DESIGN OF MANUFACTURING SYSTEM

Sasaran
Memahami konsep dan proses perancangan sistem manufaktur mulai dari perancangan produk, perancangan proses, pemilihan lokasi dan perancangan lay out

What Design IE Do ?
Integrated System Industrial System (Manufacturing System)

Human Activity System

Management Control System

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Human Activity System

Perancangan System Pengoperasian System

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 Jadwal Operasi T. Kerja

Pelaksanaan
Evaluasi

Analisis Permintaan
Tujuannya adalah menentukan jenis produk dan menghitung volume permintaan effektifnya

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 Cs 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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Comparison Scientific Method Vs Design Method

Existing Knowledge Scientific Curiosity Hypothesis Logical Analysis Proof State of The Art Identification of Need Conceptualization Feasibility Analysis 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

Conceptual Design

Problem Definition
-Problem Statement -Benchmarking -QFD -PDS -Project Planning

Gather Information
-Internet -Patent -Trade -Literature

Concept Generation
- Brainstorming - Functional Decomposition -Morphological Chart

Evaluation of Concept
-Pugh Concept Selection -Decision Matrices

Embodiment Design

Product Architecture
- Arrangement of Physical Elements to Carry out Function

Configuration Design
-Prelim. Selection Materials and Manufacturing -Modeling/sizing of part

Parametric Design
-Robust Design -Tolerances -Final Dimension -DFM

Detail Design
- Detail Drawing s and Specifications

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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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5 Correlation Matrix

4 Engineering Characteristic 1 Customer Reqment

6 Relationship Matrix
7. Absolute Importance 8. Relative Importance 9. Technical Competitive Assessment 10. Technical Difficulty 11. Target Value

2 Competitive Assessment

What?

3 Importance Rating

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Manufacturing Engineering
Designing 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 Specialized
Cost Low High Operator skill&control High , more control Low, less control Output rate Low-human pace High-machine pace Setup time Lower-problem preHigh-problem randictable &controllable dom & highly tech. Maintenance Cost Low-lower skill reqed 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
LOSES (L)

Kapasitas Effektif
EFFISIENSI

Strategi Kapasitas
CCR ( R )

Kapasitas Design
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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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Strategi Kapasitas
Policy A : Capacity leads demand

Units

Capacity

Demands

Time

Policy B : Capacity in approximate with demand

Capacity Units Demands Time

Policy C : Capacity legs demand

Units

Demands Capacity Time

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Strategi Kapasitas

Lead Demand Lag Demand Equal Demand

R > 0.5 R < 0.5 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 Fragile Berat Semen Kertas Agro Industri

SERVICES

COST
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Faktor Lokasi
2. Tangible
. Transportasi
. Tenaga Kerja . Energi . Tanah . Insentif . Utilitas . Biaya Konstruksi . Pajak . Bahan Penolong . 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
Y A B

C
X

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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

Luas lantai Tersedia

Pertimb. Modifikasi

Pertim. Praktis
PengmbanganAlternatif Lay-out
Evaluasi

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