l.1 introduction to sispro
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1Penelitian Operasional II
(TKI 226)Teknik Industri
UNIJOYO
Teknik Industri
UNIJOYO
1Sistem Manufaktur
(TKI 249)
Introduction to Manufacturing Systems
2Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
3Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
4Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
5Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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%
6Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
7Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
8Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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.
9Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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.
10Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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.
11Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
Manufaktur ?
12Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
Manufaktur? (Teknologi)
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(TKI 249)Teknik Industri
UNIJOYO
Manufaktur ? (Ekonomi)
14Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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)
15Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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.
16Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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).
17Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
18Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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.
19Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
20Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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.
21Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
22Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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”.
23Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
24Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
25Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
26Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
27Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
28Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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.
29Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
MANUFACTURING: DIFFERENT
PERSPECTIVES
• It can also be viewed from three different
perspectives:
– Firm level,
– Industry level and
– Regional or global level.
30Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
Firm Level
• Manufacturing at the firm level involves
several variables which can be broadly
grouped into the following three
categories:
– Technical
– Commercial
– Management
31Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
Technical
• The technical side has been discussed
before and involves various issues
related to the science, engineering and
technology aspects of manufacturing.
32Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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.
33Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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.
34Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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.
35Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
36Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
37Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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.
38Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
39Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
Level 1
• This level corresponds to the shop floor
level and has three key elements - Inputs,
Process and Outputs.
40Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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.
41Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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.
42Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
43Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
Respon Sistem Manufaktur
44Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
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
45Sistem Manufaktur
(TKI 249)Teknik Industri
UNIJOYO
MTS vs. MTO
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