Materi # 1

PENGANTAR TEKNIK INDUSTRI

(Engineering, Manajemen dan Industri)

Instruksional Objective
Memberikan pemahaman tentang sejarah pertumbuhan disiplin keilmuan Teknik Industri, logical reasoning process perkembangannya di masa depan. Memberikan gambaran umum konsep-konsep dasar dalam disiplin Teknik Industri & Manajemen Industri. Memberikan konsep dasar, logika berpikir dan metodemetode yang dipakai dalam disiplin Teknik Industri & Manajemen Industri. Memberikan konsep dasar berpikir secara sistemik dan pola pemecahan masalah secara komprehensif dan optimal yang menjadi ciri disiplin Teknik Industri & Manajemen Industri. Memperkenalkan teknik-teknik peningkatan produktivitas, efektivitas dan efisiensi industri.
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Sritomo W.Soebroto
Laboratorium Ergonomi & Perancangan Sistem Kerja Jurusan Teknik Industri - Fakultas Teknologi Industri

Institut Teknologi Sepuluh Nopember SURABAYA

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Engineers or Managers?

Agenda
Engineering & Manajemen Industri, Manajemen Industri dan Bisnis Proses (Pendekatan CIMOSA)
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(Teknolog atau Ekonom)

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Engineering, Mathematicians & Economists?

Engineering ?
Ingenium Ingeniators Military Engineering >< Civil Engineering The profession in which a knowledge of mathematical and natural sciences gained by study, experience and practice is applied with judgment to develop ways to utilize, economically, the materials and forces of nature for the benefit of mankind
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Engineers solve problems, but so do mathematicians. Engineers analyze, but so do statisticians and economists. Engineers design systems, do others ?
(Wayne C. Turner, et.al. Introduction to Industrial and Systems Engineering, 2003)
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Engineering ?
The profession in which a knowledge of the mathematical and natural sciences gained by study, experience, and practice is applied with judgment to develop ways to utilize, economically, the materials and forces of nature for the benefit of mankind.
(Accreditation Board for Engineering and Technology ABET, 1993)

Basic Engineering Process

Problem Symptom
(Expression of Need)

Problem Definition
(Statement of Desired Outcome)

Analysis
(Including Experimentation)

Includes the application of these mathematical and scientific principles to the planning, design, construction, operation, and maintenance of products, systems, and large fixed work that serve humankind; as such it also includes the management of such activities, research and development related to such output, and the education of persons who will be responsible for these myriad forms of activity.

Synthesis
Of Alternative Design Solutions

Decision
(selection of the best alternative) Solution, System, Product, Process or Method
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Engineering Process
General activities : (1) Solve problems, (2) Analyze problems, (3) Design Systems (Synthesis/Creativity/Innovative, etc.). Analysis : menguraikan persoalan dalam elemen-elemen dasarnya (detail), dan terkait dengan existing systems. Synthesis : kebalikan dari analysis, meng kombinasikan elemen-elemen menjadi satu kesatuan sistem yang terintegrasi, dan terkait dengan new/improved systems.
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Engineering Product Design

Engineering
(By Function)

Engineering Research
Increasing Practically

Development Design
(Engineering & Industrial Design) Production, Mfg & Maintenance

Sales, Marketing & Distribution

Commercialization
(Economic)
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The Engineering Design Process

INPUTS
Ergonomics Engineering Science Engineering Technology Psychology Economics A Better World for Us ?
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Skills and Qualities Needed for Engineering Profession

Good and math skills Strong time management skills Mechanical aptitude Good common sense A strong desire for organization and efficiency Excellent communication/ salesmanship Creative problem solving Inquisitive mind Continuous desire to learn Quantitative skills Technical competency Continuous drive for improvement Listening skills Negotiation skills Ability to adapt to many environments, wear many hat and interact with a diverse group of individuals Leadership skills Ethics Passion for improvement, etc.
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Aesthetics

Sociology

Needs ?
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Engineering Design Process

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Ecology

Science

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Increasing Abstraction

Engineering VS Management ?
Engineering Management

Role Differences Between Engineers and Managers

(P. Morrison, Making Managers of Engineers, Journal of Management Engineering, Vol.2, No. 4, 1986)

Position
1. Focus

Engineer
- More concerned with things technical/scientific. - Makes decision with much information, under conditions of greater certainty. - Works on tasks and problem solving personally. - Work based on facts with quantifiable outcomes. - Depends on personal technical expertise, attention to detail, mathematical/technical problem solving and designing. - Experiences role as autonomous. Individual accomplishment in one project, task, or problem at a time. - Creative with products, design, and materials. - Will it work?

Manager
- More concerned with people. - Makes decision often with inadequate information, under conditions of greater uncertainty. - Directs the work of others to goals. - Work based on fewer facts, less measurable outcomes. - Depends on interpersonal skills in communication, conflict management, getting ideas across, negotiating and Coaching. - Experiences role as interdependent. - Many objectives at once, requiring orchestrating a broad range of variables and organizational entities. - Creative with people and organizations - Will it make/save money for organization? 14

Engineering

Management

2. Decision Making

3. Involvement 4. Process Outcome

Problem terdefinisikan jelas Sub-sistem material Penuh dengan faktor/variable serba pasti Asumsi berlaku secara kontinyu Data bisa dikembangkan baik Keputusan diambil secara analitis
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Problem tidak bisa didefinisikan jelas Sub-sistem manusia Banyak berhadapan dengan faktor/variable Asumsi tidak berlaku kontinyu Data base tidak lengkap Keputusan lebih banyak diambil berdasarkan intuisi
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5. Effectiveness

6. Dependency 7. Responsibility

8. Creativity 9. Bottom Line

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Sains, Rekayasa & Teknik Industri

Attributes
Obyek Yang Dihasilkan Ukuran Kinerja Ukuran Nilai Diawali/Diakhiri Dengan : Profesi
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Industri?

Sains Sistem Alamiah

(Natural)

Rekayasa
(General Engineering)

Teknik Industri
(Industrial Engineering)

Sistem Buatan Produk/Proses Manfaat

(Benefits for Mankind)

Sistem Integral
(Mikro/Makro)

Teori/Pengetahuan Kebenaran Mutlak

(absolute)

Nilai Tambah
(Value Added) Produktivitas, Efektivitas dan Efisiensi

Relatif
Kebutuhan/Persoalan (Needs & Problems)

Kontekstual
Kebutuhan/Persoalan (Needs & Problems) Insinyur, Manager & Leader
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Keingin-Tahuan
(Curiousity)

Ilmuwan
(Scientist)

Insinyur
(Engineer)

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What is Industry?
INDUSTRY is the way of satisfying our needs and wants by using the basic resources of men, materials, and money

Labor

Goods

Services

Land
Industri

Capital

Profit

Private Enterprise Free Enterprise Capitalism

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WE LIVE IN AN INDUSTRIAL WORLD

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.. industri adalah lokasi (tempat) dimana aktivitas produksi akan diselenggarakan .. Aktivitas produksi . sekumpulan aktivitas yang diperlukan untuk merubah satu kumpulan masukan (inputs) menjadi produk luaran akhir (finished goods output) yang memiliki nilai tambah
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Sistem Input-Output Proses Produksi Proses Produksi

Black Box

Diagram Sistem Input-Output Proses Produksi

Value Added (Functional & Economical) Finished Goods Products

Inputs

- Formulasi Problem yang Menjadi Tanggung-Jawab Profesi Teknik Industri - Proses Transformasi (Fisik & Non-Fisik) - Proses Nilai Tambah (Fungsi & Ekonomis) - Aktivitas Produktif >< Non-Produktif

Finished Goods Output

Proses Produksi
. Material . Human . Machines/ Equipment . Information . Energy
* Factory * Hospital * Bank/Insurance * Transportation/Distribution * Dan Lain-Lain

Services

Waste
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Transformation Process (Fisik & Non-Fisik)

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Waste, Defects, etc

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Type of Modern Industry ?

Manufacturing Services & Consultation

Diagram Sistem Industri

Environment
Standard Performance * Quality * Costs * Time Delivery

Proses Manajemen

Distribution & Transportation

. Material . Human . Machines/ Equipment . Information . Energy

Finished Goods Products

Proses Produksi

Services

Construction
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Communication & Pengantar Teknik Industri/Sritomo Information

W.Soebroto

Waste, Defects, etc

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Aktivitas Produksi Ditinjau dari Proses Aliran Uang

Where are your manufacturing costs hiding?

Modal Kerja
(Working Capital)

Income
(Before Tax)

Long Term Capital Assets

Dividends Tax

Bhn Baku

Tenaga Energi Kerja

Informasi, dll

Capital (Depresiasi)

Proses Produksi/Operasional
(Proses Konversi Uang Menjadi Produk yang Memiliki Nilai Tambah) Finished Goods Product

Proses Distribusi & Pemasaran/Penjualan (Proses Konversi Produk Menjadi Uang)

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Mass Production
is the Key to Industrialization
Eli Whitney the father of mass production Henry Ford developer of the moving assembly line

GNP
(Gross National Product)
A Device Used to Measure the Economic Output of a Country

Prices of

Prices of

GOODS
Interchangeable parts are exactly alike

SERVICES =
Provided

GNP

Produced

Produce more products in a shorter time period

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PRODUCTIVITY
The Goods and Services Produced by a Country

Produktivitas, Unit Costs & Daya Saing

P2
o ts/c U ni st

UC1

P
P1 UC2

C
Cos t/ un it

t1 1997

t2 2002

t1 1997

t2 2002

Productivity May Rise or Fall

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Four Tasks of Industrial Management

PLANNING
Preparing the Future Objectives and Goals of the Company

Seven Aspects of Successful Industry

Tools and equipment to produce the product
Employees who use machines and materials to make the product

Management Manpower Plan, Organize, Direct and Evaluate/Control Industrial Operations

Machines

DIRECTING CONTROLLING
Insuring That All Operations and Activities Conform to the Plans Supervising the Workers While They Carry Out the Objectives

ALL SEVEN ASPECTS ARE EQUALLY IMPORTANT AND ESSENTIAL Markets

Where the product is sold by the industry Processes used by employees to make the product

Money
Buys facilities & materials and pays employees

ORGANIZING
Deciding What Activities Must Be Done to Meet Established Objectives

Materials Methods

Basics from which products are made 30

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Interaksi Proses Perancangan Produk, Proses Produksi, Proses Pemasaran dan Aspek Finansial
es t equ

Pendekatan Business Process CIMOSA

(Computer Integrated Manufacturing for Open System Architecture)

Manage Process

Finance
tin g

dR Fun

Fun dR equ e
Bu dge t in g

Set Direction
st

Set Strategy

Direct Business

ge Bud

Fund Request

Product Design

Core Business Process

Customer Needs D Ma es ig nu n f fac or tur Pro ing ces sN eed s Production/

Budgeting

R&D Engineering

Marketing
ore sF st ca

Develop Product/Service
y

Get Order

Fulfill Order

Support Product

le Sa

tor en Inv

Manufacturing
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Human Resources Management

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Financial Accounting

Information Technology

Maintenance Management
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Support Process

Pendekatan BP-Cimosa

BP CIMOSA
CBP : Develop Product/Sevices
Strategi perancangan dan pengembangan produk Memahami pentingnya voice of customer dan menterjemahkannya ke dalam parameter parameter teknis dalam rancangan produk (QFD Methods). Tahapan-tahapan perancangan produk dari tahap pencarian ide, konsep sampai dengan tahap komersialisasi.
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Manage Process

Core Business Process

Support Process Support Process

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BP CIMOSA CBP : Get Order

Strategi pemasaran Manajemen pemasaran Sigi pasar sebagai bagian dari strategi pemasaran

BP CIMOSA CBP : Fulfill Order

Pengenalan berbagai macam proses dan sistem produksi Teknik tata cara dan pengukuran kerja Perencanaan fasilitas dan kapasitas produksi Perencanaan dan pengendalian produksi/ operasional Strategi perencanaan Supply Chain Teknik-teknik optimasi (operation research)
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BP CIMOSA CBP : Support Product

Customer service & satisfaction Customer relation management

BP CIMOSA
SP : Human Resources Management

Organisasi dan management industri Manajemen SDM

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BP CIMOSA
SP : Financial & Accounting
Analisa biaya Analisa ekonomi teknik Manajemen keuangan

BP CIMOSA
SP : Information Technology
Peranan teknologi informasi dalam mendukung proses produksi Strategi implementasi teknologi informasi di industri

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BP CIMOSA
SP : Maintenance Management
Peranan maintenance management dalam proses produksi Reliability engineering Implementasi maintenance management

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