inception

– Design

– Production

– Use» Maintenance and repair

– Disposal– Reuse, recycle, scrap

Production System (Manufacturer) Perspective

Design Ramp-up Maturity Decline

Time

Sale

Production System Life CycleProduction System Life Cycle Lifecycle

– Inception– Design– Construction– Startup– Use– Closure

Relationship to product lifecycle– Typically production system lifecycle is longer than an

individual product’s lifecycle– Production system will revert to earlier stages in its lifecycle

when new products are introduced» Extent and cost depends on system flexibility