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DESIGN OF
MANUFACTURING SYSTEM
Sasaran
Memahami konsep dan proses
perancangan sistem manufaktur mulai
dari perancangan produk, perancangan
proses, pemilihan lokasi dan
perancangan lay out
2
What Design IE Do ?
Integrated System
Industrial System
(Manufacturing System)
Human Activity Management Control
System System
3
Human Activity System
• Perancangan System
• Pengoperasian System
4
Langkah Perancangan Sistem
Analisis Permintaan
Perancangan Produk Dan Proses
Penentuan Kapasitas
Pemilihan Lokasi
Perancangan Lay Out
5
Pengoperasian Sistem
Target Penjualan
Target Produksi
Jadwal Produksi
Material Mesin T. Kerja
Jadwal Operasi
Pelaksanaan
Evaluasi
6
Analisis Permintaan
Tujuannya adalah menentukan jenis
produk dan menghitung volume
permintaan effektifnya
7
Analisis Permintaan
Analisis Peluang Pasar
Proyeksi Demand Potential(Do)
Market Share ( S )
Proyeksi Demand Effektif (De )
De = S.Do
8
Demand Effective
Do
De
10
9
Metoda Proyeksi
• Market Research
• Kwalitatif
• Kwantitatif
–Time Series
–Causal
10
Analisis Market Share
Analisis Persaingan
5 Forces ( Porter )
» Substitute
» Supplier
» Buyer
» New Entrance
» Competitor
11
Product Design
Membuat blue print product berdasarkan
atas permintaan pasarnya
12
The Four C’s 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
13
Comparison
Scientific Method Vs Design Method
Existing State of
Knowledge The Art
Scientific Identification of
Curiosity Need
Hypothesis Conceptualization
Logical Analysis Feasibility
Analysis
Proof Production
14
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
15
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
16
Product Design Process
Conceptual Design
Problem Gather Concept Evaluation of
Definition Information Generation Concept
-
-Problem Statement -Pugh Concept
-Internet - Brainstorming
-Benchmarking Selection
-Patent - Functional
-QFD -Decision Matrices
-Trade Decomposition
-PDS
-Literature -Morphological Chart
-Project Planning
Embodiment Design
Product Configuration Parametric Detail Design
Architecture Design Design
- Arrangement of -Prelim. Selection
-Robust Design - Detail Drawing s
Physical Elements Materials and
-Tolerances and
to Carry out Manufacturing
-Final Dimension Specifications
Function -Modeling/sizing of
-DFM
part
17
Identifying Customer Needs
• Gathering Information From Customers
– Interview, Focus Group, Customer Survey, and
Customer Complaint
• Constructing Survey Instrument
• Evaluating Customer Needs
18
Dimension of Quality for
Manufactured Product
• Performance
• Features
• Reliability
• Durability
• Serviceability
• Conformance
• Aesthetics
• Perceived Quality
19
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
20
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
21
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
22
Quality Function Deployment
A Planning and Problem Solving Tool
for Translating Customer
Requirements Into the Engineering
Characteristics of Product (
Engineering Parameters)
23
5
Correlation Matrix
4
Engineering Characteristic
1
3
Customer 2
Req’ment
6 Competitive
Impor-
Relationship Matrix tance
Assessment
Rating
“What?”
7. Absolute Importance
8. Relative Importance
9. Technical Competitive
Assessment
10. Technical Difficulty
11. Target Value
24
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
25
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
26
Manufacturing Processes
• Refining and Alloying
• Casting
• Metal Forming
• Metal Cutting
• Welding
• Assembly
• Finishing
27
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
28
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
29
Equipment Selection & Specification
• Selecting Equipment to be used,
a. General-purpose or Specialized Equipment
b. Material Handling System
• Allocating Available Facilities
(Layout Design)
30
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 pre- High-problem ran-
dictable &controllable dom & highly tech.
Maintenance Cost Low-lower skill req’ed High
Product/service Based on human High-based on
Quality control machine accuracy
WIP High Low
Absolescence Slower High
31
Ancillary Function
• Tool, Jig and Fixture Design
• Cost Estimating
• Maintenance System Design
• Packaging System
• Material handling
32
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
33
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
34
Penentuan Kapasitas
Kapasitas Adalah Kemampuan
Maksimum Dari Suatu Fasilitas
Persatuan Waktu
Design(co) Effektif(ce) Aktual(ca)
( Designer ) ( Planner ) ( Executor)
35
Keterkaitan Antar Kapasitas
Co
Ce
Ca
36
Langkah
Demand Effective
LOSES (L)
Kapasitas Effektif
EFFISIENSI
Strategi Kapasitas
CCR ( R )
Kapasitas Design
37
Kapasitas Effektif
Ce = De/(1-L)
Dimana L: loses karena
- Kerusakan di gudang
- Kerusakan transportasi
- Warranty
- Sales program
38
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
39
Strategi Kapasitas
• Lead Demand R > 0.5
• Lag Demand R < 0.5
• Equal Demand R = 0.5
40
Capacity Cushion Ratio
R = ( Cx – Cs )/Cx
Dimana:
R : Capacity Cushion Ratio
Cx : Marginal Profit
Cs : Marginal Production
41
Kapasitas Design
Co = Ce/(1-E )
Dimana,
E : Effisiensi Pabrik
42
Pemilihan Lokasi
43
Kriteria Lokasi
Services Operating Cost
44
Faktor Lokasi
1. Pasar Dan Bahan Baku
Jasa Semen
Fragile Kertas
Berat Agro Industri
SERVICES COST
45
Faktor Lokasi
2. Tangible
. Transportasi . Utilitas
. Tenaga Kerja . Biaya Konstruksi
. Energi . Pajak
. Tanah . Bahan Penolong
. Insentif . Dll
46
Faktor Lokasi
3. Intangible
– Iklim
– Peraturan
– Stabilitas Politik
– Kemudahan Ekspansi
– Budaya
– Polusi
– Dll
47
Tahapan Pemilihan Lokasi
Regional
Makro
Community
Mikro
Site
48
Metoda Pemilihan
• Gravitasi
• BEP
• Transportasi
• Point Rating
• Simulasi
49
Design Of Lay-out
50
Penyebab
• Pembangunan Pabrik Baru
• Perubahan Kapasitas
• Perubahan Design Produk
• Produk Baru
• Dll
51
Type Lay-out
• Product Lay-out
• Process Lay-out
• Fix Lay-out
• Automated Lay-out
52
Product Lay-out
Berdasarkan atas urutan proses
produksi
Potong Obras Jahit Kancing Finishing Packing
53
Process Lay-out
Berdasarkan atas kesamaan jenis mesin
Y
A B C
X
D E F
54
Fix Lay-Out
Benda kerja diam mesin, peralatan,
material dan karyawan mendatangi
benda kerja
Contoh:
• Galangan Kapal
• Assembling Pesawat
• Dll
55
Automated Lay-out
Berdasarkan atas kesamaan fungsi dan
kemampuan proses produksi
56
Kriteria Kinerja
1. Minimasi Kongesti
2. Minimasi Material Handling Cost
3. Effisiensi Penggunaan Resources
4. Keselamatan dan Keamanan Kerja
5. Koordinasi dan Supervisi
57
Bagan Alir Perancangan Lay-Out
Inputan
Aliran Kerja Hub.Antar Kegiatan
Diagram Hubungan
Kegiatan
Keb. Luas Lantai Luas lantai Tersedia
Diagram Hubungan
Ruang
Pertimb. Modifikasi Pertim. Praktis
PengmbanganAlternatif
Lay-out
Evaluasi 58
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