(1)Introduction(revisi-12)

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MANUFAKTUR LANJUTMANUFAKTUR LANJUT

INDUSTRIAL ENGINEERING-UNSINDUSTRIAL ENGINEERING-UNS@ Taufiq Rochman, STP. MT.@ Taufiq Rochman, STP. MT.

04/22/2304/22/23 Introduction to Manufacturing SystemIntroduction to Manufacturing System

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Course objectiveCourse objective

• Memahami konsep mengenai sistem manufaktur dan keterkaitannya dengan fasilitas, otomasi, perpindahan material, pengendalian kualitas dan sistem pendukung manufaktur.

• Memahami dinamika perkembangan sistem manufaktur yang berpengaruh terhadap aktivitas produksi perusahaan.


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Course outlineCourse outline

W1 : Introduction to manufacturing systemW2 : Manufacturing operationW3 : Mathematical Model of Manufacturing

OperationW4 : Material transport systemW5 : Manufacturing systemW6 : Manual assembly lines (MAL)W7 : Mathematical Model of MALW8 : Mid exam


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W9 : Group TechnologyW10 : Flexible Manufacturing SystemW11 : Lean ProductionW12 : Agile ManufacturingW13 : DiscussionW14 : DiscussionW15 : DiscussionW16 : Final exam

continuouscontinuous


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Grading policyGrading policySKENARIO - 1• Tugas 1 : 10%• Tugas 2 : 20 %• UTS : 30%• UAS : 40%SKENARIO – 2• KD-1 : 25%• KD-2 : 25%• KD-3 : 25%• KD-4 : 25%


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Introduction to Production SystemIntroduction to Production System

What is the production systemIt is the collection of people, equipment and

procedures organized to accomplish the manufacturing operation of a company (or other organization) (Groover, 2008).

Production system can be divided into two categories : manufacturing support systems & factory equipment.


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PRODUCTION SYSTEMPRODUCTION SYSTEM

Input Conversation Process

Output

Elemen

Material

Data

Energy

Transformation

Machines

Interpretation

Skill

Useful products

Products

Knowledge

Services


KLASIFIKASI SISTEM KLASIFIKASI SISTEM PRODUKSIPRODUKSI

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Klasifikasi Sistem ProduksiKlasifikasi Sistem Produksi

Sistem produksi

Output Proses

Tujuan operasi

Aliran operasi


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Sistem Produksi

Output proses

Continuous process

Intermitten process / Discrete system

Repetitive process

Waktu set up rendah

Product layout

Satu jenis produk

Produksi massal

Special purpose machines

Waktu set up tinggi

Process layout

Produk bervariasi

Batch production

General purpose machines

Kombinasi continuous dan discrete process


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Engineering Pembelian Pabrikasi Perakitan Pengiriman

MTS

ATO

MTO

ETO

Manufacturing Lead time

Sistem Produksi

Tujuan operasi

Engineering to order (ETO)

Make to Order (MTO)

Assembly to Order (ATO)

Make to Stock (MTS)


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Sistem Produksi

Aliran Operasi

Flow shop Job shop Batch Proyek

Volume produksi tinggi

Mass production

Produk standar

Kontinyu & terputus

MTS

Volume produksi rendah

Waktu set up tinggi

Proses terputus/ diskrit

MTO

Seperti flow shop tetapi standar produk tidak sama

Satu jenis produk

Urutan tugas terintegrasi


Production Quantity Production Quantity & Product Variety& Product Variety


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Production QuantityProduction Quantity

Production quantity refers to the number of units of a given part or product produced annually by the plant

Product quantities can be classified into three ranges :

• Low production, quantities in the range of 1 to 100 unit annually.

• Medium production : 100 to 10.000 unit• High production : 10.000 to 1.000.000 unit


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Product VarietyProduct Variety

Product variety refers to the different product designs or types that a produced in a plant.

Product variety is high, production quantity tends to be low.Production variety is low, production quantity is high.

Low

Medium

High

1 100 10.000 1.000.000Production quantity

Pro

duct

var

iety


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Low quantity productionLow quantity production

• The type of production facility is job shop• Quantity range of 1 to 100 unit/years• Specialized and customized products• Equipment is general purpose• The labor force is highly skilled• Fixed-position layout, process layout• The product typically complex : space

capsules, aircraft and special machinery.


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Medium quantity productionMedium quantity production

• Depending on product variety• Batch production, set up time/changeover high• Quantity range: 100 – 10.000 unit annually• Used in make to stock• Process layout• Cellular manufacturing, set up time low• Group of technology, each cell is designed to

produce a limited variety of part configuration.• Cellular layout


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High productionHigh production

• Quantity range : 10.000 – 1.000.000 unit• High demand rate for the product• Mass production can be distinguished : quantity

production & flow line production• Quantity production : Single part on single pieces of equipment Standard machines Process layout• Flow line production Multiple workstations arranged in sequence Specialized tool Product layout No variation in the product on the line


LayoutsLayouts


Types of facilities and layoutsTypes of facilities and layouts

• Process Layout• Product Layout• Fixed Position Layout• Cellular Layout


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Types of facilities and layouts used for different Types of facilities and layouts used for different levels of production quantity and product varietylevels of production quantity and product variety

Job shop Batch production

Cellular manufacturing Quantity Flow line

Mass production

Fixed position layout

Process layout

Cellular layout

Product layout

1 100 10.000 1.000.000

Production quantity

Pro

duct

var

iety


Definition of Manufacturing Definition of Manufacturing SystemSystem


Definisi Sistem ManufakturDefinisi Sistem Manufaktur

• Integrasi peralatan dan sumber daya manusia yang berfungsi untuk melaksanakan satu atau lebih operasi perakitan dari bahan baku, part atau kumpulan part.

• Integrasi peralatan meliputi mesin-mesin produksi, tools, material handling, alat bantu kerja dan sistem terkomputer.

• Penciptaan nilai tambah yang dilakukan pada part atau produk.

Sistem Manufaktur bagian dari Sistem Manufaktur bagian dari Sistem ProduksiSistem Produksi


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Production system

Manufacturing support systems

Facilities : Factory Equipment

Facilities, consist of the factory, the equipment in the factory and the way the equipment is organized.

Manufacturing support systems, the set of procedure used by the company to manage production and solve the technical and logistic problems encountered in ordering material, moving work and ensuring that product meet quality standard.


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Manufacturing systems

Automaton and Control Technologies

Material Handling technologies

Quality control system

Enterprise level

Factory level

Production system

Facilities



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Manufacturing systemManufacturing system

• Single station manufacturing cells• Group technology and cellular

manufacturing• Flexible manufacturing systems• Manual assembly lines• Automated assembly system


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Material handlingMaterial handling

• Material handling system design• Material transport systems• Storage systems• Automatic identification methods


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Quality control systemsQuality control systems

• Traditional and modern quality control• Statistical process control• Inspection principles and practices• Inspection technologies


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Manufacturing support systemsManufacturing support systems

• Product design and CAD/CAM • Process planning and concurrent

engineering• Production planning and control systems• Lean production and agile manufacturing


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Manufacturing support systemsManufacturing support systems

• Manufacturing support involves a cycle of information-processing activities which is consisting of four functions :

Business functionProduct designManufacturing planningManufacturing control


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Information-processing cycle in Information-processing cycle in manufacturing support systemsmanufacturing support systems

Production System Facilities

Manufacturing planning

Bussinesfunctions

Productdesign

ManufacturingControl

Customerorder


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ReferenceReference

Groover, Mikell P, 2001, Automation, Production system, and Computer Integrated Manufacturing, Prentice hall, New Jersey, USA.

Groover, Mikell P, 2008, Automation, Production system, and Computer Integrated Manufacturing, Prentice hall, New Jersey, USA.


Documents

(1)Introduction(revisi-12)