MANUFACTURING SYSTEM

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
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What Does IE Do ?

Production Operation

Management Corporate System Services

* Comprehensive Planning * Policies & Procedures * Performance Measurement * Analysis

* Product &Services * Information System * Manufacturing Process * Financial &Cost System * Facilities * Personnel * Work Methods & Standards * Production Planning & Control

Materi
Concept of Manufacturing System Manufacturing System Design Operation & Management System

CONCEPT OF MANUFACTURING SYSTEM

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

Materi
Manufacturing

as a Production System

Transformation Process Manufacturing Function Manufacturing Cycle

Manufacture as a Production System

Input Transformation
Extraction Physical Service

Output

Feedback
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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
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Factor of Production
Man Machine Material Management Modal

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Performance Criteria
Quality Cost Delivery Flexibility Safety

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Competency
Technnical Managerial
. Cooperation
. Leadership . Adaptive . Creative

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Structural Aspect
Transformation

Boundary Man Input Mat Feed-back Environment

: Interaction
Machine

Out-put

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Transformation System
1. Classical
Project Job Shop Flow Shop

2. Emerging
Variable Production Line Manufacturing Cells FMS CIM
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Transformation Process
Form:
Manufacturing ( Discrete ) Process ( Continue) Services

Order:
- Job Shop - Flow Shop - Project

Project

Job Shop
Volume Skill Worker Equipment

Flow Shop

General Fix Lay Out Process

Special Product

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Product Lay-out
Peletakan Mesin Berdasarkan Atas Urutan Proses Produksi

Potong

Obras

Jahit

Kancing

Finishing

Packing

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Process Lay-out
Peletakan Mesin Berdasarkan Atas Kesamaan Jenis Mesin
Y A B C X D E F

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Fix Lay-out
Benda Kerja Diam Mesin, Peralatan, Material Dan Karyawan Mendatangi Benda Kerja Contoh:
Galangan Kapal Assembling Pesawat Dll
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Automated Lay-Out
Berdasarkan Atas Kesamaan Fungsi Dan Kemampuan Proses Produksi

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Equipment and Physical Layout Characteristics

Project
Size of Facility Varies Process Flow Circumference Equipment General Capital Ints. Varies Capital Add. Incremental Speed of Process Varies Control Worker Tech. Change Slow

Job Shop
Small Num, Pattern General Low Small Slow Worker & Average

Flow Shop
Large Rigid Specialized High Large Chunk Fast Process Design Fast

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Direct Labor and Work Force Characteristics

Project
Labor value added Job content scope Skill level Wage rate Worker training High Large High High V. High

Job Shop
Average Average Average Average High

Flow Shop
Very Low Small Low Low Low

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Material and Information Control Characteristics

Project
Material Requirement Varies Vertical Integration None Inv. Raw Material None WIP Large Finished Goods None QC Responsibility D. Labor Prod/Serv, Information V. High Scheduling Uncertain

Job Shop
Unpredictable Limited Small Large Small D. labor High Changes

Flow Shop
Predictable Back&Forwd Large Small High QC Specialist Low Inflexible

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Process Management Characteristic

Project
Challenges Estimating Sequencing Pacing PERT/ CPM

Job Shop

Flow Shop

Lab.Utilization Avoid Downtime Debottlenecking Time Expansion Learning Curve Cost Minimizing Load Chart Line Balancing Optimization

Tools

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Product/Service and Process Technology Life Cycles

Product/Service
Volume Variety

Start-up
Low Unique Project Job shop High Low

Growth
Increasing Inc.Standard Small Batch Medium Medium

Stable

Decline

High Declining Emergence High Standard Dom. Design Line flow Assembly Medium Medium Line flow Assembly Low High

Process Technology
Organization Innovation Integration Industry Structure Competitive Priority

Small competitor Flexibility

Consolidation and fallout Quality and Flexibility

Few large competitor Price(cost) Delivery

Survivor Price(cost)

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Variable Production Line

Dedicated High Volume Lines That Are Reconfigured to Permit Some Process Variation and Thus Several Different Products or Service

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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
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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
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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

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Stage Toward A CIM

To CIM

Stage 4

CIM
CAD/CAM Robotics AMH/GT

Information System

Integration

Stage 3

FMS
Focused factory Stable Flow

JIT &MC
Traditional Mfg. Batch/Lot Process Variable Line MRPII/SPC

Stage 2

Stage 1

Process Technology

Process Control System

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Manufacturing Function
Marketing Engineering

Production Management

Fabrication

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

Product/Service Delivery

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Engineering
Design Products Blue Print According To Customers Demand
Product Design Process Planning Product Planning Method Engineering

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Fabrication
Make Product According to the Blue Print From Engineering

Production Control Process Control Quality Control Facilities Control

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Production Management
Support Manufacturing In Order To Fulfill the Customers Demand

Production Planning And Control Inventory Control

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Manufacturing Cycle
Marketing/ Sales Product Design Process Design

Inventory Control C u s to m e r

Production Planning and Control

Work Method , Time Standard & Productivity Improvement

Receiving Fabrication Shipping Receiving

S u p pl i e r

Quality Control

Production Control

Process Control

Facilities Control

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