Program Sarjana
Jurusan Teknik Industri
Institut Teknologi Sepuluh Nopember
TI091312
Production Planning and Control
Stefanus Eko Wiratno, M.T.
Teknik Industri
Course Objective
Production Planning and Control deals with the whole
process of planning and controlling in a manufacturing
system in order to meet demand with the available
resources.
There are a number of activities involved, including
managing the flow of inbound materials, managing work
in process, schedulung machines and workforce,
prioritising orders, making capacity decisions, and
coordinating demand from the customers.
The objective of this course is to provide students with
concepts of planning and control aspects of
manufacturing systems
TI091312/PPC/2009/#1 2
Teknik Industri
Buku Referensi
1. Production and Operations Analysis (3rd Edition,
1997) by Steven Nahmias
2. Production and Inventory management (1991), by
Donald W. Fogarty, John H. Blackstone, and Thomas R.
Hoffmann
3. Computer-Based Production and Inventory Control
(1989), by Spencer B. Smith
4. Production: Planning, Control, and Integration
(1997), by Daniel Sipper and Robert L. Bulfin, JR.
5. Principles of Inventory and Materials Management
(4th Edition, 1994), by Richard J. Tersine
6. Inventory Control and Management (1992), by C.D.J.
Waters
TI091312/PPC/2009/#1 3
Teknik Industri
Evaluasi
UAS – 35% (Open books)
UTS – 35% (Open books)
Quiz – 10% (unscheduled)
Tugas – 20%
Syarat untuk lulus :
Kehadiran minimum 80% dari total jumlah tatap muka
Having good attitude
TI091312/PPC/2009/#1 4
Teknik Industri
Rules of Conduct
1. Kehadiran di kelas MINIMAL 80%
2. Sudah berada di kelas sebelum kuliah dimulai
3. Dilarang menggunakan sandal/selop, kaos oblong, dan
handphone (termasuk terima/kirim SMS) selama kuliah
4. Having good attitude
memenuhi point 2-3
tidak melakukan kecurangan akademik (copy-paste,
mencontek, ngrepek) dalam mengerjakan tugas,
UTS dan UAS
tidak menandatangani absensi orang lain atau
TI091312/PPC/2009/#1 5
Teknik Industri
Materi Kuliah (1)
Pengantar PPC
Peramalan
Pengelolaan Material
Metode EOQ dengan LT=0 dan LT0
Metode EOQ dengan quantity discount
Pengelolaan Work in Process
Metode EMQ single item
Metode EMQ multi item
Pengelolaan Produk Jadi
Model Inventori Deterministik dengan mempertimbangkan
Shortage (Backorder dan Lost Sale)
Model Inventori Probabilistik (Continous and Periodic Review)
Model Inventori Uncertainty (Newsboy Inventory Model)
TI091312/PPC/2009/#1 6
Teknik Industri
Materi Kuliah (2)
Perencanaan Produksi
Aggregate Planning
Master Production Scheduling
Material Requirement Planning
Perencanaan Kapasitas
Resource Planning
Rough-cut Capacity Planning
Capacity Requirement Planning
Pengendalian Produksi
Penjadwalan operasi
Rescheduling
Topik khusus (teknik PPC yang lain):
Theory of Constraint,
Just in Time (Toyota Production System)
TI091312/PPC/2009/#1 7
Teknik Industri
Definisi PPC
Teknik yang mengelola aliran material yang masuk dalam
sistem produksi (bahan baku, bahan pembantu), mengalir
dalam sistem produksi (komponen, subassembly), dan keluar
dari sistem produksi (produk jadi, spare parts) sehingga sistem
produksi dapat memenuhi demand dengan efektif (tepat
jumlah, tepat waktu, tepat lokasi) dan efisien (biaya minimum)
TI091312/PPC/2009/#1 8
Teknik Industri
Manufaktur dan Produksi
Istilah manufaktur (manufacture)
Pertama kali digunakan tahun 1622
Berasal dari kata latin manufactum yang berarti made by hand
Istilah produksi (production)
Pertama kali digunakan pada tahun 1483
Berasal dari kata latin producere yang berarti lead forward, yaitu
membuat sesuatu yang baru (tangible/intangible)
Berarti pengertian manufaktur lebih sempit dari
pada pengertian produksi
TI091312/PPC/2009/#1 9
Teknik Industri
Definisi manufacturing
CIRP (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 of the manufacturing industries.
TI091312/PPC/2009/#1 10
Teknik Industri
Definisi Manufaktur dan Produksi
Kata manufacturing diartikan lebih luas
Manufacturing adalah proses konversi suatu desain
menjadi produk akhir
Production adalah aktivitas fisik untuk mengubah suatu
bentuk material menjadi bentuk lain yang lebih bernilai
TI091312/PPC/2009/#1 11
Teknik Industri
Siklus Manufaktur
Perancangan Perancangan
Pemasaran
Produk Process
Perancangan
Metoda Kerja,
Pengendalian Perencanaan
K o n su m en
P em aso k
Waktu Standar,
Persediaan Produksi dan Perbaikan
Produktivitas
Penyimpanan
Proses
Penerimaan
Pembuatan
Pengiriman
Pengendalian Pengendalian Pengendalian Pengendalian
Kualitas Produksi Proses Peralatan
TI091312/PPC/2009/#1 12
Teknik Industri
Sistem Manufaktur
Sistem manufaktur adalah sistem yang melakukan
proses transformasi/konversi keinginan (needs)
konsumen menjadi produk jadi yang berkualitas tinggi
Keinginan konsumen diketahui dari studi pasar, yang
kemudian keinginan ini diterjemahkan menjadi desain
produk, dan kemudian menjadi desain proses
Komitmen terhadap kualitas produk harus dimiliki oleh
setiap level dalam perusahaan pada setiap tahap proses
produksi
Dalam proses transformasi ini terjadi pertambahan nilai
TI091312/PPC/2009/#1 13
Teknik Industri
Sistem Produksi
Sistem produksi adalah sistem yang melakukan proses
transformasi atau konversi bahan mentah menjadi
produk jadi dengan kualitas tinggi dan sesuai dengan
desain produk yang telah ditetapkan
Dalam proses transformasi ini terjadi pertambahan nilai
sehingga produk jadi mempunyai nilai yang lebih tinggi
dari pada nilai bahan mentah
TI091312/PPC/2009/#1 14
Teknik Industri
Sistem Produksi
Transformation
Input Output
process
Bahan
Barang
Mesin atau
Tenaga kerja Jasa
Dana
Manajemen
TI091312/PPC/2009/#1 15
Teknik Industri
Sistem Produksi, Sistem Manufaktur,
dan Sistem Perusahaan
SISTEM PERUSAHAAN
Sistem Personalia Sistem Manajamen Sistem Keuangan
SISTEM MANUFAKTUR
SISTEM PRODUKSI
Perencanaan Pengendalian
Produksi Produksi
Aktivitas Produksi
TI091312/PPC/2009/#1 16
Teknik Industri
Sistem Produksi dan Sistem Manufaktur
(Groover, 2000)
Enterprise level
MANUFACTURING SUPPORT SYSTEMS:
-Business Function
-Product Design Manufacturing
-Manufacturing Planning Support
-Manufacturing Control Systems
QUALITY CONTROL
SYSTEM
Factory level
Production
System MANUFACTURING
SYSTEMS
Facilities
AUTOMATION AND MATERIAL
CONTROL HANDLING
TECHNOLOGIES TECHNOLOGIES
TI091312/PPC/2009/#1 17
Teknik Industri
Production and Inventory Management
Terdapat 3 karakteristik yang menentukan keampuhan dari
suatu management policy, technique, atau prosedure
yaitu:
1. Product positioning strategy
2. Process positioning strategy (the general
organization of the production process)
3. Choice of technology
TI091312/PPC/2009/#1 18
Teknik Industri
Product Positioning Strategy
Berkenaan dengan jenis inventori yang dipilih oleh
perusahaan untuk dikelola
Alternatif strateginya adalah salah satu atau kombinasi
dari:
1. Make finished product to stock (maintain and sell
from finished product inventory)
2. Assemble finished product to order (maintain an
inventory of components, subassemblies, and
options)
3. Custom design and make finished products to order
(maintain a stock of commonly used material)
TI091312/PPC/2009/#1 19
Teknik Industri
Product Positioning Strategy
Faktor yang menentukan product positioning strategy
adalah:
1. Manufacturing lead time
2. Time a customer is willing to wait for product
delivery
3. Degree of customization desired by the customer
Secara umum operasi dari product positioning strategy:
Make to stock (MTS)
Asseble to order (ATO)
Make to order (MTO)
Engineer to order (ETO)
TI091312/PPC/2009/#1 20
Teknik Industri
Process Positioning Strategy
Disebut juga dengan Production Process Design
Terdapat 3 design tradisional yang dapat digunakan
untuk mengklasifikasi proses produksi yaitu:
1. Flow shop:
o Continuous flow
o Dedicated repetitive flow
o Mixed-model repetitive flow
o Intermittent or batch flow
2. Job shop
3. Fixed site (project)
TI091312/PPC/2009/#1 21
Teknik Industri
Process Positioning Strategy
Production quantity
Continuous
flow
process Mass
production
Batch
production
Job shop
production
Product variety
TI091312/PPC/2009/#1 22
Teknik Industri
Product vs. Process Positioning Strategy
MTS ATO MTO ETO
FS
BP
JS
Product Positioning Strategy:
MTS=make to stock; ATO=assemble to order;
MTO=make to order; ETO=engineer to order
Process Positioning Strategy:
FS=flow shop; BP=batch production; JS=job shop
TI091312/PPC/2009/#1 23
Teknik Industri
Manufacturing Lead Time
Manufacturing lead time dari keempat jenis sistem
tersebut dapat digambarkan sebagai berikut :
ETO
MTO
ATO
MTS
Engineering Procurement Fabrication Assembly Delivery
TI091312/PPC/2009/#1 24
Teknik Industri
Customer Order Decoupling Point
Inventory Raw Work in process (WIP) Finished
Suppliers
location materials Parts and Component goods
Customer
order
decoupling
point
Environment ETO MTO ATO MTS
TI091312/PPC/2009/#1 25
Teknik Industri
The Order Qualifiers Criteria
These are product or service characteristics that
allow your company to be present in the market.
They include:
Quality
Price
Reputation
Number of years in business
Reliability
...
TI091312/PPC/2009/#1 26
Teknik Industri
The Order Winners Criteria
These are product or service characteristics that
allow your company to win orders in the market.
They include:
Quality
Price
Speed of delivery
Consistency of delivery
Reliability
...
TI091312/PPC/2009/#1 27
Teknik Industri
Characteristics of
Manufacturing Environment
Increased product diversity
Reduced product life cycles
Increased awareness of the environment
Difficulties of estimating the costs and benefits
Changing social expectations
TI091312/PPC/2009/#1 28
Teknik Industri
Competitive Attributes
Flexibility Safety &
Cost Quality Delivery Responsiveness Environment Innovation
1970s 1980s 1990s 2000s
Kontribusi PPC ?
TI091312/PPC/2009/#1 29
Teknik Industri
Pengelolaan Aliran Material
Metode Klasik (EOQ dan EMQ)
Decoupling
S C
U U
P S
P T
Raw Process Process Process Final Finished
L Material I
WIP
II
WIP
III
WIP
Assembly Product O
I M
E E
R R
S S
When?
Reorder Point
What?
Safety stock
How much?
TI091312/PPC/2009/#1 30
Teknik Industri
Pengelolaan Aliran Material
Metode MRP, Closed-loop MRP, dan MRP II
TI091312/PPC/2009/#1 31
Teknik Industri
Teknik-teknik PPC
Economic Order/Manufacturing Quantity (EOQ/EMQ)
Material Requirements Planning (MRP)
Closed-loop MRP
Manufacturing Resource Planning (MRP II)
Just in Time (JIT)
Theory of Constraint (TOC)
dll
TI091312/PPC/2009/#1 32
Teknik Industri
Sistem PPC
TI091312/PPC/2009/#1 33
Teknik Industri
MRP, Closed-loop MRP, MRP II
Business Planning
Marketing Planning
Feedback
Production Planning
Resource No
OK?
CLOSED-LOOP MRP Master Scheduling
MRP I Materials Planning
Feedback
Capacity Planning
Planning No
OK?
Purchasing
Shop Floor Control
Performance Measurement
TI091312/PPC/2009/#1 34
Teknik Industri
Sistem MRP II
Business Planning
Demand Management Marketing Planning Top
Forecasting Management
Distribution Requirement Planning
Planning
Order Entry Resource
Production Planning
Planning
Rough-Cut
Final Assembly Master Production
Capacity
Scheduling Scheduling
Planning
Operations
Management
Capacity
Material Requirements Planning
Requirements
Planning
Planning
Production Activity Control Purchasing
Order release Vendor selection
Operation scheduling Order placement
Dispatching Vendor scheduling
Expediting Order follow up Operations
Production reporting Management
Execution
Performance Measurement
TI091312/PPC/2009/#1 35
Teknik Industri
Manufacturing Planning and Control System
Resource Sales and operations Demand
Planning planning management
Master production
scheduling Front End
Detailed capacity Detailed material
planning planning
Engine
Material and
capacity plans
Shop-floor Supplier Back end
systems systems
TI091312/PPC/2009/#1 36
Teknik Industri
Resource Sales and operations Demand
Planning planning management
Master production
scheduling Front End
Front End
Detailed capacity Detailed material
planning Set of activities
planningand systems
for overall
direction setting (Demand Management,
Engine
Sales & Operations
Material andPlanning, Resource
Planning and MPS)
capacity plans
Shop-floor Supplier Back end
systems systems
Manufacturing Planning and Control System
TI091312/PPC/2009/#1 37
Teknik Industri
Resource Sales and operations Demand
Planning planning management
Engine
Enterprise Resource Planning (ERP) System
Systems
Masterfor detail material and
production
capacity planning.
scheduling Front End
Detailed capacity Detailed material
planning planning
Engine
Material and
capacity plans
Shop-floor Supplier Back end
systems systems
Manufacturing Planning and Control System
TI091312/PPC/2009/#1 38
Teknik Industri
Resource Sales and operations Demand
Planning planning management
Enterprise Resource Planning (ERP) System
Master production
scheduling Front End
Back End
Detailed capacity Detailed material
MPC
planning execution systems
planning – Track
Engine
progress and collect data.
Material and
capacity plans
Shop-floor Supplier Back end
systems systems
Manufacturing Planning and Control System
TI091312/PPC/2009/#1 39
Teknik Industri
Matching MPC System
with the Firm needs
MPC system design depend on
The nature of production process
The degree of supply chain integration
Customers’ expectations
The needs of management
As competitive conditions, customer expectations, supplier
capabilities, and internal need change, the MPC system needs to
change.
The trend is towards on-line data access and systems.
MPC systems must also reflect the physical changes taking place on
the factory floor (outsurcing, contrac manufacturing, etc.)
Firms that are increasing product variety may need to strengthen the
master production scheduling and detailed material planning modeles
in order to more quickly phase in and phase out new product
Firms competing on delivery speed need to improve execution.
TI091312/PPC/2009/#1 40
Teknik Industri
Evolution of the MPC System
The key to keeping the MPC system matched to
evolving company needs is to ensure system activities
are synchronized and focused on the firm’s strategy
TI091312/PPC/2009/#1 41
Teknik Industri
Principles
Different Manufacturing processes and Supply Chains
need different designs of the MPC.
The PPC must evolve to meet changing requirements in
the market, technology, products, and processes.
Major problem – the conflict between the flexible and
changing needs of companies and the inflexibility of
ERP systems.
TI091312/PPC/2009/#1 42
Teknik Industri
Performance Indicators
Output results
Equipment utilization
Cost associated with different departments,
products, labor utilization, and project
conditions.
Measures of customer satisfaction such as late
deliveries, product returns, quantity and quality
errors.
TI091312/PPC/2009/#1 43
Teknik Industri
Perencanaan dan pengendalian produksi
(Production Planning & Control, PPC)
Tujuan perencanaan: pemanfaatan sumber secara
efektif
Tujuan pengendalian: penyesuaian rencana dengan
kegiatan sehari-hari
Issu dalam PPC:
o apa (dilakukan pada level sistem manufaktur)
o berapa banyak
o kapan
o siapa
o bagaimana penyesuaian harus dilakukan
TI091312/PPC/2009/#1 44
