DESIGN OF MANUFACTURING SYSTEM
Sasaran
Memahami konsep dan proses perancangan sistem manufaktur mulai dari perancangan produk, perancangan proses, pemilihan lokasi dan perancangan lay out
What Design IE Do ?
Integrated System Industrial System (Manufacturing System)
Human Activity System
Management Control System
3
Human Activity System
Perancangan System Pengoperasian System
Langkah Perancangan Sistem
Analisis Permintaan Perancangan Produk Dan Proses
Penentuan Kapasitas
Pemilihan Lokasi Perancangan Lay Out
5
Pengoperasian Sistem
Target Penjualan Target Produksi Jadwal Produksi Material Mesin Jadwal Operasi T. Kerja
Pelaksanaan
Evaluasi
Analisis Permintaan
Tujuannya adalah menentukan jenis produk dan menghitung volume permintaan effektifnya
Analisis Permintaan
Analisis Peluang Pasar
Proyeksi Demand Potential(Do) Market Share ( S )
Proyeksi Demand Effektif (De ) De = S.Do
8
Demand Effective
Do
De
10
Metoda Proyeksi
Market Research Kwalitatif Kwantitatif
Time Series Causal
10
Analisis Market Share
Analisis Persaingan
5 Forces ( Porter )
Substitute Supplier Buyer New Entrance Competitor
11
Product Design
Membuat blue print product berdasarkan atas permintaan pasarnya
12
The Four Cs of Design
Creativity
Requires creation of something new
Complexity
Requires decision on many Variables and Parameters
Choice
Requires making choices between many possible solution
Compromise
Requires balancing multiple conflicting requirements
13
Comparison Scientific Method Vs Design Method
Existing Knowledge Scientific Curiosity Hypothesis Logical Analysis Proof State of The Art Identification of Need Conceptualization Feasibility Analysis Production
14
Types of Design Project
Variation of Existing Product Improvement of Existing Product Development of New Product for Low Volume Production Run Development of New Product for Mass Production One-of-a-Kind Design
15
Morphology of Design
1. Conceptual Design 2. Embodiment Design 3. Detail Design 4. Planning For Manufacture 5. Planning For Distribution 6. Planning for Use 7. Planning for Retirement of the Product
16
Product Design Process
Conceptual Design
Problem Definition
-Problem Statement -Benchmarking -QFD -PDS -Project Planning
Gather Information
-Internet -Patent -Trade -Literature
Concept Generation
- Brainstorming - Functional Decomposition -Morphological Chart
Evaluation of Concept
-Pugh Concept Selection -Decision Matrices
Embodiment Design
Product Architecture
- Arrangement of Physical Elements to Carry out Function
Configuration Design
-Prelim. Selection Materials and Manufacturing -Modeling/sizing of part
Parametric Design
-Robust Design -Tolerances -Final Dimension -DFM
Detail Design
- Detail Drawing s and Specifications
17
Identifying Customer Needs
Gathering Information From Customers
Interview, Focus Group, Customer Survey, and Customer Complaint
Constructing Survey Instrument Evaluating Customer Needs
18
Dimension of Quality for Manufactured Product
Performance Features Reliability Durability Serviceability Conformance Aesthetics Perceived Quality
19
Product Design Specification
A Document Which Contains All of the Facts Related to the Outcome of the Product Development
In Use Purpose and Market Functional Requirements Corporate Constraint Social, Political, and Legal Requirements
20
Customer Requirements
Expecters
There are basic attributes that one would expect to see in the product
Spokens
There are specific features that customer defines the product in terms of these attributes that one would expect to see in the product
Unspokens Exiters
21
Customer Requirements
Unspokens
These Are Specific Features That Customers Say They Want in the Product.
Exiters
These Are Product Features That Make the Product Unique and Distinguish It From the Competition
22
Quality Function Deployment
A Planning and Problem Solving Tool for Translating Customer Requirements Into the Engineering Characteristics of Product ( Engineering Parameters)
23
5 Correlation Matrix
4 Engineering Characteristic 1 Customer Reqment
6 Relationship Matrix
7. Absolute Importance 8. Relative Importance 9. Technical Competitive Assessment 10. Technical Difficulty 11. Target Value
2 Competitive Assessment
What?
3 Importance Rating
24
Manufacturing Engineering
Designing the Production Processes for a Product
Evaluating the Manufacturing of the Product Selecting Processes and Setting Process Designing Work-Holding Device Estimating the Cost of Manufacturing the Part Assuring the Quality of the Part Produce
25
Process Planning
Defining Product Structure and Specification Assessing The Manufacturability Determining Processes Capable of Producing Part Evaluating The Cost of Each Process Determining the Sequence of Operations Documenting the Process
26
Manufacturing Processes
Refining and Alloying Casting Metal Forming Metal Cutting Welding Assembly Finishing
27
Classification Of Manufacturing Processes
1. Processes for Changing Physical Properties 2. Processes for Changing the Shape of Material 3. Processes for Machining Parts to a Fixed Dimension 4. Processes for Obtaining a Surface Finish 5. Processes for Joining Parts or Materials
28
Classification Of Service Processes
1. Process for relocating goods 2. Process for storing goods 3. Process for exchanging items 4. Process for physical transformation 5. Process for physiological transformation 6. Process for information transformation
29
Equipment Selection & Specification
Selecting Equipment to be used,
a. General-purpose or Specialized Equipment b. Material Handling System
Allocating Available Facilities (Layout Design)
30
Equipment Selection Alternatives
General Purpose Specialized
Cost Low High Operator skill&control High , more control Low, less control Output rate Low-human pace High-machine pace Setup time Lower-problem preHigh-problem randictable &controllable dom & highly tech. Maintenance Cost Low-lower skill reqed High Product/service Based on human High-based on Quality control machine accuracy WIP High Low Absolescence Slower High
31
Ancillary Function
Tool, Jig and Fixture Design Cost Estimating Maintenance System Design Packaging System Material handling
32
Material Handling
1. Increasing Speed and Precision 2. Maximizing the Use of Space and Equipment 3. Increasing Safety and Working Condition 4. Reducing Damage 5. Increasing Control
33
Principles of Material Handling
1. Minimize the Number of Material Moves 2. Maximize the Unit Load Handled 3. Maximized Safety of Material Handling Equipment 4. Simplify the Material Handling Process 5. Maximize Pace Utilization 6. Integrate Storage and Handling System 7. Integrate Materials and Information Flows 8. Minimize Human Effort 9. Design for Improved Operability, Reliability, Maintainability and Flexibility
34
Penentuan Kapasitas
Kapasitas Adalah Kemampuan Maksimum Dari Suatu Fasilitas Persatuan Waktu
Design(co) Effektif(ce) Aktual(ca)
( Designer ) ( Planner ) ( Executor)
35
Keterkaitan Antar Kapasitas
Co Ce
Ca
36
Langkah
Demand Effective
LOSES (L)
Kapasitas Effektif
EFFISIENSI
Strategi Kapasitas
CCR ( R )
Kapasitas Design
37
Kapasitas Effektif
Ce = De/(1-L) Dimana L: loses karena
Kerusakan di gudang Kerusakan transportasi Warranty Sales program
38
Strategi Kapasitas
Policy A : Capacity leads demand
Units
Capacity
Demands
Time
Policy B : Capacity in approximate with demand
Capacity Units Demands Time
Policy C : Capacity legs demand
Units
Demands Capacity Time
39
Strategi Kapasitas
Lead Demand Lag Demand Equal Demand
R > 0.5 R < 0.5 R = 0.5
40
Capacity Cushion Ratio
R = ( Cx Cs )/Cx
Dimana:
R : Capacity Cushion Ratio Cx : Marginal Profit Cs : Marginal Production
41
Kapasitas Design
Co = Ce/(1-E )
Dimana, E : Effisiensi Pabrik
42
Pemilihan Lokasi
43
Kriteria Lokasi
Services
Operating Cost
44
Faktor Lokasi
1. Pasar Dan Bahan Baku
Jasa Fragile Berat Semen Kertas Agro Industri
SERVICES
COST
45
Faktor Lokasi
2. Tangible
. Transportasi
. Tenaga Kerja . Energi . Tanah . Insentif . Utilitas . Biaya Konstruksi . Pajak . Bahan Penolong . Dll
46
Faktor Lokasi
3. Intangible
Iklim Peraturan Stabilitas Politik Kemudahan Ekspansi Budaya Polusi Dll
47
Tahapan Pemilihan Lokasi
Regional
Makro
Community
Mikro
Site
48
Metoda Pemilihan
Gravitasi BEP Transportasi Point Rating Simulasi
49
Design Of Lay-out
50
Penyebab
Pembangunan Pabrik Baru Perubahan Kapasitas Perubahan Design Produk Produk Baru Dll
51
Type Lay-out
Product Lay-out Process Lay-out Fix Lay-out Automated Lay-out
52
Product Lay-out
Berdasarkan atas urutan proses produksi
Potong
Obras
Jahit
Kancing
Finishing
Packing
53
Process Lay-out
Berdasarkan atas kesamaan jenis mesin
Y A B
C
X
54
Fix Lay-Out
Benda kerja diam mesin, peralatan, material dan karyawan mendatangi benda kerja
Contoh:
Galangan Kapal Assembling Pesawat Dll
55
Automated Lay-out
Berdasarkan atas kesamaan fungsi dan kemampuan proses produksi
56
Kriteria Kinerja
1. Minimasi Kongesti 2. Minimasi Material Handling Cost 3. Effisiensi Penggunaan Resources 4. Keselamatan dan Keamanan Kerja 5. Koordinasi dan Supervisi
57
Bagan Alir Perancangan Lay-Out
Inputan
Aliran Kerja Hub.Antar Kegiatan Diagram Hubungan Kegiatan
Keb. Luas Lantai
Diagram Hubungan Ruang
Luas lantai Tersedia
Pertimb. Modifikasi
Pertim. Praktis
PengmbanganAlternatif Lay-out
Evaluasi
58
