i

KATA PENGANTAR
Puji dan syukur kami panjatkan kehadirat Tuhan Yang Maha Esa, karena atas limpahan
berkat dan karunia-Nya, kami berhasil menyelesaikan laporan praktikum Perancangan
Teknik Industri modul 5 Perencanaan Produksi dan Kebutuhan Material dengan tepat
pada waktunya. Laporan ini kami susun guna memenuhi tugas praktikum Perancangan
Teknik Industri Program Studi Teknik Industri Universitas Diponegoro serta menambah
pemahaman mahasiswa mengenai mata kuliah Perancangan Teknik Industri.
Penyusunan laporan ini telah terselesaikan berkat bantuan banyak pihak, baik pada saat
pelaksanaan praktikum maupun pada saat penyusunan laporan praktikum. Oleh karena
itu, penyusun mengucapkan terima kasih yang sebesar besarnya kepada :
1. Seluruh dosen Teknik Industri yang telah memberikan ilmu untuk dapat
membantu kami dalam mengerjakan laporan modul 5 ini dengan baik.
2. Seluruh Asisten Dosen, khususnya Kak Diery Leonardo S. yang telah
membimbing kami dalam melakukan praktikum dan menyusun laporan
praktikum Perancangan Teknik Industri modul 4.
3. Rekan rekan mahasiswa Teknik Industri, khususnya shift 3 dan kelompok 12
khususnya pada praktikum Perancangan Teknik Industri Universitas Diponegoro
yang telah membantu dalam banyak hal.
4. Seluruh pihak yang telah membantu penyelesaian laporan praktikum
Perancangan Teknik Industri secara langsung maupun tidak langsung yang tidak
mungkin kami sebutkan satu-persatu.
Namun, kami menyadari dalam laporan ini masih terdapat banyak kekurangan.
Oleh karena itu, saran dan kritik dari pembaca sangat kami harapkan.
Akhir kata, semoga laporan ini bermanfaat bagi kita semua.
Semarang, Desember 2012
Penyusun

ii

DAFATAR ISI
HALAMAN JUDUL........................................................................................

KATA PENGANTAR......................................................................................

ii

DAFTAR ISI....................................................................................................

iv

DAFTAR GAMBAR........................................................................................

vi

DAFTAR TABEL............................................................................................

viii

BAB I PENDAHULUAN.................................................................................

1.1 Latar Belakang................................................................................

1.2 Perumusan Masalah .......................................................................

1.3 Tujuan Penulisan.............................................................................

1.4 Pembatasan Masalah dan asumsi....................................................

1.5 Sistematika Penulisan.....................................................................

BAB II TINJAUAN PUSTAKA......................................................................

2.1 Resource Requirement Planning (RRP)..........................................

2.2 Agregasi (Perencanaan Agregat)....................................................

2.2.1 Fungsi Agregat Planning...........................................................

2.2.2 Input dan Output Perencanaan Agregat.....................................

2.2.3 Strategi Perencanaan Agregat....................................................

2.2.4 Biaya-biaya dalam Perencanaan Agregat..................................

2.2.5Metode Agregat..........................................................................

2.3 Jadwal Induk Produksi (JIP)...........................................................

13

2.3.1 Konsep Dasar Aktivitas Jadwal Induk Produksi (JIP)...............

13

2.3.2 Teknik Disagregasi....................................................................

16

2.2.3 Metode Disagregasi...

16

2.4 Rough Cut Capacity Planning (RCCP)...........................................

21

2.4.1 Beberapa Pendekatan yang Digunakan dalam RCCP :.............

23

2.4.2 Alternatif Kapasitas...................................................................

25

2.5 Perencanaan Kebutuhan Material (Material Requirement Planning

iii

/ MRP).............................................................................................

27

2.5.Ciri Utama Sistem MRP...............................................................

27

2.5.2 Input Sistem MRP.....................................................................

27

2.5.3 Output Sistem MRP...................................................................

28

2.5.4 Asumsi Sistem MRP..................................................................

29

2.5.5 Mekanisme MRP.......................................................................

29

2.5.6 Teknik Penetapan Ukuran Lot...................................................

30

2.5.7 Informasi MRP..........................................................................

35

BAB III METODOLOGI PENELITIAN.........................................................

36

BAB IV PENGUMPULAN DAN PENGOLAHAN DATA............................

38

4.1 Pengumpulan Data..........................................................................

38

4.1.1 Target Produksi Satu Tahun......................................................

38

4.1.2 Data Harga Sparepart Tamiya dari supplier..............................

39

4.1.3 Data Leadtime dan Schedule Receipt Sparepart Tamiya .........

40

4.1.4 Data Biaya-Biaya Produksi.......................................................

41

4.1.5 Bill of Material..........................................................................

41

4.2 Pengolahan Data.............................................................................

42

4.2.1 Agregat Planning.......................................................................

42

4.2.1.1 Kapasitas Yang Tersedia Pada Perusahaan..........................

42

4.2.1.2 Perhitungan Agregat Planning .. 43

4.2.2 Jadwal Induk Produksi...............................................................

51

4.2.2.1 Hasil Agregat Planning........................................................

51

4.2.2.2 Hasil JIP Disagregasi...........................................................

51

4.2.2.3 Hasil JIP Konversi................................................................

54

4.2.3 Rough Cut Capacity Planning (RCCP).....................................

54

4.2.3.1 Output JIP.............................................................................

54

4.2.3.2 Output RCCP.......................................................................

54

4.2.4 Material Requirement Planning.................................................

56
iv

4.2.4.1 Safety Stock.........................................................................

56

4.2.4.2 Netting..................................................................................

56

4.2.4.3 Lotting..................................................................................

59

4.2.4.4 Offsetting..............................................................................

83

4.2.4.5 Rekap Hasil Biaya MRP Untuk Semua Level.....................

83

BAB V ANALISIS...........................................................................................

98

5.1 Agregat Planning............................................................................

98

5.2 Jadwal Induk Produksi....................................................................

98

5.3 RCCP..............................................................................................

99

5.4 MRP................................................................................................

100

5.4.1 Analisis Perbandingan Antara Biaya Manual dan Software

Komponen Terpilih....................................................................

100

5.4.2 Analisis Pemilihan Metode Masing-Masing Komponen...........

101

5.4.3 Analisis Hasil MRP dengan Metode Terpilih............................

103

BAB VI PENUTUP..........................................................................................

107

6.1 Kesimpulan.....................................................................................

107

6.2 Saran...............................................................................................

107

LAMPIRAN

DAFTAR GAMBAR
Gambar 2.2 Metode Hax and Bitran18
Gambar 3.1 Metodologi Praktikum 35
Gambar 4.1 Bill of Material....40
Gambar 4.1 Input Perhitungan Agregat dengan QS .....................................................43
Gambar 4.3 Jadwal Produksi...43
Gambar 4.4 Analisis Biaya Agregat Planning 44
Gambar 4.5 Grafik Transportasi Land.48
Gambar 4.6 Grafik RCCP ...54
Gambar 4.7 Software MRP metode LFL 55
Gambar 4.8 Software MRP Biaya metode LFL .55
Gambar 4.9 Software MRP metode EOQ ..56
Gambar 4.10 Software MRP Biaya metode EOQ ..57
Gambar 4.11 Output Software MRP Metode POQ 57
Gambar 4.12 Output Software MRP Biaya Metode POQ .57
Gambar 4.13 Output software MRP metode FOQ..58
Gambar 4.14 Output software MRP Biaya metode FOQ58
Gambar 4.15 Output Software MRP metode
FPR...59
Gambar 4.16 Output Software MRP Biaya metode FPR....59
Gambar 4.17 output Software MRP metode
LUC...62
Gambar 4.18 output Software MRP Biaya metode LUC62
Gambar 4.19 Output software MRP metode LTC...64
Gambar 4.20 Output software MRP Biaya metode LTC....64
Gambar 4.21 Output software MRP metode PPB...67
Gambar 4.22 Output software MRP Biaya metode PPB67
Gambar 4.23 Output software MRP metode AWW....79

vi

Gambar 4.24 Output software MRP Biaya metode

AWW..79
Gambar 4.25 Input BOM.82
Gambar 4.26 Input MPS..82
Gambar 4.27 Input Inventory..83
Gambar 4.28 Input Capacity.. 83
Gambar 4.29 Output software MRP AWW TAMIYA SAMBA ...88
Gambar 4.30 Output software MRP AWW TAMIYA TANGO.. 88
Gambar 4.31 Output software MRP AWW TAMIYA PUMA.. 88
Gambar 4.32 Output software MRP AWW CHASIS ASSY. 88

vii

DAFTAR TABEL
Tabel 4.1 Target produksi 1 tahun.........................................................................................
37
Tabel 4.2 Harga sparepart Tamiya.........................................................................................
38
Tabel 4.3 Data leadtime dan schedule receipt sparepart........................................................
39
Tabel 4.4 Data mengenai kebijakan perusahaan....................................................................
40
Tabel 4.5 Kapasitas Produksi.................................................................................................
42
Tabel 4.6 Tabel Transportasi.................................................................................................
44
Tabel 4.7 Perhitungan manual transportasi land....................................................................
46
Tabel 4.8 Hasil Rekap Biaya dengan Software....................................................................
47
Tabel 4.8 Rekap biaya KTTP.................................................................................................
48
Tabel 4.9 Hasil Agregat Planning..........................................................................................
49
Tabel 4.10 Hasil JIP Disagregasi...........................................................................................
49
Tabel 4.11 Hasil Agregat Planning........................................................................................
51

viii

Tabel 4.12 Hasil Prosentase JIP.............................................................................................

51
Tabel 4.13 Output JIP Konversi.............................................................................................
52
Tabel 4.14 Jadwal Induk Produksi Dalam Satuan Unit.........................................................
52
Tabel 4.15 Hasil RCCP..........................................................................................................
53
Tabel 4.16 Rekap Hasil JIP Konversi 3 bulan.......................................................................
55
Tabel 4.17 Rekap Hasil JIP Konversi 12 Minggu.................................................................
55
Tabel 4.18 Hasil Netting Tamiya Puma.................................................................................
55
Tabel 4.19 Hasil Netting Tamiya Samba...............................................................................
56
Tabel 4.20 Hasil Netting Tamiya Tango................................................................................
56
Tabel 4.21 Rekap Jumlah Nilai Netting Tamiya...................................................................
56
Tabel 4.22 MRP dengan Metode LFL...................................................................................
57
Tabel 4.23 Perhitungan Manual EOQ....................................................................................
58
Tabel 4.24 Perhitungan Manual POQ Pengunci Body, Level : 1..........................................
59
Tabel 4.25 Perhitungan Manual FOQ Pengunci Body, Level : 1..........................................
60
Tabel 4.26 Perhitungan Manual Pengunci Body FPR...........................................................
61

ix

Tabel 4.27 Perhitungan MRP dengan Metode LUC..............................................................

62
Tabel 4.28 MRP dengan Metode LUC..................................................................................
63
Tabel 4.29 Perhitungan Manual TRC(T)/T (LTC) Pengunci Body, Level : 1......................
64
Tabel 4.30 Perhitungan Manual LTC Pengunci Body, Level : 1...........................................
66
Tabel 4.31 Perhitungan Manual PPB Grade A Level : 1.......................................................
67
Tabel 4.32 Perhitungan Manual PPB.....................................................................................
68
Tabel 4.33 Lotting AWW Komponen Penutup Baterai Perhitungan Manual.......................
73
Tabel 4.34 Perhitungan F Manual Metode WWA.................................................................
78
Tabel 4.35 Rekap GR WWA.................................................................................................
79
Tabel 4.36 Rekap biaya manual dan software QS komponen chasis assy.............................
80
Tabel 4.37 Item Master..........................................................................................................
81
Tabel 4.38 Rekap biaya MRP Level 0...................................................................................
84
Tabel 4.39 Rekap biaya MRP Level 1...................................................................................
84
Tabel 4.40 Rekap biaya MRP Level 2...................................................................................
85
Tabel 4.41 Rekap biaya MRP Level 3...................................................................................
86

Tabel 4.42 Rekap POR Metode Terpilih (AWW).................................................................

93
Tabel 5.1 Perbandingan Biaya Manual dan Software Komponen Body Grade Cyber..........
98
Tabel 5.2 Rekap Pemilihan Metode Terpilih.........................................................................
99
Tabel 5.3 Analisis Hasil MRP dengan Metode Terpilih........................................................
101

xi

xii