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TEKNIK DAN SISTEM PRODUKSI

PE4652 Proses Manufaktur Lanjut

PE 4652 Proses Manufaktur Lanjut(Advanced Manufacturing Processes)

Bab : Pendahuluan



Mata kuliah ini membahas aplikasi pengetahuan tentang

manufacturing engineering melalui optimasi pengaruh

parameter kondisi pemotongan terhadap tingkat ekonomis

pengerjaan produkskala small batch dengan

memanfaatkan keilmuan pemotongan logam, standar

operasi produksi pada konsep lean manufacturing dan

perhitungan klasik ongkos proses pemesinan beserta

pengolahan datanya.

SINOPSIS

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Setelah menyelesaikan mata kuliah ini mahasiswa akandapat:

1. Mengerti topik-topik tentang metal removal processes

dan economics metal cutting

2. Merencanakan dan mengelola suatu pembuatan

produk dengan sifat small batch sesuai standar operasi

produksi

3. Optimasi proses pengerjaan suatu produk

Tujuan Instruksional Umum (TIU)



TECHNOLOGY ENGINEERING

MANUFACTURING

Manufacturing Engineering

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Function that is concerned with planning the manufacturing

processes for the economic production of high-quality

products

Principal roletransition of the product from design specification to physical

product

Goal

to optimize production




1. Process planninga) deciding what processes and methods should be used and in

what sequenceb) determining tooling requirementsc) selecting production equipment and systemsd) estimating costs of production for the selected processes,

tooling, and equipment

2. Problem solving and continuous improvement continuous efforts to reduce production costs, increase

productivity, and improve product quality

3. Design for manufacturability to develop product designs that also can be produced at

reasonable cost with minimum technical problems at highestpossible quality in the shortest possible time

The scope of manufacturing engineering activities

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(Djassemi, 2008)

Integrated process, material and product design



Lean Production

Lean production adalah sebuah sistem dinamis

yang membutuhkan lebih sedikit sumber daya

(material, tenaga kerja dan overhead) dan

menghasilkan output yang lebih baik (kualitas,

biaya, ragam dan keamanan) untuk menambah

nilai (value)

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6

Six Sigma

Metodologi terstruktur untuk memperbaiki proses yang

difokuskan pada usaha mengurangi variasi proses (process

variances) sekaligus mengurangi cacat (produk/jasa yang

diluar spesifikasi) dengan menggunakan statistik dan

problem solving tools secara intensif



Three Basic Elements of Standard Operation

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Human Automation (JIDOKA)

The relationship between people and machines

Step 1: Manual laboro Manual labor simply means that all of the work is being done

by hand

Step 2: Mechanizationo Mechanization means leaving part of the manual operations

to a machine

Step 3: Automationo All manual labor in processing is taken over by the machine

Step 4: Jidoka (human automation)o The machine itself will detect when a defect has occurred

and will automatically shut itself off



U. Zuperl, F. Cus,2003

Optimal SolutionHierarchical structure of the objectives, attributes and cutting

parameters

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Productivity



Machinability (objective function) is defined as a function

of one/several criteria and is influenced with machining

parameters-cutting condition:

MRtot=f (tool wear, machined surface roughness, cutting forces, . . .)

= f (vc, ap,f, r)

Machinability A measure of the relative ease of amachining operation usually on a work material and

type of machining operation, tooling, and cutting

conditions.

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Matriks Produk-Proses oleh by Hayes & Wheelwright [1979]

Small Batch



To against chinese products in CAFTA and all global

competition , we must have skill to make products with value

(efisien-cost, cepat-delivery and bagus-quality)

(Dr. Syafei Antonio, Metro TV Feb 2010)

Towards Free Trades :

2015 - AFTA

2020 - WTO

Experiences :

We always left behind in preparation of global competition

(could not be anticipated )

Competitiveness

process improvement

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Trends In Manufacturing

(1) Lean production and Six Sigma,

(2) Globalization,

(3) Environtmentally conscious manufacturing,

(4) Microfabrication and nanotechnology.



Mfg: China

Mfg: China, Ireland

Mfg: Malaysia

Mfg: Thailand, Singapore, Hungary,

Philippines

Mfg: Japan, Thailand, Germany,

Philippines

Mfg: Mexico, China, Taiwan,

Philippines

Mfg: Singapore,

Thailand

Mfg: China, Ireland

GLOBALIZATION AND OUTSOURCING

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Tren Teknologi yang Mempengaruhi Industri Manufaktur

Software

Modular

IoT

A new dependence on software to aid themanufacturing process, especially cloud computing.

Modular design aims to create scalable, reusablemodels by subdividing current manufacturingsystems into several smaller parts to both reducecosts and allow more flexible designs.

IoT refers to the concept of implementingnetwork capabilities into everyday objects. Thisallows devices to communicate with each other

without the direct input of the user.

http://www.digitaledge.org/three-technology-trends-affecting-the-manufacturing-industry/



1011MFT_Teknologi Manufaktur_4MDF

www.elearning.polman-bandung.ac.id

Enrollment key : ---

Elearning

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No. Materi Referensi

1 Pendahuluan & Pengenalano Pengertian manufakturo Standar Produksio Perkembangan industrio Penjelasan materi

Berbagaireferensi

2 Machinabilityo Sifat-sifat materialoPemilihan materialo Jenis-jenis material karbidao Pemilihan alat potong karbida

1/ ch 232/ ch 114,5

3 Dasar pemotongan logam :o Geometri proses pemotongan

orthogonalo Karakterisasi chipo Gaya pemotongan logam

1/ ch 212/ch 8

Silabus PE 4652v13




4 Dasar pemotongan logam :o Energi dan daya pemotongano Pengenalan parameter pemotongan

1/ ch 214

5 Eco Manufacturing/Machiningo Temperaturo Cairan pendingin dan manajemennyao Kerusakan alat potong

1/ ch 232/ ch 84,5

6 Alat potong untuk proses pemesinano Keausan pahato Umur pahato Kekasaran permukaan (surface

finish)

1/ ch 232/ ch 8

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7 Analisis klasik ongkos pemotongan logam 1/ ch 242/ ch 31

8 Jig & FixtureDasar-dasar jig & fixtureFaktor lokasiGaya pencekaman

3 / ch1,2,3,5,7

9 Perencanaan operasi pengerjaanEstimasi set-up dan cycle timeUrutan operasi

1/ ch 24, 40,412/ ch 23, 31

10 Proses Finishing (Grinding & polishing) 1/25

11 Getaran pada alat potong 8




12 Dasar solusi optimalo Lean Manufacturingo DMAIC six sigmao Design of Experiment

5

13 Alat bantu solusi optimalo Solusi faktorialo Robust design

5

14 Tugas Besar :Membuat perencanaan pembuatan produk komponen untukjumlah n buah per minggu dengan memperhatikan: Pemilihan urutan proses pengerjaan yang optimal Menentukan jenis mesin yang digunakan dan spesifikasinya Menentukan alat potong yang sesuai Menentukan kondisi pemotongan agar dihasilkan ongkos yang

minimal dengan jumlah produksi maksimal

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Text Book:

1. Mikell P. Groover,Fundamental of Modern Manufacturing, Material, Processesand Systems,3rd , 2007, John Wiley

Referensi lain :

1. Ostwald & Munoz, Manufacturing Processes and Systems, 9th, 1997, John Wiley& Sons

2. P.H.Joshi, Jigs & Fixtures Design Manual, 2nd, 2003, Mc.Graw Hill

3. Hiroyuki Hirano, The Complete Guide to Just-in-Time Manufacturing 2nd Ed.,Standardized Operations Jidoka and Maintenance /Safety, 2009, CRC Press-Taylor & Francis Group

4. Rehman M. Khan, Problem Solving and Data Analysis using Minitab, A clear andeasy guide to Six Sigma methodology, 2013, John Wiley & Sons

5. Sandvik Catalogue 2009 dari www.coromant.sandvik.com (e-book)

6. Sandvik Technical Guide dari www.coromant.sandvik.com (e-book)

7. Sandvik Coromant How to reduce vibration in metal cutting,

C-2920:23

Buku Referensi :



Tugas Besar : 30 %Ujian Tengah Semester : 35 %Ujian Akhir Semester : 35 %

Metoda Evaluasi

1PE5662_rev15.1

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