SISTEM MANUFAKTUR (SM)

Pengenalan Sistem Manufaktur

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SISTEM MANUFAKTUR (SM)

Pengenalan Sistem Manufaktur
Tujuan pmbelajaran:
Memahami definisi sistem manufaktur, konsep
dasar dan model sistem manufaktur, serta ruang
lingkup sistem manufaktur

SISTEM MANUFAKTUR (SM)

Pengenalan Sistem Manufaktur

Outline:
Definis sistem manufaktur
Konsep dasar dan model sistem manufaktur
Ruang lingkup sistem manufaktur

Definisi Sistem Manufaktur

Sistem Manufaktur merupakan penggabungan
dari dua suku kata, SISTEM dan MANUFAKTUR.

SISTEM adalah kumpulan elemen

yang bekerja bersama untuk
mencapai tujuan yang diharapkan
(Blanchard, 1991).

Definisi Sistem Manufaktur

The word manufacturing is defined from the
Latin

manu factus

made by hand
manu = hand
factus = made

Definisi Sistem Manufaktur

Manufacturing involves making products from
raw materials by means of various processes,
machinery, and operations, through a wellorganized plan for each activity required.

Definisi Sistem Manufaktur

Manufakturing menurut Random House Websters Dictionary:
The making of goods or wares by manual or by machiney, on
large scale.
Manufaturing menurut Nationa Science Foundations
Workshop: The creation and integration of informational and
physical processes to create economic wealth through the
production of artifacts.
Manufakturing menurut Degarmo: Manufacturing is the
economic term of making goods and services available to
satisfy human wants.
Manufakturing menurut International Conference on
Production Engineering (1983): A Series of interrelated
activities and operations involving the design, materials
selection, planning, manufacturing production, quality

Definisi Sistem Manufaktur

Productio
n
Manufacturing
Engineering

Manufacturi
is ng
the term used

widely in the United States to describe this

area of industrial activity.
Production Engineering is equivalent term
to manufacturing Engineering in other
countries.

Spring, 2005

Definisi Sistem Manufaktur

The manufacturing System is a collection
of manufacturing processes used to obtain
a desired product(s)
The manufacturing System is the design or
arrangement
of
the
manufacturing
processes.
Control of a manufacturing system applies
to overall control of the whole processes or
equipment.
The entire manufacturing system must be
controlled in order to schedule and control
production, inventory levels, product
quality and so forth.
Spring, 2005

Definisi Sistem Manufaktur

Manufacturing system can be viewed as an
integrated combination of processes, machine
systems,
people,
organizational
structures,
information flows, control systems and computers,
designed and operated in order to properly support
a coherent manufacturing strategy.
Manufacturing systems engineering is a
methodology which is associated with the optimum
design, analysis, operation and control of
manufacturing systems.
*B. Wu, Manufacturing Systems Design and Analysis, Chapman & Hall, 1992.

Definisi Sistem Manufaktur

Manufacturing

engineer

Designs/selects the processes and operations required to produce the product

e.g., fixturing, tooling, feed rates, cutting speeds, etc.

Human

factors engineer

Design of the individual human operated workstation

e.g., bench heights, lifting angles, placement of tools, presentation of visual information, etc.

Konsep Dasar & Model Sistem

Manufaktur
The Economics Transformation System
Boundary of system

Inputs
Labor,
capital,
manageme
nt

Transformation

Economics system
transforms inputs to
outputs

Feedback loop

Outputs
Goods
and
service
s

Konsep Dasar & Model Sistem

Manufaktur

The manufacturing System takes inputs

produces products for the external customer

LATH
E
INPUTS:
RAW MATERIAL
SUB ASSEMBLIES
COMPONENT

BROAC
H

PAINT

SUB
ASSEMBL
Y

SAW

LATHE

DRILL

FINAL
ASSEMBL
Y

CAST

MILL

GRIND
ER

PLATING

Sequence of processes

Flow shop manufacturing system

Spring, 2005

and

OUTPUTS:
FINAL PRODUCTS
COMPONENTS
PARTS
SUB ASSEMBLIES

Konsep Dasar & Model Sistem

Manufaktur
Manufacturing System may produce

Discrete products
Individual parts (e.g. nails, gears, engine blocks,
etc.)

Continuous products
May be cut into individual pieces and thus become
discrete parts (e.g. metal or plastic sheets, tubes,
etc.)

Spring, 2005

Konsep Dasar & Model Sistem

Manufaktur
Produksi (production)
Istilah produksi berasal dari kata latin
producere yang berarti lead forward, yaitu
membuat
sesuatu
yang
baru
(tangible/intangible).
Sebuah Sistem produksi adalah sistem yang
melakukan proses transformasi atau konversi
bahan mentah menjadi produk yang memiliki
nilai tambah dan sesuai dengan desain
produk yang telah ditetapkan.

Konsep Dasar & Model Sistem

Manufaktur
Definisi
menurut
International
Conference on Production Engineering:
Production system is defined as an
organization in the industrial sector for the
creation of manufacturing goods and
commodities and/or providing services

Konsep Dasar & Model Sistem

Manufaktur
Production Systems
A production system, or the enterprise, will
refer to the total company and will include
with
the manufacturing
system.
The it production
system
includes
the
manufacturing system plus all the other
functional areas of the plant for information,
design, analysis, and control.
These subsystems are connected by various
means to each other to produce products(s).
Spring, 2005

Konsep Dasar & Model Sistem

Manufaktur

The Product Transformation

System

Boundary of system

Inputs
Labor,
capital,
material,
machine,
man

Transformation

Product
Transformastion

Feedback loop

Outputs
Produc
t&
waste

Konsep Dasar & Model Sistem

Manufaktur
Production system terdiri dari kumpulan stasiun kerja
(workstation) yang melakukan operasi pekerjaan
seperti manufaktur, perakitan, inspeksi, finishing,
pengujian, dll untuk membuat suatu produk.

Workstation
Kumpulan mesin/operator yang
melakukan
operasi
pekerjaan
untuk set produk yang sama.
Sebuah
mesin/operator
dapat
berupa:
Mesin
yang
bekerja
secara
otomatis
Mesin yang dioperasikan oleh

Konsep Dasar & Model Sistem

Manufaktur
Work station layout
Pengaturan workstation, mendikte pola aliran produk,
dan kebutuhan sumber daya pada setiap workstation
WS5
WS2
WS1

WS3

WS4

Workstation layout

Konsep Dasar & Model Sistem

Manufaktur
Production system
Pada tingkat abstraksi yang disajikan, kinerja sistem produksi dievaluasi dengan menentukan hal-hal berikut:
How fast
Throughput (e.g., jobs/hour, parts/minute)
How long
Time-In-System (TIS)
Flow Time
Cycle Time (CT)
How much
Work-In-Progress (WIP)

Konsep Dasar & Model Sistem

Manufaktur
Production Systems

Konsep Dasar & Model Sistem

Manufaktur
Production Types
Low-quantity production (1 ~ 100 units/yr)
Job shop, prototyping.
Medium-quantity production (100 ~ 10,000 units/yr)
Batch production & cellular manufacturing.
High-quantity production (> 10,000 units/yr)
Mass production.

Konsep Dasar & Model Sistem

Manufaktur
Machine
A specific piece of equipment designed to
accomplish specific processes, often
called a Machine Tool
Examples: Milling machine, punch press, .

Machine tools linked together to

make a manufacturing system cell

Konsep Dasar & Model Sistem

Manufaktur
Operation (Process)

A specific action or treatment, often done on

a machine, the collection of which makes up
the job of a worker.
Examples: Drilling, Forming, Welding, assembly,

Konsep Dasar & Model Sistem

Manufaktur
Model VS Flow Manufacturing
System
Definition of product needs;
marketing information

Material specification; process

and equipment selection;
safety review

Conceptual design and eavulation;

feasibility study

Pilot production

Prototype production;
testing and evaluation

Production drawing;
instruction manuals

Computer
Aided Design
(CAD)

Design analysisi; codes/standard review;

physical and analytical models

Production

Inspection and quality

assurance

Packaging; marketing
and sales literature

Product

Computer
Aided
Manufacturi
ng and
Process
Panning
(CAM) and
CAPP
Computer
Integrated
Manufacturi
ng (CIM)

Ruang Lingkup Sistem

Manufacturing

Model VS Flow Manufacturing System

5. Process planning: Group
technology, process
selection, process design,
process , parameters, tool
and dies, part programming,
jigs and fixtures, quality
control
4. Product preparation:
assembly drawing, part
drawing, make/buy decision
bill of material

6. Process R&D:
process choise,
optimization,
modeling,
environmental

Common
database

3. Product design,
specification development
industrial design, product
R&D, prototyping
2. Conceptual design,
product concept, market
forecast, market research

1.
Customers
needs

7. Processing: parts
manufacturing, sensing
and corrective action,
storing, moving,
handling, assembly
8. Production control,
routing, schedulling,
production tracking,
machine load monitoring,
inventory (part materials
in processing),
purchashing,
maintenance, quality
assurance
9. Shipping,
inventory,
sales, invoicing,
accounting
10. Customers service

Ruang Lingkup Sistem Manufaktur

Organizational Charts
Manufacturing
Operations
Facilities

Construction; maintenance

Production and inventory

control
Scheduling; materials
control

Quality assurance and

control
Supply-chain
management
Manufacturing
Tooling; fabrication;
assembly

Design

Product development and

design
Detailed product
specifications

Finance/
accounting
Disbursement
s/
credits
Receivables
Payables
General
ledger
Funds
Management
Money
market
International
exchange
Capital
requirements

Marketing
Sales
promotion
Advertising
Sales
Market
research

Ruang Lingkup Sistem Manufaktur

Manfaat yang diperoleh dari penerapan sistem
pada proses manufaktur, antara lain:
Hasil produksi lebih cepat dan tepat waktu karena
dalam
sistem
manufaktur
menggunakan
seperangkat
komputer
sebagai
alat
proses
pengendalian produksinya.
Aliran informasi lebih cepat, akurat dan terpercaya.
Dokumentasi
lebih
terstruktur
karena
menggunakan sistem database
Kegagalan produksi dapat diminimalisir.

Ruang Lingkup Sistem Manufaktur

FLOW
FLOW
FLOW
FLOW

OF
OF
OF
OF

STRATEGIC MANAGEMENT INFORMATION

MANAGERIAL INFORMATION
TECHNOLOGICAL INFORMATION
MATERIALS

EXTERNAL
INFORMATI
ON
MANAGEMEN
T
PLANNING

PRODUCTIO
N
PLANNING

FACTORY
PLANNING

SALES
PLANNING

LAYOUT
DESIGN
RESEARCH &
DEVELOPMEN
T

MATERI
AL
SUPPLI
ERS

PROCUREME
NT/MATERIA
L PLANNING

PRODUCT
DESIGN

RAW
MATERI
AL

PROCESS
PLANNING

SCHEDULIN
G

PRODUCTION &
ASSEMBLY
QUALIT
Y
CONTR
OL

PROCE
SS
CONTR
OL

PRODU
CT

COST
CONTR
OL

Model VS Flow Manufacturing System

DISTRIBUTI
ON/SALES

CUSTOM
ERS

Ruang Lingkup Sistem

Manufaktur

Jika dilihat pada gambar model aliran dalam sistem

manufakturing di atas, maka dapat dipetakan ruang
lingkup dari sistem manufakturing.
Ruang lingkup sistem manufakturing dalam pembahasan
matakuliah ini meliputi:
Perencanaan produk
dan seleksi proses (Product
Design and Process Selection)
Perencanaan produksi (Production Planning)
Perencanaan kebutuhan bahan baku (Material Planning)
Perencanaan penjadwalan produksi (Scheduling)
Pelaksanaan produksi dan assembly

Ruang Lingkup Sistem Manufaktur

Sistem Manufaktur yang dikembangkan oleh Oliver Wight dan Goerge Plossl
yang dikenal sebagai Manufacturing Resource Planning (MRP II)

Ruang Lingkup Sistem

Manufaktur

Adalah Oliver Wight dan Goerge Plossl, konsultan yang

mengembangkan konsep MRP (Manufacturing Resource
Planning).
MRP mengintegrasikan semua sistem yang
berhubungan dengan semua bagian yang mendukung
kegiatan produksi, sehingga antar bagian dalam
lingkaran sistem produksi akan saling terhunung satu
sama lain.
Data-data dari stetiap bagian diintegrasikan melalui
jaringan kerja, mulai dari jenis produk pesanan, jumlah
permintaan, perencanaan produksinya, kebutuhan
material, sampai proses administrasi dan keuanganya.

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