SISTEM MANUFAKTUR (SM)

Pengantar Sistem Manufaktur

 SISTEM MANUFAKTUR (SM)

Pengantar Sistem Manufaktur

Tujuan pmbelajaran:
Memahami definisi sistem manufaktur, konsep dasar dan
model sistem manufaktur, serta ruang lingkup sistem
manufaktur
 SISTEM MANUFAKTUR (SM)

Pengantar 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

Manufaktur melibatkan pembuatan produk dari bahan

mentah melalui berbagai proses, mesin, dan operasi,
melalui rencana yang terorganisir dengan baik untuk setiap
kegiatan yang diperlukan.
Contoh Sistem Manufaktur
Definisi Sistem Manufaktur
Manufakturing menurut Random House Webster’s Dictionary: The making of
goods or wares by manual or by machiney, on large scale.

Manufaturing menurut Nationa Science Foundation’s 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 assurance,
management and marketing of products on the manufacturing industries.
Definisi Sistem Manufaktur

Production Manufacturing
Manufacturing Engineering is 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 Transformation
Outputs

Labor, Goods
Economics system transforms
capital, and
inputs to outputs
management services

Feedback loop
 Konsep Dasar & Model Sistem Manufaktur
The manufacturing System takes inputs and produces products
for the external customer

SUB
LATHE BROACH PAINT ASSEMBLY

FINISHED GOODS
INPUTS: OUTPUTS:
RECEIVING

RAW MATERIAL FINAL PRODUCTS

STORAGE
FINAL
SUB ASSEMBLIES SAW LATHE DRILL ASSEMBLY COMPONENTS
COMPONENT PARTS
SUB ASSEMBLIES
CAST MILL GRINDER PLATING

Sequence of processes

Flow shop manufacturing system

Spring, 2005
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 it the manufacturing system.
The 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 Transformation
Outputs

Labor, Product &

Product
capital, waste
Transformastion
material,
machine, man

Feedback loop
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 manusia
Operator melakukan operasi manual
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
Hubungan antara variasi produk dan kuantitas produksi pada manufaktur
produk discrete

Production Types

Low
Variasi Produk

Medium

High

1 100 10.000 1.000.000

Jumlah Produksi
Production System Facilities And Production
Quantity And Quality
Fixed
position Process
layout layout Cellular
layout Product
layout
Job Shop
Production Variety

Batch Production
Cellular Quantity Flow Line
Manufacturing
Mass Production

1 100 10.000 1.0000.000

Production Quantity
 Information- Processing Cycle In
Manufacturing Support Systems

Product
design
Customer
order

Business Production System Manufacturing

Facilities planning
functions

Manufacturing
control
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

Computer
Material specification; process
Definition of product needs; and equipment selection; safety Aided
marketing information review Manufacturing
and Process
Conceptual design and eavulation;
Planning (CAM)
Pilot production
feasibility study and CAPP

Production Computer
Design analysisi; codes/standard review;
physical and analytical models Integrated
Manufacturing
Inspection and quality
Computer Aided

assurance (CIM)
Design (CAD)

Prototype production;
testing and evaluation

Packaging; marketing
and sales literature
Production drawing;
instruction manuals

Product
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
3. Product design, specification
development industrial design,
product R&D, prototyping
2. Conceptual design, product
concept, market forecast, market
research
6. Process R&D: process 7. Processing: parts
choise, optimization, manufacturing, sensing and
modeling, environmental corrective action, storing,
moving, handling, assembly
8. Production control, routing,
schedulling, production
tracking, machine load
monitoring, inventory (part
Common materials in processing),
database purchashing, maintenance,
quality assurance
9. Shipping, inventory, sales,
invoicing, accounting
1. Customers 10. Customers service
needs
Ruang Lingkup Sistem Manufaktur
Organizational Charts
Manufacturing

Operations Finance/ Marketing

Facilities accounting Sales
Construction; maintenance Disbursements/ promotion
Production and inventory control credits Advertising
Scheduling; materials control Receivables Sales
Quality assurance and control Payables
General ledger Market research
Supply-chain management
Funds Management
Manufacturing
Tooling; fabrication; assembly Money market
International
Design exchange
Product development and design
Detailed product specifications Capital
Industrial engineering requirements
Efficient use of machines, space, Stock issue
and personnel Bond issue
Process analysis and recall
Development and installation of
production tools and equipment
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
EXTERNAL
FLOW OF STRATEGIC MANAGEMENT INFORMATION INFORMATION
FLOW OF MANAGERIAL INFORMATION
FLOW OF TECHNOLOGICAL INFORMATION
FLOW OF MATERIALS MANAGEMENT
PLANNING

FACTORY PRODUCTION SALES

PLANNING PLANNING PLANNING

LAYOUT
DESIGN

RESEARCH & PRODUCT PROCESS

DEVELOPMENT DESIGN PLANNING SCHEDULING

MATERIAL PROCUREMENT/ RAW DISTRIBUTION/

MATERIAL PRODUCTION & ASSEMBLY PRODUCT SALES
SUPPLIERS MATERIAL
PLANNING

QUALITY PROCESS COST

CONTROL CONTROL CONTROL
CUSTOMERS

Model VS Flow Manufacturing System

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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