sm 2_konsep dasar dan model sistem manufaktur.ppt

SISTEM MANUFAKTUR (SM)

Pengenalan Sistem ManufakturPengenalan Sistem Manufaktur

Link materi kuliah http://

SISTEM MANUFAKTUR SISTEM MANUFAKTUR ((SMSM))


Tujuan pmbelajaran:Memahami definisi sistem manufaktur, konsep dasar dan

model sistem manufaktur, serta ruang lingkup sistem manufaktur

SISTEM MANUFAKTUR (SM)


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.


The word manufacturing is defined from the Latin

manu factusmanu factus

made by hand

manu = hand

factus = made


Manufacturing involves making products from raw

materials by means of various processes, machinery, and

operations, through a well-organized plan for each activity

required.


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.


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


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


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.


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


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


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.


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


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


Boundary of system


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



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


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


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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