Jurusan Teknik Industri, Universitas Andalas

TIN 218
Perencanaan dan Pengendalian
Produksi
Pertemuan 21 dan 22: Pengendalian
Aktivitas Produksi
Jurusan Teknik Industri
Universitas Andalas

TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Kompetensi yang ingin dicapai

Mampu memahami konsep pengendalian

aktivitas produksi dan perannya dalam P3

Mampu menggunakan teknik-teknik
pengendalian aktivitas produksi

2
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Production Activity Control (1)

Function of PAC:
To have activities performed as planned
Report on operating results
To revise plans as required to achieve the desired results

3
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Production
Activity
Control (2)

4
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Scheduling for Batch Flow Lines

Runout time is the period existing inventory will last given

forecast usage

Units in Inventory
Demand (usage) Rate

5
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Job shop scheduling

Scheduling is the assigning of starting and

completion times to orders (jobs) and frequently
includes the time when orders are to arrive and
leave each department

Sequencing is the assigning of the sequence in

which orders are to be processed

6
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Priority Control

Priority rules: for establishing the priority of

orders

Commond priority rules

First Come First Served

Shortest Processing (operation) Time
Shortest Total Processing Time
Earliest Due Date
Fewest Operation
Slack Time
Critical Rasio

7
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Queue Length Management

Objective: to control lead time and work in

process and to obtain full utilization of bottleneck
workcenters

8
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Typical queue distribution (1)

9
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Typical queue distribution (2)

10
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Operation Overlapping (Transfer

batches)

Technique to reduce the total lead time of production order

by dividing the lot into two or more batches and linking at
least two successive operation directly.

11
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Calculation of minimum batch size (1)

Q Q1 Q2
Q1 PB TAB S B Q2 PA TAB

where
Q = total lot size
Q1 = minimum size of first batch
Q2 = maximum size of second batch
SB = setup time of Operation B
PA = processing time per unit, Operation A
PB = processing time per unit, Operation B
TAB = transit time between Operation A and B
* assuming Q2 is to be at Operation B before Operation B
is completed on Q1

12
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Calculation of minimum batch size (2)

Thus,

Example:

QPA S B
Q1
PB PA

Q = 100 units
SB = 10 minutes
PA = 5 minutes
PB = 40 minutes
TAB = 30 minutes

100 10 40 960
Q1

64
10 5
15
13
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Comparison of lead time without and with

overlapping

14
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Operation splitting

A production lot is divided into two or more batches and the

same operation is then performed simultaneously on each of
these sublots

15
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Input/Output control

Is an effective technique for controlling queues,

work in process and manufacturing lead time
Planning the acceptable input and output performance
ranges per time period in each work center
Measuring and reporting actual inputs and outputs
(feedback)
Correcting out-of-control situations

16
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Single Work Center Proceess (1)

Basic concept:
ending WIP = beginning WIP + input output

17
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Single Work Center Proceess ICD

(2) ICD
i

Situation in control

i 1

PI i AI i

OCDi OCDi 1 POi AOi

PWIPi PWIPi 1 PI i POi
AWIPi AWIPi 1 AI i AOi

18
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Single Work Center Proceess (3)

WIP reduction

19
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Single Work Center Proceess (4)

Inadequate input

20
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Principles of input/output control

The planned output should be realistic and should

represent labor and equipment capacity
A planned or actual input greater that the realistic
output will increase WIP, hinder production, and
increase manufacturing lead time.
All significant deviation from planned input and
planned output indicate operational problems that
must be identified and solved

21
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Multiple Work Center

Gateway work center control

Management of the release of orders controls the input, queues and
WIP at gateway work centers

Downstream work center control

The input and queues at downstream work centers are controlled by
dispatching at upstream work centers in the process flow

Final work center control

The output of the final work centers influences shipments, due date

22
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22

Jurusan Teknik Industri, Universitas Andalas

Rate of flow

23
TIN218 Perencanaan dan Pengendalian Produksi, Pertemuan 21 dan 22