PERENCANAAN DAN PERANCANGAN PRODUK

Dr. Mohammad Abdul Mukhyi, SE., MM.

Process Planning and Design

Inputs: Product/Service Information Production System Information Operations Strategy Process Planning & Design: Select process type Vertical integration studies Process/Product studies Equipment studies Production procedures studies Facilities studies

Outputs: Process Technology Facilities Personnel Estimates

Dr. Mohammad Abdul Mukhyi, SE., MM

Major Factors Affecting Process Designs

Nature of product/service demand Degree of vertical integration Production flexibility Degree of automation Product/Service quality

Dr. Mohammad Abdul Mukhyi, SE., MM

Tingkat Integrasi Vertikal

Integrasi vertikal adalah jumlah dari rantai distribusi dan produksi yang kepemilikan dikuasai suatu perusahaan. Menentukan berapa banyak proses produksi yang diperlukan untuk direncanakan dan dirancang. Keputusan pengintegrasian didasarkan pada biaya, ketersediaan modal, kualitas, kemampuan teknologi, dan sebagainya. Strategi outsourcing (menurunkan derajat tingkat pengintegrasian) adalah proses outsourcing yang bereaksi lebih cepat dalam mengantisipasi perubahan kebutuhan pelanggan, tindakan pesaing, dan teknologi.
Dr. Mohammad Abdul Mukhyi, SE., MM 4

Fleksibilitas Produksi
Product flexibility -- ability of the production (or delivery) system to quickly change from producing (delivering) one product (or service) to another. Volume flexibility -- ability to quickly increase or reduce the volume of product (or service) produced (or delivered).
Dr. Mohammad Abdul Mukhyi, SE., MM 5

Degree of Automation
Advantages of automation
Improves product quality Improves product flexibility Reduces labor and related costs

Disadvantages of automation
Equipment can be very expensive Integration into existing operations can be difficult

Dr. Mohammad Abdul Mukhyi, SE., MM

Types of Process Designs

Product-Focused Process-Focused Group Technology/Cellular Manufacturing

Dr. Mohammad Abdul Mukhyi, SE., MM

Product-Focused (Production Line)

Proses ( konversi) diatur berdasarkan pada urutan operasi untuk menghasilkan suatu produk atau menyediakan suatu jasa Dua format umum Unit terpisah Proses ( Berlanjut) Contoh Mobil Penghisap debu

Dr. Mohammad Abdul Mukhyi, SE., MM

Product-Focused Production
Raw Material 2 Components 4

Assemblies 1 Raw Material Components 3 Subassem. Subassem. Purchased 6 Product/Material Flow Production Operation Components, Subassemblies 5 7

Fin. Goods

Dr. Mohammad Abdul Mukhyi, SE., MM

Process-Focused (Job Shop)

Proses (konversi) diatur berdasarkan pada jenis proses, seperti proses dikelompokkan bersama-sama Products/Services (pekerjaan) dipindah dari departemen (kelompok proses) ke departemen mendasarkan pada pekerjaan-pekerjaa tertentu dalam memproses kebutuhan Contoh Perbaikan body repair Pekerjaan tukang kayu
Dr. Mohammad Abdul Mukhyi, SE., MM 10

Process-Focused Production
Custom Woodworking Shop
Cutting
1 Job A 2 3 4

Planing Shaping Assembly Sanding Finishing

2 3 4 5 6 5 6 7

Job B 1

Drilling

Turning

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Group Technology/Cellular Manufacturing

Group technology forms parts with similar processing requirements into part families or groups. A manufacturing cell is an arrangement of the processes required to make the parts that make up the group.
Dr. Mohammad Abdul Mukhyi, SE., MM 12

Group Technology/Cells
Advantages (relative to a job shop)
Menyederhanakan proses perubahan sistem kerja Mengurangi variabilitas tugas Lebih mengarahkan rute melalui sistem Peningkatan pengendalian mutu Perencanaan dan pengendalian produksi lebih sederhana Otomasi yang lebih sederhana
Dr. Mohammad Abdul Mukhyi, SE., MM 13

Group Technology/Cells
Disadvantages
Duplikasi peralatan Pemanfaatan peralatan rendah Pengolahan materi yang tidak berkaitan dengan kelompoknya adalah tidak efisien

Dr. Mohammad Abdul Mukhyi, SE., MM

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Product/Process Design & Inventory Policy

Standard Products and Produce to Stock
Forecast/orders drive production schedule Maintain pre-determined finished-goods levels MRP forecast drives material ordering

Custom Products and Produce to Order

Orders set production schedule and drive material deliveries Design time may be required before production can be scheduled
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Process Design in Services

Quasi manufacturing -- produksi barangbarang berlangsung sepanjang lini produksi dengan hampir tidak ada interaksi pelanggan Customer-as-participant tingginya derajat keterlibatan pelanggan dalam proses meningkatkan ayanan Customer-as-product -- layanan diberikan sampai ke pribadi pelanggan

Dr. Mohammad Abdul Mukhyi, SE., MM

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Deciding Among Processing Alternatives

Batch Size and Product/Service Variety Capital Requirements Economic Analysis
Cost functions of alternatives Operating leverage - relationship between a firms annual costs and its annual sales Break-even analysis Financial analysis

Dr. Mohammad Abdul Mukhyi, SE., MM

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Process Design Depends on Product Diversity and Batch Size

Product Focused, Dedicated Systems

Batch Size

Product Focused, Batch System Cellular Manufacturing ProcessProcess-Focused, Job Shop

Number of Product Designs

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Flexible Manufacturing System

Products General purpose 1000 100 10 Work cells CIM

Flexible Manufacturing Focused System automation Dedicated automation 1 10 100 1000 10000 100000 1000000 Volume

Dr. Mohammad Abdul Mukhyi, SE., MM

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Economic Analysis
Cost Function of Processing Alternatives
If capital is not a factor, the process design preferred depends upon product volume

Operating Leverage
Relationship between firms annual costs and annual sales If high % firms costs fixed, then high degree of operating leverage Small % change in sales drives large % change in operating income

. . . more
Dr. Mohammad Abdul Mukhyi, SE., MM 20

Economic Analysis
Break Even Analysis
Formulas for comparing processes Cannot incorporate uncertainty, costs assumed over entire range of values, and does not take into account time value of money

Financial Analysis
Incorporate time value of money .... net present value, internal rate of return, etc.
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Cost Functions of Processing Alternatives

Annual Cost of Production ($000)

2,000 1,500 1,000 500 Job Shop Preferred 100,000 Cellular Manufacturing Preferred

Automated Assembly Line Preferred Units Produced Per Year

250,000
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Dr. Mohammad Abdul Mukhyi, SE., MM

Example: Cost Functions of Processing Alternatives

Three production processes - A, B, and C - have the following cost structure: Fixed Cost Per Year $120,000 90,000 80,000 Variable Cost Per Unit $3.00 4.00 4.50

Process A B C

What is the most economical process for a volume of 8,000 units per year?
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Example: Cost Functions of Processing Alternatives

Most Economical Process at 8,000 Units TC = FC + v(Q)
A: TC = 120,000 + 3.00(8,000) = $144,000 per year B: TC = 90,000 + 4.00(8,000) = $122,000 per year C: TC = 80,000 + 4.50(8,000) = $116,000 per year

Process C has the lowest annual cost.

Dr. Mohammad Abdul Mukhyi, SE., MM

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Deciding Among Processing Alternatives

Bagan perakitan ( Gozinto Tabel) Pandangan makro bagaimana material dipersatukan Titik awal untuk memahami kebutuhan tataruang pabrik, kebutuhan peralatan, kebutuhan latihan Tabel Proses Rincian bagaimana cara membangun produk pada masing-masing proses Meliputi kebutuhan material, jenis aliran proses produksi, waktu proses produk sampai masingmasing step
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Stages of a Products Life Cycle

Automobile Cell Phone Color Laser Printer Color Copier Video Recorder Compact Disc Player Fax Machine B&W TV

Introduction

Growth

Maturity

Decline

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Product Life Cycle & Sales, Cost, and Net Revenues

Sales Revenue Net Revenue Loss

Sales, Cost & Profit

Introduction

Growth

Maturity

Decline

Time
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Operations Emphasis in Product Life Cycle

Stage

Operations Emphasis

Introductory Research Product development Process modification & enhancement Supplier development Growth Capacity determination/enhancement Maturity High volume production with innovation Cost control Reduction in options Paring down of product line Termination of production if necessary

Decline

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American Approach to Product Design

Research

Development t

Manufacturing Process Design

Manufacturing

Product

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Japanese Approach to Product Design

Research, Development, and Manufacturing Process Design

Manufacturing

Product

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Product/Service Design
Kapan suatu product/service dirancang: Karakteristik terperinci produk/jasa adalah establis Karakteristik produk/jasa yang secara langsung mempengaruhi bagaimana produk/jasa dapat diproduksi/dikirim Bagaimana produk/jasa adalah diproduksi/dikirim ditentukan disain produksi/sistem pengiriman.

Dr. Mohammad Abdul Mukhyi, SE., MM

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Product/Service Design
Desain produk/jasa secara langsung mempengaruhi: Kualitas produk/jasa Biaya produksi/jasa Kepuasan pelanggan

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Product/Service Design and Development

Sumber. Mengembangkan produk/jasa baru Membawanya ke pasar lebih cepat. Meningkatkan produk/jasa sekarang. Merancang untuk mempermudah produksi. Perancangan mutu. Perancangan dan pengembangan jasa baru.
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Sources of Product/Service Innovation

Customers Managers Marketing Operations Engineering Research and Development (R&D)
Basic research Applied research
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Steps in Designing and Developing New Products

1. Technical and economic feasibility studies
2. Prototype design 3. Performance testing of prototype 4. Market sensing/evaluation and economic evaluation of the prototype 5. Design of production model 6. Market/performance/process testing and economic evaluation of production model 7. Continuous modification of production model

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Getting New Products to Market Faster

Speed creates competitive advantages Speed saves money Tools to improve speed: Autonomous design and development teams Computer-aided design/computeraided manufacturing (CAD/CAM) Simultaneous (concurrent) engineering
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Improving the Design of Existing Products/Services

Focus is improving performance, quality, and cost Objective is maintaining or improving market share of maturing products/services Little changes can be significant Small, steady (continuous) improvements can add up to huge long-term improvements Value analysis is practiced, meaning design features are examined in terms of their cost/benefit (value).
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Designing for Ease of Production

Ease of Production (Manufacturability) Specifications - Precise information about the characteristics of the product Tolerances - Minimum & maximum limits on a dimension that allows the item to function as designed Standardization - Reduce variety among a group of products or parts Simplification - Reduce or eliminate the complexity of a part or product

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Designing for Quality

Crucial element of product design is its impact on quality Quality is determined by the customers perception of the degree of excellence of the product/services characteristics Covers the principles of designing products/services for quality . . . more

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Designing and Developing New Services

Three general dimensions of service design are: Degree of standardization of the service Degree of customer contact in delivering the service Mix of physical goods and intangible services
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Literatur
N. Gaither and Frazier, Production and Operations Management, 8th Edition, Duxbury Press, NY, NY, 1999. (Road server) Handouts for most classes are available on the ROAD server. The handouts can be accessed at: _ HYPERLINK http://road.uww.edu __http://road.uww.edu_ The handouts are under my name (HOUSEMAJ) and Course #: 250306.
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