Teknik Manufaktur-Layout Teknik Manufaktur Rev 1 PDF

UNIVERSITAS MUHAMMADIYAH TANGERANG
Perancangan Sistem Manufaktur

Pertemuan II
Background
Dalam organisasi manufaktur, pekerjaan diproduksi akan menghabiskan
sebagian besar waktu dalam pergerakan produk dan menunggu produk yang
diperlukan untuk pekerjaan produksi selanjutnya. Untuk pengurangan
pergerakan produk dan waktu menunggu pekerjaan / bagian lainnya, maka
perlu memiliki tata letak yang tepat dan prosedur penjadwalan yang tepat.
“Plant layout is such a systematic and efficient functional arrangement of

various departments, machines, tools, equipment and other supports
services of an industrial organization that will facilitate the smooth
processing of the proposed or undertaken product in the most effective,
most efficient and most economical manner in the minimum possible time”
Mengingat efek proses manufaktur sehingg benda/objek akan

memiliki konfigurasi dan struktur, pada umumnya terdapat lima
jenis proses manufaktur yang dapat diidentifikasi
 Material removal processes - Geometri yang dihasilkan dengan mengubah
massa material yang masuk
dengan cara yang terkontrol dan terdefinisi dengan baik,
misalnya,turning, electrodischarge machining, and polishing.
 Proses Deformasi - Bentuk dari benda kerja yang solid diubah oleh
deformasi plastik tanpa mengubah massa atau komposisi, misalnya,
rolling, penempaan, dan stamping.
 Proses pembentukan primer didefinisikan karena ole proses bulk forming
sebuah material geometri yang awalnya tidak memiliki bentuk, misalnya,
casting, injection molding, die casting, dan konsolidasi serbuk.
 Structure-change processes — Mikrostruktur, properties, atau tampilan
dari benda kerja diubah tanpa mengubah bentuk asli dari benda kerja,
misalnya heat treatment dan surface hardening.
 Joining and assembly processes - benda kecil yang disatukan untuk

mencapai geometri, struktur, dan / atau properti yang diinginkan.
 Pada umumnya ada dua jenis :
(1) Proses konsolidasi yang menggunakan mekanikal, kimia, atau
energi panas untuk ikatan suatu objek (misalnya, pengelasan dan
difusi ikatan) dan
(2) Strictly mechanical joining (misalnya., riveting, shrink fitting, dan
conventional assembly).
A good plant layout should meet the following basic
requirement:
1.Integration of manufacturing centre facilities in terms of man, machine and
material.
2.Movements of production personnel and material handling should be
minimized.
3.Smooth and continuous flow of production or manufacturing work with least
possible bottlenecks and congestion points.
4.Floor space utilization should be optimum as for as possible.
5.Working place should be free from pollution and safe working conditions
should prevail in each shop of the plant.
6.The handling of raw material, semi finished and finished product should be
should be tackled optimally and effectively
7.Plant layout and shop layouts must be flexible to facilitate changes in
production requirements
8.There should be better working environment in term of proper light,
ventilation and other amenities such as drinking water and toilets for welfare
Keuntungan dari suatu Layout yang baik

1. Mengurangi men dan Machine hour per unit produksi,
2. Pemanfaat seluruh ruang pabrik akan efektif dan ekonomis
3. Aliran keja smooth dan berkesinambungan
4. Proses dalam persediaan kerja berkurang
5. Pengendalian Produksi lebih baik
6. Waktu Manufacturing berkurang
7. Luas ruangan yang diperlukan akan berkurang
8. Material handling akan berkurang.
TYPES OF LAYOUTS
1. Fixed or Position Layout All its accessories, auxiliary material,
2. Process or Functional Layout machinery, equipment needed, tools
3. Line or Product Layout required and the labor are brought to the
fixed site to work.
4. Combination Layout
Keuntungan
1. Fixed or Position Layout 1. Tata letak sangat fleksibel untuk
jenis produk yang memiliki
permintaan intermiten Seperti
jenis produk dan proses yang
terkait dapat dengan mudah
diubah tanpa perubahan apapun
dalam tata letak.
2. Pergerakan manpower, material,
Fixed or position layout is also known as dan perkakas selama manufaktur
project layout. In this type of layout the major proses menjadi minimal.
part of an assembly or material remains at a
fixed position.
3. Kebutuhan materila drastis berkurang.
4. Operator yang terampil diperlukan untuk menyelesaikan pekerjaan pada
titik tertentu dan Tanggung jawab kualitas ada pada satu orang atau kru
perakitan.
5. Setiap personil dari tim manufaktur bertanggung jawab dalam kualitas
kerja manufaktur produk. Kerugian kerugian utama dari lay out ini
1. Biaya penanganan peralatan sangat tinggi.
2. Tenaga Kerja dan peralatan sulit untuk memanfaatkan sepenuhnya.
3. Hal ini terbatas pada barang-barang besar saja.
Project or Fixed-Position
 Design is for stationary project
 Workers & equipment come to site
 Complicating factors
 Limited space at site
 Changing material needs
 Examples
 Ship building
 Highway construction
2. Process or Functional Layout

Process-Oriented Layout
 Design places departments with large flows of material or

people together
 Dept. areas have similar processes
 e.g., All x-ray machines in same area
 Used with process-focused processes
 Examples
 Hospitals
 Machine shops
Process Layout
+ Allows specialization - focus on one skill
+ Allows economies of scale - worker can watch several machines at once
+ High level of product flexibility
-- Encourages large lot sizes
-- Difficult to incorporate into JIT
-- Makes cross-training difficult
Process-Oriented Layout Floor Plan
Table Saws Office
© 1995
Corel Corp.
Drill Presses
Tool Room
© 1995 Corel Corp.

Line or Product Layout

Product-Oriented Layout
Operations
Belt Conveyor
Product-Oriented Layout
 Facility organized around product

 Design minimizes line imbalance
 Delay between work stations
 Types: Fabrication line; assembly line
 Examples
 Auto assembly line
 Brewery
 Paper manufacturing.
Combination Layout
Layout Types Example

 Office layout
 Warehouse layout
 Retail/service layout
Cellular Layout (Work Cells)

 Special case of process-oriented layout
 Consists of different machines brought together to make a product
 May be temporary or permanent
 Example: Assembly line set up to produce 3000 identical parts in a
job shop
Work Cell Floor Plan
Saws Drills Office
Work Cell
Tool Room
Work Cell Advantages Increases:

Equipment
utilization
Reduces: Employee
Inventory participation
Floor space Quality
Direct labor
costs
Work Cell Layout

+ Facilitates cross-training
+ Can easily adjust production volumes
+ Easy to incorporate into JIT
-- Requires higher volumes to justify
-- May require more capital for equipment
Process-Oriented Example
You work in facilities engineering. You want to
find the cost of this layout. The cost of moving 1
load between adjacent dept. is $1. The cost
between nonadjacent dept. is $2.
Dept. 1 Dept. 2 Dept. 3
40 ft.
Dept. 4 Dept. 5 Dept. 6
60 ft.
There are 6! or 720 possibilities! Clearly,

we can’t look at them all.
From-to-Matrix
Department
Dept. 1 2 3 4 5 6
50 100 0 0 20
1
30 50 10 0
2
20 0 100
3
Number of Trips 50 0
4
0
5
6
Schematic Diagram & Cost
100 Dept. Dept. Cost
1 3 $ 200
1 2 $ 50
50 30 1 6 $ 40
1 2 3 4 2 $ 50
4 3 $ 40
10
20 4 5 $ 50
50 2 5 $ 10
100 2 3 $ 30
20 3 6 $ 100
4 5 6
50 Total Cost $570

Schematic Diagram & Cost Dept. Dept. Cost

30 1 2 $ 50
1 3 $ 100
1 6 $ 20
50 100 4 2 $ 50
2 1 3 4 3 $ 40
4 5 $ 50
10 2 5 $ 10
50 100 2 3 $ 60
20 3 6 $ 100
20
4 5 6
50
Total Cost $480
Line Balancing
 Situation: Assembly-line production.

 Many tasks must be performed, and the sequence is flexible
 Parts at each station same time
 Tasks take different amounts of time
 How to give everyone enough, but not too much work for the limited
time.
Draw precedence graph

Precedence Diagram
(times in seconds)
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
Cycle Time
 The more units you want to produce per hour, the less time
a part can spend at each station.
Production Time in
 Cycle time = time spent at each spot
each day
CT =
Required output per day (in units)
 C = 800 min / 32 = 25 min

 800 min = 13:20
Number of Workstations
 Given required cycle time, find out the theoretical minimum number of
stations
Sum of task times (T)

Nt =
Cycle Time (C)
 Nt = 97 / 25 = 3.88 = 4 (must round up)
Assignments
Assign tasks by choosing tasks:
 with largest number of following tasks
 OR by longest time to complete
Break ties by using the other rule

Nodes # after
NumberCof Following6 Tasks
D 5 Choose C first, then, if possible,
add D to it, then A, if possible.
A 4
B,E,F 3
G,H 2
I 1
Draw precedence graph

Precedence Diagram
(times in seconds)
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
Number of Following Tasks

A could not be added to first
Nodes # after station, so a new station must be
A 4 created with A.
B,E,F 3
G,H 2 B, E, F all have 3 stations after,
I 1 so use tiebreaker rule: time.
B=5
E=8
F=3
Use E, then B, then F.
Precedence Diagram
E cannot be added to A, but E can be added to C&D.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
Precedence Diagram
Next priority B can be added to A.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
Next priority B can be added to A.

Precedence Diagram
Next priority F can’t be added to either.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
Nodes # after
G,H 2 of Following Tasks
Number
I 1 G and H tie on number coming after.
G takes 15, H is 12, so G goes first.
G can be added to F.
Precedence Diagram
H cannot be added.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
I is next, and can be added to H, but J cannot be added also.

Precedence Diagram
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
Calculate Efficiency
 We know that at least 4 workstations will be needed. We needed 5.
Sum of task times (T)
Efficiencyt =
Actual # WS * Cycle Time
 = 97 / ( 5 * 25 ) = 0.776
 We are paying for 125 minutes of work, where it only takes 97.
Try choosing longest activities first.

A isPrecedence Diagram
first, then G, which can’t be added to A.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
H and I both take 12, but H has more coming after it, then add I.
Precedence Diagram
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
D isPrecedence
next, followed by E, so we combine them, but we could have
Diagram
combined E&G. We’ll try that later.
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
J is next, all alone, followed by C and B.

Precedence Diagram
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
F is last. We end up with 6 workstations.

Precedence Diagram
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
Go back and try combining G and E instead of D and E.

Precedence Diagram
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
J is next, all alone. C is added to D, and B is added to A.

Precedence Diagram
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
Can we do better?
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
F can be added to C&D. Five WS again.

Precedence Diagram
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
Reduced CT
 Efficiency = 97/100 = 0.97. Much better.
 If we set CT = 20, we can produce 3 units per hour.
 Goal of 32 units can be produced in 20 * 32 = 640 minutes.
 Significant savings over original 800 minutes.
If we have to use 5 stations, we can get a solution with CT = 20.

Can we do better?
B
A 5 G
20
15
E I J
8
C D 12 7
H
5 10 F 12
3
Calculate Efficiency
 With 5 WS at CT = 20 Sum of task times (T)
Efficiencyt =
Actual # WS * Cycle Time
 = 97 / ( 5 * 20 ) = 0.97
 We are paying for 100 minutes of work, where it only takes 97.
 With 20 min CT, and 800 minute workday

Output and Labor Costs
 Output = 800 min / 20 min/unit = 40
 Don’t need to work 800 min
 Goal 25 units: 25 * 20 = 500 min/day
 5 workers * 500 min = 2,500 labor min.
 We were trying to achieve
 4 stations * 800 min = 3,200 labor min.

 Significant labor cost savings
Handling Long Tasks

 Long tasks make it hard to get efficient combinations.
 Consider splitting tasks, if physically possible.
 If not:
 Parallel workstations
 use skilled (faster) worker to speed up

Warehouse Layout
 Design balances space (cube)

utilization & handling cost
 Similar to process layout
 Items moved between dock
& various storage areas
 Optimum layout depends on
 Variety of items
stored
 No. items picked
© 1995 Corel Corp.

Warehouse Flow
Receiving
Shipping
Warehouse Layout
Try to organize storage in such a way that order pickers
can move through the product in a logical and timely
manner.
Manufacturing System
Machines
Raw “Finished”
Material Products
 Characterized by:  Demand patterns

 Number of machines  Raw material/component
 Number of part types availability
 Part routes through the  Equipment
system layout/configuration
 Processing times  Operator availability
 Machine setups
Manufacturing System
Machines
Raw “Finished”
Material Products
 Interested in:
 Lead time for products
 Cost of processing
 Decisions include:
 System configuration
 Scheduling methods
Manufacturing System Configurations

 Job Shop
 Process layout that groups functionally similar machines
 Flow Line
 Product layout that groups machines based on a product’s flow
 Cellular Manufacturing System

 Hybrid layout that groups similar parts and the corresponding
processing machines
 Flexible Manufacturing System is an automated application
 Project Shop
 Product is fixed and people and equipment brought to it
 Continuous Process

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UNIVERSITAS MUHAMMADIYAH TANGERANG

Perancangan Sistem Manufaktur

“Plant layout is such a systematic and efficient functional arrangement of

Mengingat efek proses manufaktur sehingg benda/objek akan

 Joining and assembly processes - benda kecil yang disatukan untuk

Keuntungan dari suatu Layout yang baik

2. Process or Functional Layout

 Design places departments with large flows of material or

Process-Oriented Layout Floor Plan

Table Saws Office

© 1995 Corel Corp.

Line or Product Layout

 Facility organized around product

Layout Types Example

Cellular Layout (Work Cells)

Saws Drills Office

Work Cell Advantages Increases:

Work Cell Layout

There are 6! or 720 possibilities! Clearly,

50 Total Cost $570

Schematic Diagram & Cost Dept. Dept. Cost

 Situation: Assembly-line production.

Draw precedence graph

 C = 800 min / 32 = 25 min

Sum of task times (T)

 OR by longest time to complete

Break ties by using the other rule

Draw precedence graph

Number of Following Tasks

Next priority B can be added to A.

I is next, and can be added to H, but J cannot be added also.

Try choosing longest activities first.

J is next, all alone, followed by C and B.

F is last. We end up with 6 workstations.

Go back and try combining G and E instead of D and E.

J is next, all alone. C is added to D, and B is added to A.

F can be added to C&D. Five WS again.

If we have to use 5 stations, we can get a solution with CT = 20.

 With 20 min CT, and 800 minute workday

 Don’t need to work 800 min

 Goal 25 units: 25 * 20 = 500 min/day

 5 workers * 500 min = 2,500 labor min.

 We were trying to achieve

 4 stations * 800 min = 3,200 labor min.

Handling Long Tasks

 use skilled (faster) worker to speed up

 Design balances space (cube)

© 1995 Corel Corp.

 Characterized by:  Demand patterns

Manufacturing System Configurations

 Cellular Manufacturing System

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