DESIGN OF MANUFACTURING SYSTEM

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Sasaran

Memahami konsep dan proses perancangan sistem manufaktur mulai dari perancangan produk, perancangan

proses, pemilihan lokasi dan perancangan lay out

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What Design IE Do ?

Integrated System

Industrial System(Manufacturing System)

Human Activity Management Control System System

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Human Activity System

• Perancangan System

• Pengoperasian System

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Langkah Perancangan Sistem

Analisis Permintaan

Perancangan Produk Dan Proses

Penentuan Kapasitas

Pemilihan Lokasi

Perancangan Lay Out

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Pengoperasian Sistem Target Penjualan

Target Produksi

Jadwal Produksi

Material Mesin T. Kerja

Jadwal Operasi

Pelaksanaan

Evaluasi

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Analisis Permintaan

Tujuannya adalah menentukan jenis produk dan menghitung volume

permintaan effektifnya

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Analisis Permintaan

Analisis Peluang Pasar

Proyeksi Demand Potential(Do)

Market Share ( S )

Proyeksi Demand Effektif (De )De = S.Do

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Demand Effective

Do

De

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Metoda Proyeksi

• Market Research

• Kwalitatif

• Kwantitatif–Time Series–Causal

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Analisis Market Share

Analisis Persaingan

5 Forces ( Porter )» Substitute» Supplier» Buyer» New Entrance» Competitor

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Product Design

Membuat blue print product berdasarkan atas permintaan pasarnya

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The Four C’s of Design• Creativity

– Requires creation of something new

• Complexity– Requires decision on many Variables and

Parameters

• Choice– Requires making choices between many possible

solution

• Compromise– Requires balancing multiple conflicting

requirements

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ComparisonScientific Method Vs Design Method

Existing Knowledge

Scientific Curiosity

Hypothesis

Logical Analysis

Proof

State of The Art

Identification of Need

Conceptualization

FeasibilityAnalysis

Production

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Types of Design Project

• Variation of Existing Product

• Improvement of Existing Product

• Development of New Product for Low Volume Production Run

• Development of New Product for Mass Production

• One-of-a-Kind Design

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Morphology of Design

1. Conceptual Design

2. Embodiment Design

3. Detail Design

4. Planning For Manufacture

5. Planning For Distribution

6. Planning for Use

7. Planning for Retirement of the Product

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Product Design Process

Problem Definition

-Problem Statement-Benchmarking

-QFD-PDS

-Project Planning

GatherInformation

-Internet-Patent-Trade

-Literature

ConceptGeneration

- Brainstorming- Functional

Decomposition-Morphological Chart

Evaluation ofConcept

--Pugh Concept

Selection-Decision Matrices

Parametric Design

-Robust Design -Tolerances

-Final Dimension-DFM

ConfigurationDesign

-Prelim. SelectionMaterials and

Manufacturing-Modeling/sizing of

part

Product Architecture

- Arrangement ofPhysical Elements

to Carry outFunction

Detail Design

- Detail Drawing sand

Specifications

Conceptual Design

Embodiment Design

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Identifying Customer Needs

• Gathering Information From Customers– Interview, Focus Group, Customer Survey, and

Customer Complaint

• Constructing Survey Instrument

• Evaluating Customer Needs

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Dimension of Quality for Manufactured Product

• Performance• Features• Reliability• Durability• Serviceability• Conformance• Aesthetics• Perceived Quality

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Product Design Specification

A Document Which Contains All of the Facts Related to the Outcome of the

Product Development

• In Use Purpose and Market• Functional Requirements

• Corporate Constraint• Social, Political, and Legal Requirements

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Customer Requirements

• Expecters– There are basic attributes that one would expect

to see in the product

• Spokens– There are specific features that customer defines

the product in terms of these attributes that one would expect to see in the product

• Unspokens

• Exiters

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Customer Requirements

• Unspokens– These Are Specific Features That

Customers Say They Want in the Product.

• Exiters– These Are Product Features That Make the

Product Unique and Distinguish It From the Competition

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Quality Function Deployment

A Planning and Problem Solving Tool for Translating Customer

Requirements Into the Engineering Characteristics of Product ( Engineering Parameters)

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5Correlation Matrix

4Engineering Characteristic

6Relationship Matrix

7. Absolute Importance

8. Relative Importance

9. Technical Competitive Assessment

10. Technical Difficulty

11. Target Value

1CustomerReq’ment

“What?”

2CompetitiveAssessment

3Impor-tance

Rating

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Manufacturing EngineeringDesigning the Production Processes for a

Product

• Evaluating the Manufacturing of the Product• Selecting Processes and Setting Process• Designing Work-Holding Device• Estimating the Cost of Manufacturing the Part• Assuring the Quality of the Part Produce

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Process Planning• Defining Product Structure and

Specification

• Assessing The Manufacturability

• Determining Processes Capable of Producing Part

• Evaluating The Cost of Each Process

• Determining the Sequence of Operations

• Documenting the Process

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Manufacturing Processes

• Refining and Alloying

• Casting

• Metal Forming

• Metal Cutting

• Welding

• Assembly

• Finishing

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Classification Of Manufacturing Processes

1. Processes for Changing Physical Properties

2. Processes for Changing the Shape of Material

3. Processes for Machining Parts to a Fixed Dimension

4. Processes for Obtaining a Surface Finish

5. Processes for Joining Parts or Materials

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Classification Of Service Processes

1. Process for relocating goods

2. Process for storing goods

3. Process for exchanging items

4. Process for physical transformation

5. Process for physiological transformation

6. Process for information transformation

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Equipment Selection & Specification

• Selecting Equipment to be used,a. General-purpose or Specialized Equipment

b. Material Handling System

• Allocating Available Facilities

(Layout Design)

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Equipment Selection Alternatives

General Purpose SpecializedCost Low High

Operator skill&control High , more control Low, less control

Output rate Low-human pace High-machine pace

Setup time Lower-problem pre- High-problem ran-

dictable &controllable dom & highly tech.

Maintenance Cost Low-lower skill req’ed High

Product/service Based on human High-based on

Quality control machine accuracy

WIP High Low

Absolescence Slower High

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Ancillary Function

• Tool, Jig and Fixture Design

• Cost Estimating

• Maintenance System Design

• Packaging System

• Material handling

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Material Handling

1. Increasing Speed and Precision

2. Maximizing the Use of Space and Equipment

3. Increasing Safety and Working Condition

4. Reducing Damage

5. Increasing Control

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Principles of Material Handling

1. Minimize the Number of Material Moves

2. Maximize the Unit Load Handled

3. Maximized Safety of Material Handling Equipment

4. Simplify the Material Handling Process

5. Maximize Pace Utilization

6. Integrate Storage and Handling System

7. Integrate Materials and Information Flows

8. Minimize Human Effort

9. Design for Improved Operability, Reliability, Maintainability and Flexibility

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Penentuan Kapasitas

Kapasitas Adalah Kemampuan Maksimum Dari Suatu Fasilitas

Persatuan Waktu

Design(co) Effektif(ce) Aktual(ca) ( Designer ) ( Planner ) ( Executor)

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Keterkaitan Antar Kapasitas

Co

Ce

Ca

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Langkah

Demand Effective

Kapasitas Effektif

Strategi Kapasitas

Kapasitas Design

LOSES (L)

EFFISIENSI

CCR ( R )

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Kapasitas Effektif

Ce = De/(1-L)

Dimana L: loses karena- Kerusakan di gudang- Kerusakan transportasi- Warranty- Sales program

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Policy A : Capacity leads demand

Policy B : Capacity in approximate with demand

Policy C : Capacity legs demand

Capacity DemandsUnits

Time

Time

Time

Units

Units

Capacity

Demands

Demands

Capacity

Strategi Kapasitas

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Strategi Kapasitas

• Lead Demand R > 0.5

• Lag Demand R < 0.5

• Equal Demand R = 0.5

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Capacity Cushion Ratio

R = ( Cx – Cs )/Cx

Dimana:

R : Capacity Cushion Ratio

Cx : Marginal Profit

Cs : Marginal Production

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Kapasitas Design

Co = Ce/(1-E )

Dimana,

E : Effisiensi Pabrik

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Pemilihan Lokasi

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Kriteria Lokasi

Services Operating Cost

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Faktor Lokasi

1. Pasar Dan Bahan Baku

Jasa Semen Fragile Kertas

Berat Agro Industri

SERVICES COST

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Faktor Lokasi

2. Tangible . Transportasi . Utilitas

. Tenaga Kerja . Biaya Konstruksi

. Energi . Pajak

. Tanah . Bahan Penolong

. Insentif . Dll

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Faktor Lokasi

3. Intangible – Iklim– Peraturan– Stabilitas Politik– Kemudahan Ekspansi– Budaya– Polusi– Dll

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Tahapan Pemilihan Lokasi

Regional

Makro

Community

Mikro

Site

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Metoda Pemilihan

• Gravitasi

• BEP

• Transportasi

• Point Rating

• Simulasi

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Design Of Lay-out

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Penyebab

• Pembangunan Pabrik Baru

• Perubahan Kapasitas

• Perubahan Design Produk

• Produk Baru

• Dll

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Type Lay-out

• Product Lay-out

• Process Lay-out

• Fix Lay-out

• Automated Lay-out

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Product Lay-out

Berdasarkan atas urutan proses produksi

Potong Obras Jahit Kancing Finishing Packing

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Process Lay-out

Berdasarkan atas kesamaan jenis mesin

X

Y

A

F

CB

ED

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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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Kriteria Kinerja

1. Minimasi Kongesti

2. Minimasi Material Handling Cost

3. Effisiensi Penggunaan Resources

4. Keselamatan dan Keamanan Kerja

5. Koordinasi dan Supervisi

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Bagan Alir Perancangan Lay-Out

Inputan

Aliran Kerja Hub.Antar Kegiatan

Diagram Hubungan Kegiatan

Keb. Luas Lantai

Diagram Hubungan Ruang

PengmbanganAlternatifLay-out

Luas lantai Tersedia

Evaluasi

Pertimb. Modifikasi Pertim. Praktis