Pengertian Umum

Sistem
Manufaktur
D0394 Perancangan
Sistem Manufaktur
Pertemuan I II
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Definisi Manufaktur
Manufacturing Suatu kumpulan operasi dan aktifitas yang berkorelasi
untuk menghasilkan produk, seperti perancangan produk, pemilihan bahan
baku, perencanaan, pemrosesan, inspeksi, dan manajemen.
Manufacturing process Aktifitas manufaktur merubah bentuk suatu produk
dengan mesin-mesin seperti, milling, drilling dll.
Assembly Kumpulan dari semua proses dengan mana bermacam komponen
dan sub perakitan dibentuk bersamaan untuk membentuk rancangan rakitan
atau produk secara geometris secara lengkap.
Manufacturing System Suatu pengorganisasian beberapa proses
manufaktur dan perakitan yang saling berinteraksi. Tujuannya adalah untuk
menjembatani dengan diluar fungsi produksi berkenaan dengan
mengoptimasikan produktifitas kinerja sistem.

Manufacturing Historical Perspective
English system (1800s)
Memperkenalkan mesin-mesin yang digunakan secara
umum yang dapat digunakan untuk produk yang bervariasi.
American system (1850s)
Menekankan pada presisi dan kemampuan untuk saling
bertukar proses. Berubah dari best fit fokus kepada
greatest clearance without loss of functionality.
Scientific management (1900s)
Prespecified worker motions - Moved the control totally
into the hands of management.
Process improvement (SPC) (1950s)
Identical procedures produce different results on same
machine at different times. Emphasized outliers instead of
mean performance.
Manufacturing Historical Perspective
Numerical control (1970s)
Combining the versatility of general purpose machines
with the precision and control of special-purpose
machines.
Computer integrated manufacturing (1980s)
Pervasive use of computers to design products, plan
production, control operations, and perform various
business-related functions.
Agile Manufacturing / Mass Customization (1990s)
Creation of highly flexible organizational structures that
allow systems to produce highly customized product

Manufacturing System
Characterized by:
Number of machines
Number of part types
Part routes through the
system
Processing times
Machine setups
Demand patterns
Raw material/component
availability
Equipment
layout/configuration
Operator availability
Machines
Raw
Material
Finished
Products
Manufacturing System
Interested in:
Lead time for products
Cost of processing
Decisions include:
System configuration
Scheduling methods
Machines
Raw
Material
Finished
Products
Manufacturing System
Configurations
Job Shop
Process layout that groups functionally similar machines
Flow Line
Product layout that groups machines based on a products 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
Manufacturing System
Configurations
M
G
D T
T
T
T
M M
D
G G
T
M
G D
M
T
M
G
Job Shop Configuration
Flow Line
Configurations
Manufacturing System
Configurations
Cellular Configuration
Cell 1
Cell
2
Cell 3
Cell 4
Product Volume vs. Product
Variety
Volume
Variety
Low High
Low
High
Continuous
Flow Line /
Transfer Line
Cellular /
Flexible Mfg. Sys.
Job Shop
Manufacturing System Design
Manufacturing System
Design
Resource
Requirement
Buffer
Capacity
Material
Flow
Resource
Lay Out
Manufacturing System
Operation
Operation Decomposition
Planning
Deciding what to do
Scheduling
Deciding when to do what you planned
Execution
Carrying out the planned tasks according to the schedule
Hierarchical System Structure
Shop
Workstation
Equipment
Principles of Manufacturing
Systems
Littles Law
WIP = Production Rate Throughput Time
(L= W)
Matter is conserved
Larger scope implies reduced reliability
Objects decay
Exponential growth in complexity
M components, N states ==> NM possible
system states
Principles of Manufacturing
Systems
Technology advances
System components appear to behave
randomly
Limits of (Human) rationality
Combining, simplifying, and eliminating
save time, money, and energy

Manufacturing Systems
Overview
Product Design
Process Planning
Production System Design
Production Planning
Operational Planning
Shop Floor Control
Execution

Product Design
Idea
Understanding and identifying
customer needs
Initial Design
Feasibility study to determine initial
functionality
Prototype
Market Research
Market potential, economic analysis,
strategic assessment
Design Refinement
Functional specifications
Detailed Specifications
Detailed design considering functions,
quality/reliability, manufacturing, etc.
Idea Generation
(Product Design)
Feasibility Study
(Performance Specification)
Preleminary Design
(Prototype)
Final Design
(Final Design Specification)
Process Planning
(Manufacturing Specication)
Product Design (Cont.)
Functional analysis
Customer specifications
Product reliability
Design for X
Manufacture or Assembly
Simplification, standardization, modularization
Testing
Repair
Robustness to variations
Concurrent engineering
Consider how product will be manufactured (process and
production planning) during design phase
Reduce cost and time to market
Product Design (Cont.)
Computer-Aided Design
Use of computer graphics to assist in the creation,
modification, and analysis of a design
Common uses
Geometric modeling
Automated drafting and documentation
Engineering analysis
Design analysis
CAD/CAM
Generation of manufacturing instructions directly from
CAD design data
Product Life Cycle
Product (Consumer) Perspective
Inception
Design
Production
Use
Maintenance and repair
Disposal
Reuse, recycle, scrap
Production System
(Manufacturer)
Perspective
Design
Ramp-up
Maturity
Decline

Time
S
a
l
e

Production System Life Cycle
Lifecycle
Inception
Design
Construction
Startup
Use
Closure
Relationship to product lifecycle
Typically production system lifecycle is longer than an
individual products lifecycle
Production system will revert to earlier stages in its lifecycle
when new products are introduced
Extent and cost depends on system flexibility