Sritomo W
W.Soebroto
Soebroto
Laboratorium Ergonomi & Perancangan Sistem Kerja
Jurusan Teknik Industri
Institut Teknologi Sepuluh Nopember
SURABAYA
9/19/2011 Pengantar Teknik Industri/Sritomo 1
W.Soebroto
Agenda
Historis Disiplin Teknik
I d ti
Industri
Arah dan perkembangan
disiplin Teknik Industri
dan Manajemen industri
Macam, problematika
dan tantangan industri
sebagai tulang punggung
pertum buhan ekonomi
9/19/2011 Pengantar Teknik Industri/Sritomo 2
W.Soebroto
1
Perkembangan Disiplin Teknik Industri
(Industrial Engineering)
Statistics Quality & Reliability
Logic
Operation Research
Scientific
Military Civil Mechanical Industrial
Management
Engineering Engineering Engineering (early IE) Engineering
Psychology
& Sociology VA/VE and
Productivity Sc.
Management
Phil
Philosophy
h Ergonomics
Production/Mfg Economics
Engineering
Physiology
Chemistry Chemical
Engineering
2
Definisi Teknik Industri
System
Specify - Predict - Evaluate
People
Engineering Analysis & Design Energy
(Mathematical - Physical - Social)
3
Chronological Development of Production Technology
(Hardware) and Production Methodology (Software)
Internet/
Information (hardware)
Degree of Developm
Space Technology T
Technology
h l
4
Pioneer Teknik Industri, Manajemen Industri,
Engineering Management ?
• 1895 – menyajikan paper “A Piece of Rate System”
pada pertemuan ASME.
• 1903 – menyajikan “Shop Management” yang
menyangkutk beberapa
b b prinsip
i i d dan kkonsep mengenaii
methods study, time study, standardization of tools,
planning department, classification systems for parts
and products, routing system, dll. Tanggapan
kurang positif.
• 1907 – menulis makalah panjang (200 halaman)
berjudul “Study of Metal Cutting” pada Transaction
of ASME (rumus Taylor yang terkait dengan biaya
produksi dan umur pahat : C = VTn).
• 1909 – menulis “The Principles of Scientific
Management” yang sangat kontroversial dan
fenomental : (1) menaikkan output produksi
sekaligus menurunkan biaya operator, namun juga
menaikkan gaji/upah mereka, (2) melatih operator
dan meminta mereka bekerja pada kemampuan
Frederick Winslow Taylor maksimal untuk kenaikan upah (bonus/insentif) yang
(1856 – 1915) melebihi standard.
5
Perkembangan Teknik Industri
(s/d tahun 1950-an)
Tokoh-Tokoh :
Adam Smith ((1776)) – specialization,
p , productivity
p y
Charles Babbage (1832) – Division of Labor
Frederick W. Taylor (1905) – Scientific Management
Frank & Lillian Gilbreth (1912) – Micro-motion Study
Organisasi :
Society to Promote the Science of Management (1912)
The Taylor Society (1915)
Society of Industrial Engineers (1917)
Konsep-Konsep :
Wealth of Nations – spesialisasi/keahlian untuk meningkatkan
produktivitas kerja
Economy of Machinery and Manufacturers – pembagian kerja
Principles of Scientific management
Human Factors, Ergonomics, Micro-motion Economy
6
Perkembangan Teknik Industri
(1970-1990)
AIIE menjadi IIE (Institute of Industrial Engineers)
Bidang perhatian :
Bidang Industri : antariksa, bank dan keuangan, elektronika,
pemerintahaan, pelayanan kesehatan (rumah sakit), retail,
industri baja, transportasi dan distribusi, utilitas, dll.
Bidang Sistem Manusia dan Informasi : komputer dan sistem
informasi, ekonomi teknik, ergonomi, hubungan kerja dan
industri, manajemen, tata-cara dan pengukuran kerja, dll
Bidang
Bid Si
Sistem
t P
Produksi
d k i : manajemen
j energi, i perancangan d
dan
perencanaan fasilitas, sistem manufaktur, penelitian operasional,
pengendalian produksi dan persediaan, pengendalian mutu dan
keandalan.
7
Phase-Phase Perkembangan
Aktivitas Produksi di Industri
Phase-Phase Macam & Area Lokasi Sifat Perubahan
P i d
Periode
Perkembangan Volume Produk Pemasaran Terjadi
Sebelum
Customized, Tersendat,
Job Order
kecil, terbatas
Lokal trial & error
revolusi
industri
Mass Standard, seri, Lambat, Revolusi
Production batch, massal
Regional Scientific Method Industri - 1930
M
Mass Diversifikasi,
Di ifik i
Marketing banyak model
Nasional Cepat 1930 - 1950
Kronologis Perkembangan
Disiplin Teknik Industri
Phase Problematik, Kasus, Konsep, atau Skala
Perkembangan Pengembangan Teori Pandang
Revolusi Industri Mekanisasi Proses-2 Produksi, Interchange-ability
(1750-1900-an) Parts, Standardisasi Produk (awal Mass Production)
Scientific Time & Motion Studies, Organization (Functional)
Management Design, Production Planning & Scheduling, Inventory MIKRO
(1890 - 1930-an) Model (EOQ), Statistical QC, Line Balancing, etc.
Tool Design, Engineering Economy, Human Engineering
Industrial Engineering
(Ergonomics), Facilities Location & Layout, Queuing
(1930-1950-an)
Theory, Analyzing Productivity, Management Controls, etc
Operations Digital Computer, Mathematical Programming, Reliability
Research Analysis, Decision/Optimization Theory, System MIKRO
(1945-1970-an) Engineering, Automation, Mgmt Information System, etc.
&
Industrial & Control Theory, Large-Scale System, Total System MAKRO
System Engineering Design, Social System, Cybernetics, Behavioral Theory
8
The Role of the Industrial Engineers
in Integrating New Technologies
(1960 - 1980)
100%
Manajemen Persediaan Desain SIM
Perbaikan Metode Perbaikan Metoda & Persediaan
dan P
Penyederhanaan
d h K
Kerja
j Rekayasa
Penyederhanaan Proyek Analisa Finansial
Rekayasa
Kerja Proyek Rancangan Fasilitas Perenc.Sistem Non-Mfg
9
Kronologi Pengembangan Profesi Teknik Industri
Macro & Micro View
Micro View
Industrial & Systems Engineering
Operation Research
Scientific Management Industrial Engineering
Resource
Labor Union Management
Robots
Tool Design Reliability System
Engineering Design
CAD/
Management CAM
Statistical MRP
Controls
Analysis
Efficiency Experts Line Balancing Decision Artificial Intelligence
& Queueing Productivity Theory
Mass Production Japanese Computer
Engineering Simulation
Wage Incentive Plan Production System Network
Economy
Operation
Standardization Group Flexible
Line & Staff Human Relations Analysis
Organization Technology Automation
Interchangeable Division and Ergonomics/
E i /
Parts Inventory Material
Specialization of Human System Flexible Mfg System
Motion Study Model EOQ Handling Factors
Labor Engineering
Statistical Computer
Accounting Piecework Schedule Quality Network Optimization Office
Time Study Plant Layout Integrated
Incentives Charts Control Planning Theory Automation Manufacturing
1494 1750 1890 1900 1915 1929 1941 1958 1980 1990 2000
Industrial Revolution WW I Depression WW II Space age High Tech. Globalization
10
Kompetensi Dan Tantangan
Profesi Teknik Industri Di Masa Depan
Karakteristik Keilmuan TI
• TI memberikan peluang untuk bekerja dalam berbagai jenis
bidang kerja (bisnis/ industri).
• Aspek yang paling menonjol dari disiplin TI adalah “flexibility” dalam aplikasi ilmu TI
(all share the common goal of saving companies money and increasing efficiencies).
• Dalam kondisi dimana banyak manajer perusahaan menghadapi masalah peningkatan
daya saing, maka mereka harus mampu memperbaiki kualitas/produktivitas, menekan
biaya, dan mempercepat waktu penyerahan barang. Disini diperlukan lulusan TI,
karena disiplin TI memang mengajarkan kompetensi dan/atau kemampuan (spesialis)
untuk permasalahan ini (eliminate waste of time, money, materials, energy, and other
commodities).
• Disiplin TI diharapkan mampu “menyelamatkan” uang perusahaan, itu sebabnya
banyak perusahaan yang kemudian merekrut lulusan TI dan mempromosikan dalam
posisi manajemen karena orang-orang TI dianggap bisa memahami proses tetapi juga
sekaligus melihat proses produksi tidak hanya sebagai proses aliran material (material
flow) namun juga sekaligus sebagai proses aliran uang (cash flow).
• Industrial engineers figure out how to do things better; they engineer
processes and systems that improve quality and productivity.
9/19/2011 Pengantar Teknik Industri/Sritomo 22
W.Soebroto
11
Ruang Lingkup Aktivitas Profesi Teknik Industri
(What Do IEs Do?)
Doing more, Business Efficiency and
less and less Profitability Productivity Improvement
Human
Cost Analysis & Production Planning Decision
Product Design Reduction Program and Inventory Control Analysis
Resources
Management
and Development
Organization Development
Value Analysis/
Engineering
Facilities Planning,
Design & Layout
&
Industrial Management ?
9/19/2011 Pengantar Teknik Industri/Sritomo 23
W.Soebroto
Sistem Pengendalian
Manajemen (Management
Control System)
12
Ruang Lingkup Profesi
Teknik Industri
• Human Activity System Design
Berkaitan dengan area kerja fisik dimana
kegiatan produksi (interaksi sistem manusia-mesin)
dilaksa nakan. Perancangan fasilitas produksi
(layout), manufacturing processes, methods
engineering, ergonomics, etc.
• Management Control System Design
Berkaitan dengan prosedur perencanaan, pengu
kuran dan pengendalian produksi, cost analysis &
control, management information system, etc.
9/19/2011 Pengantar Teknik Industri/Sritomo 25
W.Soebroto
• Proses Manufaktur
• Bahan dan Sumber Daya
Proses Produksi
• Tata Cara Kerja
• Tata letak Fasilitas Pabrik dan
Pemindahan Bahan
• Sarana dan Prosedur
Penanganan Material
• Ergonomi & Perancangan
Stasiun Kerja (Sistem
Manusia- Mesin)
• Keselamatan dan Kesehatan
Kerja
• Dll.
13
Sistem Pengendalian Manajemen
• Sistem Perencanaan Manajemen
• Teknik dan Prosedur Peramalan
Produksi
• Penganggaran
g gg dan Analisis Ekonomi
• Rencana Pengupahan/Penggajian
• Rencana Insentif dan Sistem
Hubungan Karyawan
• Manajemen Sumber Daya Manusia
• Perencanaan Kebutuhan Material
(MRP)
• Perencanaan dan Pengendalian
Persediaan
• Penjadwalan Produksi
• Sistem Informasi Manajemen
j
• Sistem Pengendalian (Manajemen)
Kualitas
• Perencanaan dan Pengendalian Biaya
• Perancangan Organisasi Kerja
• Sistem Pendukung Keputusan
• Dsb
14
WHAT DOES IE DO?
15
Macam Aktivitas Teknik Industri
(Operasi Produksi)
Produk atau jasa :
¾ Analisis mengenai produk atau jasa yang diusulkan
¾ Perbaikan berkelanjutan (continuous improvement)
Proses manufaktur (pembuatan
( b t benda)
b d )
¾ Penentuan cara terbaik untuk pembuatan
¾ Pemilihan peralatan, otomatisasi, robot
¾ Pengaturan assembling (perakitan)
¾ Penentuan aliran bahan, sistem dan prosedurnya
Fasilitas (sarana, ruangan, dll)
¾ Penentuan tata-letak peralatan, penyimpanan bahan/produk jadi
¾ Penentuan sistem pemeliharaan, proses pemeriksaan dan pengujian, sarana pendukung,
keamanan dan keadaan darurat.
Tata-cara kerja dan standard kerja
¾ Studi
S pengukuran kerja, penentuan waktu/output
/ standard
¾ Perbaikan tata-cara kerja, value analysis/engineering, costs reduction dan waste.
Perencanaan dan pengendalian produksi
¾ Peramalan kegiatan, analisis kapasitas, perencanaan produksi, analisis persediaan dan
kebutuhan bahan, pengendalian kualitas produk, dll
¾ Penyelarasan produksi, inventory, tenaga kerja
¾ Perancangan sistem dan prosedur untuk pengendalian pabrik (shop floor)
16
Macam Aktivitas Teknik Industri
(Aspek Perusahaan)
Perencanaan pabrik menyeluruh (komprehensif &
strategis)
Perancangan dan pengoperasian sistem perencanaan
Pelaksanaan rencana strategis
Penyusunan model bisnis, pengembangan perusahaan,
kepemimpinan, dsb
Kebijakan (policy) dan prosedur
Perancangan dan analisis organisasi
Pengelompokan secara fungsional, policy
manual,, dsb
Pengukuran kinerja
Kinerja perorangan, organisasi, manajemen
Analisis sistem
Sistem kerja, organisasi, manajemen, kepemimpinan
What Do IEs Do ?
• As a management engineer in a hospital, you may help
doctors and nurses make the best use of their time in
treating patients. You may also design procedures for
optimum use of medical facilities to help bring the cost
of healthcare down.
• As an ergonomist in a television manufacturing plant, you may
change the tools workers use to assemble televisions to reduce
the risk of repetitive stress injuries.
• As an operations analysts for an airline, you may design a bar
coding system for identifying and transporting passengers
passengers’
luggage to ensure that it does not get lost.
• As a quality engineer for a public gas and electric company,
you may improve customer satisfaction by designing a process
to schedule service calls around the availability of the customer.
9/19/2011 Pengantar Teknik Industri/Sritomo 34
W.Soebroto
17
Performance Industri Masa Depan
• Manufacturing : focus on processes,
continuous improvement, mass
mass-customization.
customization.
• Reach the market faster, at lower costs, at higher
quality, high customer satisfaction and loyalty.
• Quality - reliability – maintainability - sustain
ability
• Manufacturing ethics : emphasis on
people and environment (human capital/
assets, humanware, brainware, etc.
9/19/2011 Pengantar Teknik Industri/Sritomo 35
W.Soebroto
18
Kesenjangan antara Lulusan PT dan
Kebutuhan Industri
Lulusan Perguruan Tinggi Kebutuhan Industri
19
“Successful industrial engineers must possess
the
h ability
bili to communicate
i effectively,
ff i l for f without
ih it
i
you cannot sell your ideas. You must be able
to manage projects and multiple tasks,
for without those skills you will be able less efficient and
of less use to your employer.
You must be able to observe others and understand
why they are doing what they do, for without that
change is an uphill battle”
(Advice from an IIE Member)
9/19/2011 Pengantar Teknik Industri/Sritomo 39
W.Soebroto
20