L.1 Introduction to Sispro

1Penelitian Operasional II

(TKI 226)Teknik Industri

UNIJOYO

Teknik Industri

UNIJOYO

1Sistem Manufaktur

(TKI 249)

Introduction to Manufacturing Systems

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1. Askin, R.G., and Standridge, C.R., (1993), “Modeling and Analysis

of Manufacturing Systems”, John Wiley & Sons.

2. Hitomi, K., (1996), “Manufacturing System Engineering”, Taylor &

Francis.

3. Askin, R.G., and Standridge, C.R., (2002), “Design and Analysis of

Lean Production Systems”, John Wiley & Sons.

4. Groover, M.P.,(2001), “Otomation, Production System and

Computer Integrated Manufacturing”, Prentice Hall.

5. Singh, N., (1996), “Systems Approach to Computer-Integrated

Design and Manufakturing”, John Wiley & Sons.

6. Suzaki, K., (1993), “Tantangan Industri Manufaktur”, Productivity &

Quality Management Consultans

Referensi

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Tujuan Instruksional

1. Memperkenalkan cara pikir sistemik terintegrasi

dan metoda keteknikindustrian dalam

memecahkan permasalahan dalam sistem

manufaktur

2. Mahasiswa dapat melakukan analisis dan

memodelkan sistem manufaktur

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Rule Of Conduct

• Min 80% Present in Classroom

• Present in Class Before Starting the Lecture

• Don’t Use Sandal, Kaos Oblong and Hand

Phone ringing During the Lecture

• Having Good Attitude

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Assessment

• Requirements:

– Min 80% Present in Class

– Having Good Attitude

• Score/Grade : A, B, C, D, E

– Mid Semester Test (UTS) : 35%

– Final Test (UAS): 35%

– Assignment (Tugas) : 30%

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Definisi Teknik Industri*

• Teknik Industri berkaitan dengan perancangan, perbaikan dan penginstalasian sistem integral yang terdiri atas manusia, bahan, peralatan, informasi dan energi.

• Teknik Industri menggunakan pengetahuan dan keahlian dalam ilmu-ilmu matematika, alam dan sosial secara bersama-sama dengan prinsip-prinsip dan metoda-metoda analisis dan perancangan kerekayasaan untuk menentukan, memprediksikan dan mengevaluasi hasil-hasil yang diperoleh dari sistem integral tersebut.

*) The Institute of Industrial Engineering

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Teknik Industri sebagai suatu disiplin

kerekayasaan*

• Profesi dimana pengetahuan matematika dan

ilmu alam yang diperoleh dengan studi,

pengalaman, dan praktek diterapkan dengan

pertimbangan bagi pengembangan cara-cara

untuk menggunakan secara ekonomis bahan-

bahan dan kekuatan alam untuk kemanfaatan

*) ABET

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Body of Knowledge dari

Displin Teknik Industri* (1)

• Operational Science

– Operations Research, Organization Design, Management

Information System, Economics Analysis, etc.

• Ergonomics/Human Factors Engineering

– Ergonomics, Work Design, Wage Administration, Work Safety

and Hygiene, etc.

• Production Engineering

– Production Planning and Control, Quality Control, Manufacturing

Process, Plant Layout, etc.

*) Biles, W.E., The engineering science of industrial engineering: a viewpoint of industrial engineering

curriculum, IEE Transaction 23, 1991, 208-214.

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Body of Knowledge dari

Displin Teknik Industri* (2)

Ergonomics/Human Factors

Engineering

Production EngineeringOperational Science

*) BIles, W.E., The engineering science of industrial engineering: a viewpoint of industrial engineering

curriculum, IEE Transaction 23, 1991, 208-214.

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Body of Knowledge dari

Displin Teknik Industri* (3)

Behavioral and

Social ScienceLife Science Physical Science Mathematics

Industrial Engineering

Science

General Engineering

Science

Industrial Engineering Functions:

1. Production Engineering

2. Operational Science

3. Ergonomics/Human Factors

Engineering

*) BIles, W.E., The engineering science of industrial engineering: a viewpoint of industrial engineering

curriculum, IEE Transaction 23, 1991, 208-214.

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Manufaktur ?

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Manufaktur? (Teknologi)

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Manufaktur ? (Ekonomi)

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Sistem

dalam Kontek Pengambilan Keputusan

• Sistem is kumpulan komponen-komponen yang

terorganisasi dan berhubungan untuk melakukan

sesuatu yang tidak dapat dilakukan sendiri pleh satu

komponen saja.

• Kita gunakan model sistem sebagai cara yang tepat

untuk melihat sesuatu dalam rangka tujuan pengambilan

keputusan (memecahkan masalah)

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Sistem

dalam Kontek Pengambilan Keputusan

• A System is described by:

• Observer: Who is interested in the system? Observer

• Purpose: Why define the system? Improve, output of interest

• Environment: outside the system. Define the system boundary

• Hierarchy: components and/or sub-systems are organised

• Inputs: Affect the system but are not affected by it. Can be

controllable or uncontrollable. Decision variables/parameters

• Outputs: Are affected by the system. These are of interest to

the observer. Include measure of success

• Components: Both affect and are affected by the system.

• Relationship/transformation process: Between system

inputs, outputs and components –relevant aspects.

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Aplikasi Berpikir Sistem (1)

• Berpikir tentang fenomena secara hirarki yang

tergorganisasi keseluruhan.

• Identifikasi beberapa prinsip umum yang memungkinkan

sistem dapat didefisnisikan dan tentukan batas-

batasnya.

• Penentuan input dan input yang melintasi batas sistem

(system boundary).

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Aplikasi Berpikir Sistem (2)

• Identifikasi mekanisme pengendalian dengan cara apa

sistem mempertahankan identitasnya dan hubungannya.

• Identifikasi tujuan sistem (purpose or goals), dan

komponen-komponennya, atau sub-sistem

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A Systems View of Manufacturing

• Manufacturing can be viewed either as a transformationprocess or as a system.

• As a Transformation Process: A narrow definition ofmanufacturing is that it a process of transformationwhere raw material are converted into products.

• As a System: Manufacturing is not limited to materials transformation performed in a factory. Rather, it is a complex system comprising of several elements.

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Flow of Materials, Information and Cost

Figure 2.3: Flow of Material, Information and Costs (Hitomi, 1996)

Info

rmat

ion

Flo

w o

f

RAW

MATERIALS PROCESS

Materials Flow of

CONTROL

PLANNING

PRODUCTS

Flow

of cost

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A Systems View of Manufacturing

• This involves an internal environment and an

external environment.

• The inputs are from the external environment

and involve several variables.

• The outputs are to the external environment and

also involve several variables.

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Figure 2.2: Systems View of Manufacturing (Murthy, 1995a)

OUTPUTS PRODUCTS/SERVICES

FINANCIAL CONSEQUENCES

HUMAN

CONSEQUENCES

OPERATIONS

TECHNOLOGY

MANAGEMENT

LABOR’S EFFORTS

TRANSFORMATION PROCESS

INPUTS - FINANCIAL - HUMAN - MATERIAL - INFORMATION - TECHNOLOGY

INTERNAL ENVIRONMENT

EXTERNAL

ENVIRONMENT

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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”.

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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

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Siklus Manufaktur

Perancangan

ProdukPemasaran

Perancangan

Process

Pengendalian

Persediaan

Perencanaan

Produksi

Perancangan

Metoda Kerja,

Waktu Standar,

dan Perbaikan

Produktivitas

PenyimpananProses

PembuatanPenerimaan

Kons

umen

Pem

asok

Pengendalian

Kualitas

Pengendalian

Produksi

Pengendalian

Proses

Pengendalian

Peralatan

Pengiriman

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Sistem produksi, sistem manufaktur,

sistem perusahaan

SISTEM PERUSAHAAN

Sistem Personalia Sistem KeuanganSistem Manajemen

SISTEM MANUFAKTUR

Desain

produk dan

proses

Penjaminan Kualitas

Studi Pasar

SISTEM PRODUKSI

Perencanaan

produksi

Pengendalian

produksi

Aktivitas Produksi

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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

• Kualitas produk harus dimiliki oleh setiap level dalam perusahaan pada setiap tahap proses produksi

• Dalam proses transformasi ini terjadi pertambahan nilai

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A Systems View of Manufacturing

• Can be viewed from three different Aspects:

1. Technical: Dealing with engineering, science and

technology issues.

2. Commercial: Dealing with financial, marketing, legal

issues

3. Management: Dealing with planning, operations and

other related issues such as information. And also

organisational issues dealing with human related issues.

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MANUFACTURING: DIFFERENT

PERSPECTIVES

• It can also be viewed from three different

perspectives:

– Firm level,

– Industry level and

– Regional or global level.

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Firm Level

• Manufacturing at the firm level involves

several variables which can be broadly

grouped into the following three

categories:

– Technical

– Commercial

– Management

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Technical

• The technical side has been discussed

before and involves various issues

related to the science, engineering and

technology aspects of manufacturing.

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Commercial

• The commercial side deals with issues such as costs,

sales, revenue and profits. Each of these involves many

variables.

• For example, the costs can be investment costs, unit

manufacturing costs, cost of rework and so on. The

basic bottom line for a firm is that it must make

reasonable profit for its investment.

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Management

• Deal with managing the various activities atstrategic and operational levels taking intoaccount the many different legal and socio-political aspects and various constraints.

• Another very important issue relates to theorganizational side that deals with the humanrelated issues – organisational structure,communication and flow of information, skillbase of the workforce and so on.

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National Level

• In the national level, a manufacturing firm is influenced

by factors such as market competition and government

policies.

• Obviously, the market competition is not only determined

by manufactured goods within the nation but also

affected by imported manufactured goods.

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National Level

• Some of the government policies that affect themanufacturing enterprise are indicated below.

• Industry or Technology development policies,

• Taxation policies,

• Environmental policies.

• Trade policies – export and import subsidies, protection

• Financial investment

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Regional and Global Levels

• Manufacturing at the regional and global levels deals

with the following factors :

• Fierce competition

• Open market - free trade

• Trade organisation - regional partnerships

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A THREE LEVEL MODEL OF

MANUFACTURING

• Manufacturing is a complex system involving several

elements. It can be viewed as a three level system

(Level 1 - 3)

• Note that Level 1 is nested within Level 2, in turn, is

nested within Level 3. We briefly discuss the elements at

each of these levels.

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Figure 2.9: Three Level Model of Manufacturing (Murthy, 1995b)

Strategic Level Level 3

Research and Development Partnerships Finance

Operations Level Level 2

Accounting Legal Planning

Process Level Level 1

Inputs Processes Outputs SUPPLIERS

CUSTOMERS

Human

Resource

Environmental Marketing

New Technologies New Markets Socio/Political

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Level 1

• This level corresponds to the shop floor

level and has three key elements - Inputs,

Process and Outputs.

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Level 2

• This level includes Level 1 as well as six new elements.

The focus of this level is management of business at the

operations level and the six new elements with a range

of operational issues.

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Level 3

• This level includes the Levels 1 and 2 and six new

elements. Here, the management focus is long term and

strategic.

• This is important, as survival of businesses in the fiercely

competitive global market requires long term strategies.

The six new elements deal with a range of long term

issues.

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Planning Horizon Associated with

Production Analysis

Planning Horizon Level of Analysis

Months-Years Facilities Planning

Months-Years Product design and Process Planning

Weeks-Months Production Planning

Hours-Weeks Production control

Minutes-Hours Quality control

Seconds-Minutes Machine-level real-time control

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Respon Sistem Manufaktur

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Sistem manufaktur vs. Respons

kepada konsumen

• Jenis sistem:

– MTS=make to stock; ATO=assemble to order; MTO=make to order; ETO=engineer to order

• Jenis respon:

– FS=flow shop; BP=batch production; JS=job shop

MTS ATO MTO ETO

FS

BP

JS

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MTS vs. MTO