PROSES

MANUFAKTUR
introduction
 What Is
Manufacturing?
What Is Manufacturing?
• Manus (hand) and factus (make)
• Teknologi → Ketika dilakukan perubahan
bentuk (geometry), Karakteristik
(property) dan tampilan (apperance),
pada sebuah material, dengan proses
fisika dan kimia
• Ekonomi → Ketika dilakukan transformasi
terhadap sebuah material, sehingga
didapatkan nilai tambah, melalui satu atau
lebih proses
Contoh
Industri Manufaktur

Primary
industries cultivate and exploit natural resources

Secondary take the outputs of the primary industries and

industries convert them into consumer and capital goods

Tertiary
industries constitute the service sector of the economy
 Produk
Manufaktur

Consumers Capital
goods goods
Production Quantity and Product Variety

Low Medium High

production production production
Quantities in the From 100 to
10,000 to
range 1 to 100 10,000 units
millions of units
units per year annually
Hubungan Antara Variasi Produk dengan
Jumlah Produksi
Kapabilitas Manufaktur
Kemampuan Pengolahan Teknologi
• Hal ini mencakup kemampuan mesin atau peralatan yang dimiliki, atau lebih
spesifik terhadap pengolahan material tertentu

Limitasi Produk
• Terkait ukuran dan berat produk yang dibuat.

Kapasitas Produksi
• Berhubungan dengan kapasitas sebuah plant, atau kapasitas dalam sekali produksi
Material pada Proses
Manufaktur Engineering
Materials

Metals Ceramics Polymers Composites

Crystalline Metal Matrix

Ferrous Metals Thermoplastics
Ceramics Composites

Nonferrous Ceramic Matrix

Glasses Thermosets
Metals Composites

Polymer Matrix
Elastomers
Composites
Proses Manufaktur
• Untuk menghasilkan perubahan secara fisika atau kimia pada sebuah
material diperlukan rangkaian prosedur yang didesain dengan baik,
sehingga didapatkan peningkatan nilai material.
• Sebuah proses manufaktur memiliki satuan operasi (tahapan yang
diperlukan untuk mentransformasikan material menjadi produk
akhir).
• Dua jenis operasi manufaktur:
• Processing operation
• Assembly operation
 Manufacturing
processes

Processing Assembly
operations operations

Shaping Property enhancing Surface processing Permanent joining Mechanical

processes processes operations processes fastening

Solidification Cleaning and surface Threaded

Heat treatmen Welding
processes treatments fasteners

Particulate Coating and Brazing and Permanent fastening

processing deposition processes soldering methods

Deformation Adhesive
processes bonding

Material
removal
Mesin Produksi dan Perlengkapannya
Sistem Produksi
Manufacturing Support Systems
Manufacturing engineering

• bertanggung jawab terhadap perencanaan proses manufaktur

Production planning and control

• bertanggung jawab terhadap pemecahan masalah logistik pada proses

manufaktur

Quality control

• bertanggung jawab terhadap kualitas produk dan memberikan kepuasan

terhadap pelanggan
Beberapa Tipe Layout Produksi

fixed-position layout process layout

cellular layout
product layout
Production Cycle Time Analysis

Tc = cycle time of the unit operation, min/pc

To = actual processing time in the operation, min/pc
Th = work part handling time, min/pc
Tt = tool handling time, min/pc
• Apabila sistem produksi berupa jenis batch and job shop:

Tb = total time to complete the batch, min/batch

Tsu = setup time, min/batch
Q = batch quantity, number of pieces (pc)
• Sehingga apabila apabila dihitung rata-rata waktu produksi per pcs:

Tp = average production time per piece, min/pc

Rp = average hourly production rate, pc/hr

Rc = hourly cycle rate, cycles/hr or pc/hr

Overhead Cost
Factory overhead Corporate overhead

• Materials • Sales
• Direct labor • marketing
• Equipment • accounting
• Plant supervision • legal
• maintenance • engineering
• insurance • research and development
• heat and light • office space
• utilities
• health benefits
Manufacturing Cost Models
• Cost per piece
Cpc = cost per piece, $/pc
Cm = starting material cost, $/pc
Co = cost rate of operating the work cell, $/min
Tp = average production time per piece, min/pc
Ct = cost of tooling used in the unit operation, $/pc

• The cost rate (consists of labor and equipment costs)

CL = cost rate of labor, $/min
Ceq = cost rate of equipment in the work cell, $/min
• Labor cost rate
CL = labor cost rate, $/min
RH = worker’s hourly wage rate, $/hr
RLOH = labor overhead rate, %

• Equipment cost rate

• Fixed cost
• variable costs Ceq = equipment cost rate, $/min
IC = initial cost of the equipment, $
N = anticipated number of years of service
H = annual number of hours of operation, hr/yr
ROH = applicable overhead rate for the equipment, %

• Scrap consideration
Q = the required quantity of parts to be delivered
Qo = the starting quantity
q = the scrap rate
Biaya Manufaktur Produk