Introduction to Manufacturing Systems

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Sistem Operasional Penelitian Manufaktur II 249) (TKI 226)

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Referensi
1. Askin, R.G., and Standridge, C.R., (1993), Modeling and Analysis of Manufacturing Systems, John Wiley & Sons. 2. Hitomi, K., (1996), Manufacturing System Engineering, Taylor & Francis. 3. Askin, R.G., and Standridge, C.R., (2002), Design and Analysis of Lean Production Systems, John Wiley & Sons. 4. Groover, M.P.,(2001), Otomation, Production System and Computer Integrated Manufacturing, Prentice Hall. 5. Singh, N., (1996), Systems Approach to Computer-Integrated Design and Manufakturing, John Wiley & Sons. 6. Suzaki, K., (1993), Tantangan Industri Manufaktur, Productivity & Quality Management Consultans

Teknik Industri UNIJOYO

Sistem Manufaktur (TKI 249)

Tujuan Instruksional
1. Memperkenalkan cara pikir sistemik terintegrasi dan metoda keteknikindustrian dalam memecahkan permasalahan dalam sistem manufaktur 2. Mahasiswa dapat melakukan analisis dan memodelkan sistem manufaktur

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Rule Of Conduct
Min 80% Present in Classroom Present in Class Before Starting the Lecture Dont Use Sandal, Kaos Oblong and Hand Phone ringing During the Lecture Having Good Attitude

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Assessment
Requirements: Min 80% Present in Class Having Good Attitude Score/Grade : A, B, C, D, E Mid Semester Test (UTS) : 35% Final Test (UAS): 35% Assignment (Tugas) : 30%

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Definisi Teknik Industri*

Teknik Industri berkaitan dengan perancangan, perbaikan dan penginstalasian sistem integral yang terdiri atas manusia, bahan, peralatan, informasi dan energi.

Teknik Industri menggunakan pengetahuan dan keahlian dalam ilmu-ilmu matematika, alam dan sosial secara bersama-sama dengan prinsip-prinsip dan metodametoda analisis dan perancangan kerekayasaan untuk menentukan, memprediksikan dan mengevaluasi hasilhasil yang diperoleh dari sistem integral tersebut.
*) The Institute of Industrial Engineering Teknik Industri UNIJOYO Sistem Manufaktur (TKI 249) 6

Teknik Industri sebagai suatu disiplin kerekayasaan*

Profesi dimana pengetahuan matematika dan ilmu alam yang diperoleh dengan studi, pengalaman, dan praktek diterapkan dengan pertimbangan bagi pengembangan cara-cara untuk menggunakan secara ekonomis bahanbahan dan kekuatan alam untuk kemanfaatan

*) ABET Teknik Industri UNIJOYO Sistem Manufaktur (TKI 249) 7

Body of Knowledge dari Displin Teknik Industri* (1)

Operational Science Operations Research, Organization Design, Management Information System, Economics Analysis, etc. Ergonomics/Human Factors Engineering Ergonomics, Work Design, Wage Administration, Work Safety and Hygiene, etc. Production Engineering Production Planning and Control, Quality Control, Manufacturing Process, Plant Layout, etc.

*) Biles, W.E., The engineering science of industrial engineering: a viewpoint of industrial engineering curriculum, IEE Transaction 23, 1991, 208-214. Teknik Industri UNIJOYO Sistem Manufaktur (TKI 249) 8

Body of Knowledge dari Displin Teknik Industri* (2)

Operational Science

Production Engineering

Ergonomics/Human Factors Engineering

*) BIles, W.E., The engineering science of industrial engineering: a viewpoint of industrial engineering curriculum, IEE Transaction 23, 1991, 208-214. Teknik Industri UNIJOYO Sistem Manufaktur (TKI 249) 9

Body of Knowledge dari Displin Teknik Industri* (3)

Industrial Engineering Functions: 1. Production Engineering 2. Operational Science 3. Ergonomics/Human Factors Engineering
Industrial Engineering Science Behavioral and Social Science Life Science General Engineering Science Physical Science Mathematics

*) BIles, W.E., The engineering science of industrial engineering: a viewpoint of industrial engineering curriculum, IEE Transaction 23, 1991, 208-214. Teknik Industri UNIJOYO Sistem Manufaktur (TKI 249) 10

Manufaktur ?

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Manufaktur? (Teknologi)

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Manufaktur ? (Ekonomi)

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Sistem dalam Kontek Pengambilan Keputusan

Sistem is kumpulan komponen-komponen yang terorganisasi dan berhubungan untuk melakukan sesuatu yang tidak dapat dilakukan sendiri pleh satu komponen saja.
Kita gunakan model sistem sebagai cara yang tepat untuk melihat sesuatu dalam rangka tujuan pengambilan keputusan (memecahkan masalah)

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Sistem dalam Kontek Pengambilan Keputusan

A System is described by: Observer: Who is interested in the system? Observer Purpose: Why define the system? Improve, output of interest Environment: outside the system. Define the system boundary Hierarchy: components and/or sub-systems are organised Inputs: Affect the system but are not affected by it. Can be controllable or uncontrollable. Decision variables/parameters Outputs: Are affected by the system. These are of interest to the observer. Include measure of success Components: Both affect and are affected by the system. Relationship/transformation process: Between system inputs, outputs and components relevant aspects.
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Aplikasi Berpikir Sistem (1)

Berpikir tentang fenomena secara hirarki yang tergorganisasi keseluruhan. Identifikasi beberapa prinsip umum yang memungkinkan sistem dapat didefisnisikan dan tentukan batasbatasnya.
Penentuan input dan input yang melintasi batas sistem (system boundary).
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Aplikasi Berpikir Sistem (2)

Identifikasi mekanisme pengendalian dengan cara apa sistem mempertahankan identitasnya dan hubungannya.

Identifikasi tujuan sistem (purpose or goals), dan komponen-komponennya, atau sub-sistem

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A Systems View of Manufacturing

Manufacturing can be viewed either as a transformation process or as a system. As a Transformation Process: A narrow definition of manufacturing is that it a process of transformation where raw material are converted into products. As a System: Manufacturing is not limited to materials transformation performed in a factory. Rather, it is a complex system comprising of several elements.

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Flow of Materials, Information and Cost

PLANNING

RAW MATERIALS

Flow of

Information

PROCESS

Materials

PRODUCTS

CONTROL

Flow of

Flow of cost

Figure 2.3: Flow of Material, Information and Costs (Hitomi, 1996)

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A Systems View of Manufacturing

This involves an internal environment and an external environment. The inputs are from the external environment and involve several variables. The outputs are to the external environment and also involve several variables.

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INPUTS - FINANCIAL - HUMAN - MATERIAL - INFORMATION - TECHNOLOGY TRANSFORMATION PROCESS LABORS EFFORTS MANAGEMENT TECHNOLOGY OPERATIONS

EXTERNAL ENVIRONMENT

INTERNAL ENVIRONMENT

OUTPUTS PRODUCTS/SERVICES FINANCIAL CONSEQUENCES HUMAN CONSEQUENCES

Figure 2.2: Systems View of Manufacturing (Murthy, 1995a)

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Definisi manufacturing
CIRP (International Conference on Production Engineering), 1983:
A Series of interrelated activities and operations involving the design, materials selection, planning, manufacturing production, quality assurance, management and marketing of products of the manufacturing industries.

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Definisi Manufaktur dan Produksi

Kata manufacturing diartikan lebih luas Manufacturing adalah proses konversi suatu desain menjadi produk akhir

Production adalah aktivitas fisik untuk mengubah suatu bentuk material menjadi bentuk lain yang lebih bernilai

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Siklus Manufaktur
Pemasaran Perancangan Produk Perancangan Process

Pengendalian Persediaan

Perencanaan Produksi

Konsumen

Penyimpanan Pengiriman

Proses Pembuatan

Penerimaan

Pengendalian Kualitas

Pengendalian Produksi

Pengendalian Proses

Pengendalian Peralatan

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Pemasok
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Perancangan Metoda Kerja, Waktu Standar, dan Perbaikan Produktivitas

Sistem produksi, sistem manufaktur, sistem perusahaan

SISTEM PERUSAHAAN Sistem Keuangan

Sistem Personalia

Sistem Manajemen

SISTEM MANUFAKTUR
SISTEM PRODUKSI Desain produk dan proses
P erencanaan produksi P engendalian produksi

Studi Pasar
Aktivitas P roduksi

Penjaminan Kualitas

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Teknik Industri UNIJOYO

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Sistem Manufaktur
Sistem manufaktur adalah sistem yang melakukan proses transformasi/konversi keinginan (needs) konsumen menjadi produk jadi yang berkualitas tinggi Keinginan konsumen diketahui dari studi pasar, yang kemudian keinginan ini diterjemahkan menjadi desain produk, dan kemudian menjadi desain proses Komitmen terhadap kualitas

Kualitas produk harus dimiliki oleh setiap level dalam perusahaan pada setiap tahap proses produksi
Dalam proses transformasi ini terjadi pertambahan nilai
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A Systems View of Manufacturing

Can be viewed from three different Aspects: 1. Technical: Dealing with engineering, science and technology issues.

2. Commercial: Dealing with financial, marketing, legal issues

3. Management: Dealing with planning, operations and other related issues such as information. And also organisational issues dealing with human related issues.
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MANUFACTURING: DIFFERENT PERSPECTIVES

It can also be viewed from three different perspectives:
Firm level, Industry level and Regional or global level.

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Firm Level
Manufacturing at the firm level involves several variables which can be broadly grouped into the following three categories:
Technical Commercial Management

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Technical
The technical side has been discussed before and involves various issues related to the science, engineering and technology aspects of manufacturing.

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Commercial
The commercial side deals with issues such as costs, sales, revenue and profits. Each of these involves many variables. For example, the costs can be investment costs, unit manufacturing costs, cost of rework and so on. The basic bottom line for a firm is that it must make reasonable profit for its investment.

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Management
Deal with managing the various activities at strategic and operational levels taking into account the many different legal and sociopolitical aspects and various constraints. Another very important issue relates to the organizational side that deals with the human related issues organisational structure, communication and flow of information, skill base of the workforce and so on.

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National Level
In the national level, a manufacturing firm is influenced by factors such as market competition and government policies. Obviously, the market competition is not only determined by manufactured goods within the nation but also affected by imported manufactured goods.

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National Level
Some of the government policies that affect the manufacturing enterprise are indicated below. Industry or Technology development policies, Taxation policies, Environmental policies. Trade policies export and import subsidies, protection Financial investment

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Regional and Global Levels

Manufacturing at the regional and global levels deals with the following factors : Fierce competition Open market - free trade Trade organisation - regional partnerships

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A THREE LEVEL MODEL OF MANUFACTURING

Manufacturing is a complex system involving several elements. It can be viewed as a three level system (Level 1 - 3)
Note that Level 1 is nested within Level 2, in turn, is nested within Level 3. We briefly discuss the elements at each of these levels.

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Level 3
Research and Development Finance

Strategic Level
Partnerships

Level 2
Accounting Legal

Operations Level
Planning

Level 1

Process Level

SUPPLIERS

Inputs

Processes

Outputs

CUSTOMERS

Human Resource

Environmental

Marketing

New Technologies

Socio/Political

New Markets

Figure 2.9: Three Level Model of Manufacturing (Murthy, 1995b)

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Level 1
This level corresponds to the shop floor level and has three key elements - Inputs, Process and Outputs.

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Level 2
This level includes Level 1 as well as six new elements. The focus of this level is management of business at the operations level and the six new elements with a range of operational issues.

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Level 3
This level includes the Levels 1 and 2 and six new elements. Here, the management focus is long term and strategic. This is important, as survival of businesses in the fiercely competitive global market requires long term strategies. The six new elements deal with a range of long term issues.

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Planning Horizon Associated with Production Analysis

Planning Horizon
Months-Years
Months-Years Weeks-Months

Level of Analysis
Facilities Planning
Product design and Process Planning Production Planning

Hours-Weeks
Minutes-Hours Seconds-Minutes
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Production control
Quality control Machine-level real-time control
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Respon Sistem Manufaktur

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Sistem manufaktur vs. Respons kepada konsumen

MTS FS BP JS ATO MTO ETO

Jenis sistem: MTS=make to stock; ATO=assemble to order; MTO=make to order; ETO=engineer to order Jenis respon: FS=flow shop; BP=batch production; JS=job shop
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MTS vs. MTO

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