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DESIGN OF MANUFACTURING SYSTEM
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Sasaran
Memahami konsep dan proses perancangan sistem manufaktur mulai dari perancangan produk, perancangan
proses, pemilihan lokasi dan perancangan lay out
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What Design IE Do ?
Integrated System
Industrial System(Manufacturing System)
Human Activity Management Control System System
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Human Activity System
• Perancangan System
• Pengoperasian System
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Langkah Perancangan Sistem
Analisis Permintaan
Perancangan Produk Dan Proses
Penentuan Kapasitas
Pemilihan Lokasi
Perancangan Lay Out
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Pengoperasian Sistem Target Penjualan
Target Produksi
Jadwal Produksi
Material Mesin T. Kerja
Jadwal Operasi
Pelaksanaan
Evaluasi
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Analisis Permintaan
Tujuannya adalah menentukan jenis produk dan menghitung volume
permintaan effektifnya
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Analisis Permintaan
Analisis Peluang Pasar
Proyeksi Demand Potential(Do)
Market Share ( S )
Proyeksi Demand Effektif (De )De = S.Do
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Demand Effective
Do
De
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Metoda Proyeksi
• Market Research
• Kwalitatif
• Kwantitatif–Time Series–Causal
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Analisis Market Share
Analisis Persaingan
5 Forces ( Porter )» Substitute» Supplier» Buyer» New Entrance» Competitor
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Product Design
Membuat blue print product berdasarkan atas permintaan pasarnya
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The Four C’s 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
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ComparisonScientific Method Vs Design Method
Existing Knowledge
Scientific Curiosity
Hypothesis
Logical Analysis
Proof
State of The Art
Identification of Need
Conceptualization
FeasibilityAnalysis
Production
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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
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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
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Product Design Process
Problem Definition
-Problem Statement-Benchmarking
-QFD-PDS
-Project Planning
GatherInformation
-Internet-Patent-Trade
-Literature
ConceptGeneration
- Brainstorming- Functional
Decomposition-Morphological Chart
Evaluation ofConcept
--Pugh Concept
Selection-Decision Matrices
Parametric Design
-Robust Design -Tolerances
-Final Dimension-DFM
ConfigurationDesign
-Prelim. SelectionMaterials and
Manufacturing-Modeling/sizing of
part
Product Architecture
- Arrangement ofPhysical Elements
to Carry outFunction
Detail Design
- Detail Drawing sand
Specifications
Conceptual Design
Embodiment Design
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Identifying Customer Needs
• Gathering Information From Customers– Interview, Focus Group, Customer Survey, and
Customer Complaint
• Constructing Survey Instrument
• Evaluating Customer Needs
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Dimension of Quality for Manufactured Product
• Performance• Features• Reliability• Durability• Serviceability• Conformance• Aesthetics• Perceived Quality
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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
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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
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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
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Quality Function Deployment
A Planning and Problem Solving Tool for Translating Customer
Requirements Into the Engineering Characteristics of Product ( Engineering Parameters)
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5Correlation Matrix
4Engineering Characteristic
6Relationship Matrix
7. Absolute Importance
8. Relative Importance
9. Technical Competitive Assessment
10. Technical Difficulty
11. Target Value
1CustomerReq’ment
“What?”
2CompetitiveAssessment
3Impor-tance
Rating
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Manufacturing EngineeringDesigning 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
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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
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Manufacturing Processes
• Refining and Alloying
• Casting
• Metal Forming
• Metal Cutting
• Welding
• Assembly
• Finishing
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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
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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
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Equipment Selection & Specification
• Selecting Equipment to be used,a. General-purpose or Specialized Equipment
b. Material Handling System
• Allocating Available Facilities
(Layout Design)
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Equipment Selection Alternatives
General Purpose SpecializedCost Low High
Operator skill&control High , more control Low, less control
Output rate Low-human pace High-machine pace
Setup time Lower-problem pre- High-problem ran-
dictable &controllable dom & highly tech.
Maintenance Cost Low-lower skill req’ed High
Product/service Based on human High-based on
Quality control machine accuracy
WIP High Low
Absolescence Slower High
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Ancillary Function
• Tool, Jig and Fixture Design
• Cost Estimating
• Maintenance System Design
• Packaging System
• Material handling
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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
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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
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Penentuan Kapasitas
Kapasitas Adalah Kemampuan Maksimum Dari Suatu Fasilitas
Persatuan Waktu
Design(co) Effektif(ce) Aktual(ca) ( Designer ) ( Planner ) ( Executor)
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Keterkaitan Antar Kapasitas
Co
Ce
Ca
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Langkah
Demand Effective
Kapasitas Effektif
Strategi Kapasitas
Kapasitas Design
LOSES (L)
EFFISIENSI
CCR ( R )
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Kapasitas Effektif
Ce = De/(1-L)
Dimana L: loses karena- Kerusakan di gudang- Kerusakan transportasi- Warranty- Sales program
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Policy A : Capacity leads demand
Policy B : Capacity in approximate with demand
Policy C : Capacity legs demand
Capacity DemandsUnits
Time
Time
Time
Units
Units
Capacity
Demands
Demands
Capacity
Strategi Kapasitas
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Strategi Kapasitas
• Lead Demand R > 0.5
• Lag Demand R < 0.5
• Equal Demand R = 0.5
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Capacity Cushion Ratio
R = ( Cx – Cs )/Cx
Dimana:
R : Capacity Cushion Ratio
Cx : Marginal Profit
Cs : Marginal Production
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Kapasitas Design
Co = Ce/(1-E )
Dimana,
E : Effisiensi Pabrik
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Pemilihan Lokasi
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Kriteria Lokasi
Services Operating Cost
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Faktor Lokasi
1. Pasar Dan Bahan Baku
Jasa Semen Fragile Kertas
Berat Agro Industri
SERVICES COST
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Faktor Lokasi
2. Tangible . Transportasi . Utilitas
. Tenaga Kerja . Biaya Konstruksi
. Energi . Pajak
. Tanah . Bahan Penolong
. Insentif . Dll
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Faktor Lokasi
3. Intangible – Iklim– Peraturan– Stabilitas Politik– Kemudahan Ekspansi– Budaya– Polusi– Dll
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Tahapan Pemilihan Lokasi
Regional
Makro
Community
Mikro
Site
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Metoda Pemilihan
• Gravitasi
• BEP
• Transportasi
• Point Rating
• Simulasi
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Design Of Lay-out
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Penyebab
• Pembangunan Pabrik Baru
• Perubahan Kapasitas
• Perubahan Design Produk
• Produk Baru
• Dll
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Type Lay-out
• Product Lay-out
• Process Lay-out
• Fix Lay-out
• Automated Lay-out
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Product Lay-out
Berdasarkan atas urutan proses produksi
Potong Obras Jahit Kancing Finishing Packing
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Process Lay-out
Berdasarkan atas kesamaan jenis mesin
X
Y
A
F
CB
ED
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Fix Lay-Out
Benda kerja diam mesin, peralatan, material dan karyawan mendatangi
benda kerja
Contoh: • Galangan Kapal• Assembling Pesawat• Dll
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Automated Lay-out
Berdasarkan atas kesamaan fungsi dan kemampuan proses produksi
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Kriteria Kinerja
1. Minimasi Kongesti
2. Minimasi Material Handling Cost
3. Effisiensi Penggunaan Resources
4. Keselamatan dan Keamanan Kerja
5. Koordinasi dan Supervisi
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Bagan Alir Perancangan Lay-Out
Inputan
Aliran Kerja Hub.Antar Kegiatan
Diagram Hubungan Kegiatan
Keb. Luas Lantai
Diagram Hubungan Ruang
PengmbanganAlternatifLay-out
Luas lantai Tersedia
Evaluasi
Pertimb. Modifikasi Pertim. Praktis
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