PEMILIHAN PROSES

MANUFAKTUR
(From Design to Manufacture)

Dr. M.K. Herliansyah, ST. MT.

Program Studi Teknik Industri

Jurusan Teknik Mesin dan Industri
Fakultas Teknik Universitas Gadjah Mada
2010
Alasan Pemilihan Proses Manufaktur:

♦ Hasil sesuai Yang Diinginkan

♦ Efisien
♦ Murah
♦ Cepat
♦ Kualitas Baik
Permasalahan : Bisnis Manufaktur
• Kompetisi / persaingan ketat • Memperbaiki kualitas
• Harapan konsumen yang • Harga jual murah
semakin tinggi • Penyediaan yang cepat

¾ Menaikkan efisiensi
¾ Perbaikan kualitas
¾ Investasi/otomatisasi
¾ Penurunan cost
¾ Mesin-mesin yang advance
¾ Pemilihan proses yang tepat (efisien + ekonomis)
¾ Teknologi dan biaya perancangan
MANUFACTURING INFORMATION FOR DESIGN

♦Produk mengalami perubahan sebelum sampai ke

konsumen
♦ Faktor-faktor Pertimbangan Dalam
Pemilihan Proses Manufaktur :
a. Jumlah produk
b. Biaya peralatan (equipment)
c. Biaya tooling
d. Waktu proses
e. Intensitas pekerja
f. Supervisi – proses
g. Perawatan
h. Konsumsi energy + overhead cost
Cont’
i. Biaya material + ketersediaannya
j. Bentuk dan dimensi komponen
k. Toleransi yang diperlukan
l. Surface finish
m. Bulk treatment
n. Keragaman komponen
o. Limbah/sisa
p. Daur ulang komponen/recycling
♦ Agar produk
yang
dihasilkan E
kompetitif, X
identifikasi
fisibilitas A
teknologi dan M
ekonomi dari
kombinasi P
proses L
manufaktur
dan bahan, E
A PROCESS SELECTION STRATEGY

♦ diperlukan suatu metode atau alat untuk memilih

proses yang sesuai dan mengestimasi biaya se-awal
mungkin.

♦ PRIMA (Process Information Maps) bertujuan :

– memberikan informasi mengenai proses yang

tepat untuk pembuatan suatu komponen
Strategi!!!
a. Tentukan atau perkirakan kuantitas produk dalam setahun
b. Pilihlah bahan yang sesuai dengan spesifikasi desain
c. Pilihlah alternative proses yang sesuai menurut PRIMAs
d. Pertimbangkan setiap alternative tersebut berdasarkan
persyaratan engineering dan ekonomi:
i. Mengerti proses dan variasinya
ii. Mempertimbangkan kesesuaian bahan dan proses
iii. Assess conformance of component concept with design
rules
iv. Compare tolerance and surface finish requirements with
process capability data
Cont’
e. Mempertimbangkan posisi ekonomi dari proses
dan dapatkan estimasi biaya komponen dari
setiap alternative

f. Sesuaikan proses manufaktur yang telah dipilih

dengan persyaratan bisnis.
Design for X Topics
♦ Design for Manufacturing
♦ Design for Assembly
♦ Design for Production
♦ Design for Recycling/Disposal
♦ Design for Life Cycle
♦ Prototyping
♦ Design for Automation
Gathering DFM Information
♦ Design documents:
– Sketches,
– Drawings,
– Spesifikasi produk, dan
– Alternatif-alternatif desain.
♦ Pemahaman dan informasi detil mengenai
proses produksi dan perakitan/assembly
♦ Perkiraan:
– manufacturing costs,
– production volumes, dan
– ramp-up timing.
DFM Method
♦ Memperkirakan manufacturing costs.
♦ Mengurangi biaya-biaya untuk
mempersiapkan/pembuatan components.
♦ Mengurangi biaya-biaya untuk proses
perakitan/assembly.
♦ Mengurangi biaya-biaya pendukung proses
production.
♦ Mempertimbangkan dampak/pengaruh DFM
decisions pada faktor-faktor yang lain.
 DFM Method
Proposed Design

Estimate The Manufacturing Cost

Reduce the Cost of Reduce the Cost of Reduce the Cost of

Components Assembly Supporting Production

Consider the Impact of DFM Decisions on Other Factors

Recompute the Manufacturing Costs

N Good Enough
?

Y
Acceptable Design
 Estimate the Manufacturing Costs
Equipment Information Tooling

Raw Materials

Labor
Manufacturing System Finished Goods
Purchased
Components

Energy Supplies Services Waste

Manufacturing Costs Defined
• Menghitung seluruh pengeluaran untuk
input system (sebagai contoh: pembelian
komponen-komponen, energi, raw materials,
dan lain-lain) dan pengeluaran untuk
penanganan limbah yang dihasilkan oleh
sistem.
 Elements of the Manufacturing Cost
of a Product
Manufacturing Cost

Components Assembly Overhead

Equipment Indirect
Standard Custom Labor Support
and Tooling Allocation

Raw
Processing Tooling
Material
Manufacturing Cost of a Product
♦ Component Costs (komponen-komponen dari
produk yang dibuat)
– Komponen-komponen yang dibeli dari supplier
– Custom parts yang dibuat didalam shop floor-nya sendiri
atau shop floor para supplier sesuai dengan spesifikasi
desain dari manufacturer’s
♦ Assembly Costs (labor, equipment, & tooling)
♦ Overhead Costs (all other costs)
– Support Costs (material handling, quality assurance,
purchasing, shipping, receiving, facilities, etc.)
– Indirect Allocations (tidak berhubungan secara langsung
dengan suatu particular product tetapi harus dibayar
dalam proses bisnis)
Fixed Costs vs. Variable Costs
♦ Fixed Costs – ditentukan terlebih dahulu
dalam suatu jumlah tertentu tanpa
memperhatikan jumlah unit yang diproduksi
(i.e. setting up the factory work area or cost
of an injection mold)
♦ Variable Costs – ditentukan secara
langsung dalam jumlah yang proporsional
dengan jumlah unit yang diproduksi (i.e.
cost of raw materials)
Reduce the Cost of Components
1. Understand the Process Constraints and
Cost Drivers
2. Redesign Components to Eliminate
Processing Steps
3. Choose the Appropriate Economic Scale
for the Part Process
4. Standardize Components and Processes
5. Adhere to “Black Box” Component
Procurement
1. Understand the Process Constraints
and Cost Drivers
Redesign costly parts with the same
performance while avoiding high
manufacturing costs.

Work closely with design engineers—raise

awareness of difficult operations and high
costs.
2. Redesign Components to Eliminate
Processing Steps
♦ Reduce the number of steps of the
production process
– Will usually result in reduce costs
♦ Eliminate unnecessary steps.
♦ Use substitution steps, where applicable.
♦ Analysis Tool – Process Flow Chart and
Value Stream Mapping
3. Choose the Appropriate Economic
Scale for the Part Process
Economies of Scale – As production volume
increases, manufacturing costs usually
decrease.
♦ Fixed costs divided among more units.
♦ Variable costs are lower since the firm can
use more efficient processes and equipment.
4. Standardize Components and
Processes
♦ Economies of Scale – The unit cost of a
component decreases as the production
volume increases.
♦ Standard Components—common to more
than one product
♦ Analysis tools – group technology and mass
customization
5. Adhere to “Black Box” Component
Procurement
♦ Black box—only give a description of what
the component has to do, not how to
achieve it
♦ Successful black box design requires clear
definitions of the functions, interfaces, and
interactions of each component.
DFM Tools and Methodology
ƒ Tools and Methodologies
ƒ Design For Assembly (DFA), (IBM experience)
ƒ Failure Mode and Effect Analysis (FMEA), (Sun
example)
ƒ Taguchi Method, (Hitachi experience)
ƒ Value Analysis--”Value Engineering” (HP example)
ƒ Quality Function Deployment (QFD), Going to the
Gemba (Hitachi)
ƒ Group Technology, (IBM example)
ƒ Cost management and optimization, SPC, Six-Sigma
(Motorola), TQC, etc
DFA Systems
♦ Boothroyd Dewhurst DFM & A
♦ Munro & Assoc. (Design Prophet/Profit)
♦ Others
DFM/A System In Global Manufacturing
Commercial Airplanes - Military Aircraft & Missiles - Space & Communications - Air Traffic
Management - Boeing Capital Corporation - Shared Services Group - Phantom Works
747 Final Assembly at Everett, Washington
747 Freighter
747 Freighter
 DFM Tools: DFA Guidelines

- One assembly direction “tops - Easy to fabricate parts

down”
-No adjustments required
-No hidden features - Standard parts (one screw type)

- Test direction access from top - Parts are self-guiding

- Avoid tangle with use of

fixtures
- Sub-assemblies reduce
handling of small hard to grip
parts - Symmetry in two axis

- Holes large enough -Die cast with minimal amount of

(straightness issues if too deep) holes (debris chip)
-Standard cutters
- Common datum’s for all fixtures -Guide features
-One common plane for assembly
- Tabs for robotic lift
- bottom rails for conveyor
DFM Tools: DFA Guidelines
ƒ Summary of DFA Guidelines
1. Minimize the number of parts
2. Standardize and use as many common parts as
possible
3. Design parts for ease of fabrication (use castings
without machining and stampings without bend)
4. Minimize the number of assembly planes (Z-axis)
5. Use standard cutters, drills, tools
6. Avoid small holes (chips, straightness, debris)
7. Use common datum’s for tooling fixtures
8. Minimize assembly directions
9. Maximize compliance; design for assembly
DFM Tools: DFA Guidelines
ƒ Summary of DFA Guidelines
10. Minimize handling
11. Eliminate adjustments
12. Use repeatable, well understood processes
13. Design parts for efficient testing
14. Avoid hidden features
15. Use Guide features
16. Incorporate symmetry in both axis
17. Avoid designs that will tangle.
18. Design parts that orient themselves
DFM Tools and Methodology
ƒ FMEA (Failure Mode and Effects Analysis)
ƒ Method for analyzing the causes and effects of
failures.
ƒ Highlights designs and assemblies most likely to
cause failures.
ƒ Helps identify and prioritize corrective action
ƒ Indicates where the most improvement in terms of
severity, frequency, and detectability can be made.
ƒ Widely used manufacturing technique (Mil
standards, SAE, ANSI Specs)
Reduce the Costs of Assembly
1. Design for Assembly (DFA) index
2. Integrated Parts (Advantages and
Disadvantages)
3. Maximize Ease of Assembly
4. Consider Customer Assembly
1. Design for Assembly Index

(Theoretical minimum number of parts) x (3 seconds)

DFA index =
Estimated total assembly time
Determining the Theoretical Minimum
Number of Parts
♦ Does the part need to move relative to the
rest of the assembly?
♦ Must the part be made of a different
material from the rest of the assembly for
fundamental physical reasons?
♦ Does the part have to be separated from the
assembly for assembly access, replacement,
or repair?
2. Advantages of Integrated Parts
♦ Do not have to be assembled
♦ Often less expensive to fabricate rather than
the sum of each individual part
♦ Allows critical geometric features to be
controlled by the part fabrication process
versus a similar assembly process
2. Disadvantages of Integrated Parts
♦ Conflict with other sound approaches to
minimize costs
♦ Not always a wise strategy
3. Maximize Ease of Assembly
♦ Part is inserted from the top of the assembly
♦ Part is self-aligning
♦ Part does not need to be oriented
♦ Part requires only one hand for assembly
♦ Part requires no tools
♦ Part is assembled in a single, linear motion
♦ Part is secured immediately upon insertion
4. Consider Customer Assembly
♦ Customers will tolerate some assembly
♦ Design product so that customers can easily
and assemble correctly
♦ Customers will likely ignore directions
Reduce the Costs of Supporting
Production
♦ Minimize Systemic Complexity (inputs, outputs,
and transforming processes)
– Use smart design decisions
♦ Error Proofing (Poka Yoke)
– Anticipate possible failure modes
– Take appropriate corrective actions in the early
stages
– Use color coding to easily identify similar
looking, but different parts
Consider the Impact of DFM
Decisions on Other Factors
♦ Development Time
♦ Development Cost
♦ Product Quality
♦ External Factors
– Component reuse
– Life cycle costs
DFM&A Road Map
♦ Membentuk sebuah multifunctional team
♦ Menetapkan sasaran produk melalui competitive
benchmarking
♦ Melakukan DFA analysis
♦ Melakukan segmentasi produk hingga mencapai
manageable subassemblies atau levels of assembly
♦ Sebagai sebuah team, menggunakan prinsip-prinsip DFA
♦ Menggunakan teknik-teknik kreatif untuk meningkatkan
desain yang dihasilkan
♦ Sebagai sebuah team, melakukan evaluasi dan memilih ide
rancangan yang terbaik
♦ Memastikan bahwa setiap bagian komponen diproduksi
pada level yang ekonomis
♦ Menentukan target cost untuk setiap komponen dalam
desain produk yang baru
TERIMA KASIH
ATAS PERHATIAN DAN KERJASAMANYA

Dr. Muhammad K. Herliansyah, ST. MT.

mkherliansyah@gadjahmada.edu
herliansyah@ugm.ac.id
http://herliansyah.staff.ugm.ac.id