Jurusan Teknik IndustriKuliah : Benny Ch. N.
MANUFACTURING SYSTEM
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
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
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
What Does IE Do ?
Production Management Corporate Operation System Services* Product &Services * Information System * Comprehensive Planning* Manufacturing Process * Financial &Cost System * Policies & Procedures* Facilities * Personnel * Performance Measurement* Work Methods & Standards * Analysis * Production Planning & Control
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Materi
• Concept of Manufacturing System
• Manufacturing System Design
• Operation & Management System
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
CONCEPT OF MANUFACTURING SYSTEM
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Sasaran
Memahami manufactring sebagai kerangka acuan dalam pendidikan
teknik industri baik aspek struktural maupun fungsionalnya
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Materi
• Manufacturing as a Production System
• Transformation Process
• Manufacturing Function
• Manufacturing Cycle
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Manufacture as a Production System
Input Transformation Output
ExtractionPhysicalService
Feedback
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
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
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Factor of Production
»Man (Manuasia)
»Machine (Mesin)
»Material
»Management
»Modal
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Performance Criteria
• Quality
• Cost
• Delivery
• Flexibility
• Safety
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Competency
»Technnical
»Managerial . Cooperation
. Leadership
. Adaptive
. Creative
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Structural Aspect
MachineMan
Mat
Boundary
Environment
Input Out-put
: Interaction
Feed-back
Transformation
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Transformation System
1. Classical• Project
• Job Shop
• Flow Shop
2. Emerging• Variable Production Line
• Manufacturing Cells
• FMS
• CIM
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Transformation Process
Form: Order:– Manufacturing ( Discrete ) - Job Shop– Process ( Continue) - Flow Shop– Services - Project
Project Job Shop Flow Shop
Volume Skill Worker Equipment General Special Lay Out Fix Process Product
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Product Lay-out
Peletakan Mesin Berdasarkan Atas Urutan Proses Produksi
Potong Obras Jahit Kancing Finishing Packing
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Process Lay-out
Peletakan Mesin Berdasarkan Atas Kesamaan Jenis Mesin
X
Y
A
F
CB
ED
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Fix Lay-out
Benda Kerja Diam Mesin, Peralatan, Material Dan Karyawan Mendatangi
Benda Kerja
Contoh: • Galangan Kapal
• Assembling Pesawat
• Dll
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Automated Lay-Out
Berdasarkan Atas Kesamaan Fungsi Dan Kemampuan Proses Produksi
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Equipment and Physical Layout Characteristics
Project Job Shop Flow ShopSize of Facility Varies Small Large
Process Flow Circumference Num, Pattern Rigid
Equipment General General Specialized
Capital Ints. Varies Low High
Capital Add. Incremental Small Large Chunk
Speed of Process Varies Slow Fast
Control Worker Worker & Process Design
Tech. Change Slow Average Fast
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Direct Labor and Work Force Characteristics
Project Job Shop Flow ShopLabor value added High Average Very Low
Job content scope Large Average Small
Skill level High Average Low
Wage rate High Average Low
Worker training V. High High Low
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Material and Information Control Characteristics
Project Job Shop Flow ShopMaterial Requirement Varies Unpredictable Predictable
Vertical Integration None Limited Back&Forwd
Inv. Raw Material None Small Large
WIP Large Large Small
Finished Goods None Small High
QC Responsibility D. Labor D. labor QC Specialist
Prod/Serv, Information V. High High Low
Scheduling Uncertain Changes Inflexible
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Process Management Characteristic
Project Job Shop Flow ShopChallenges Estimating Lab.Utilization Avoid Downtime
Sequencing Debottlenecking Time Expansion
Pacing Learning Curve Cost Minimizing
Tools PERT/ Load Chart Line Balancing
CPM Optimization
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Product/Service Start-up Growth Stable Decline
Volume Low Increasing High DecliningVariety Unique Inc.Standard Emergence High Standard Dom. Design Process Technology Organization Project Small Batch Line flow Line flow Job shop Assembly AssemblyInnovation High Medium Medium LowIntegration Low Medium Medium High
Industry Structure Small Consolidation Few large Survivor competitor and fallout competitor Competitive Flexibility Quality and Price(cost) Price(cost) Priority Flexibility Delivery
Product/Service and ProcessTechnology Life Cycles
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Variable Production Line
Dedicated High Volume Lines That Are Reconfigured to Permit Some Process
Variation and Thus Several Different Products or Service
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
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
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
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
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
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
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Stage Toward A CIM
Batch/Lot ProcessMRPII/SPC
JIT &MC Focused factoryStable Flow
FMS CAD/CAMRobotics AMH/GT
CIMInformation System
Integration
Traditional Mfg. Variable Line
Stage 3
Stage 1
Stage 2
Stage 4
To CIM
Process Technology Process Control System
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Manufacturing Function
Marketing Engineering
FabricationProduction
Management
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Marketing• Need Identification
• Type of Product/Service• Customer • Specification• Purchasing Power • Volume• Distribution Channel
• Product/Service Delivery• Marketing Mix
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Engineering
Design Product’s Blue Print According To Customer’s Demand
• Product Design
• Process Planning
• Product Planning
• Method Engineering
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Fabrication
Make Product According to the Blue Print From Engineering
Production Control
Process Control
Quality Control
Facilities Control
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Production Management
Support Manufacturing In Order To Fulfill the Customer’s Demand
• Production Planning And Control• Inventory Control
Pengantar Teknik Industri - Manufacturing System
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Jurusan Teknik IndustriKuliah : Benny Ch. N.
Manufacturing Cycle
Marketing/ Sales
Product Design Process Design
Inventory Control
Production Planning and
Control
Work Method , Time Standard & Productivity Improvement
Fabrication Receiving
Receiving
Shipping
Suppl i er
Cus tomer
Quality Control
Production Control
Process Control
Facilities Control
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