Bagian 2

Departemen Teknik Industri

EVOLUTION OF IE THOUGHT


Sasaran Memahami konsep dan perke kem m ba ng a n kerangka berpikir dan keilmuan serta keahlian disiplin teknik industri

TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Sasaran Memahami konsep dan perke kem m ba ng a n kerangka berpikir dan keilmuan serta keahlian disiplin teknik industri


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Evolution Of IE Thought •

•

•

•

Scientific Management Administrative And Behavior Management Management Science Sistem Sis temic ic & Integ Integrat rated ed Appr Approac oach h


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Relationship of Industrial Engineering to Other Engineering and Scientific Disciplines Quality & Reliability

Statistics

Logic

Mathematics

Physics

Operation Research

Electrical Engineering

Computer & Inf.Sci Control Theory

Civil Engineering

Mechanical Engineering

Productivity Science

Psychology and Sociology

Military Engineering

Industrial Engineering

Early Industrial Engineering (Scientific Management)

Early Management Philosophy

Ergonomics

Manufacturing Engineering Chemistry

Chemical Engineering TI-1101 Pengantar Teknik Industri Evolution of IE Thought

Economics

Physiology

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Chronology Of Development In The Evolution Of IE Macro View Micro View Operation Research

Industrial & System Engineering

Industrial Engineering Industrial Engineering Scientific Management

Interchangeable Time Part Accounting Studi

1494

1750

1890

Indust Ind ustria riall Revolution

Piece Work

1900

Layout SQC

Net- Optimi- Autowork zation mation

CIM

1915

1929

1941

1958

1980

World World War I

Depres Depres sion

World Wor ld War II

Space Space Age

High Hig h Global Glo baliza izatio tion n Technology


1990

2000

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IE Thought Scientific Management

Man-Machine System

End of 18 Century

Adm & Behavior Management

Management Science

Systemic & Integrated

Human and Organization

Optimization and Modeling

Integrated System

End of 18 Century

Beginning of 20 Century

Mid of 20 Century


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Obyek dan Keilmuan Teknik Industri Obyek

Komponen

Keilmuan

Kinerja

Work Station

Man, Machine Material

Ergonomy Eng. Economy Psychology

Productivity Efficiency

Manufactur Man, Machine Material

Inventory, PPC Quality Control Lay out, OR & Modeling

QCD

Company

Labor, Facility Material

Management Leadership Behavior Science

ROI, IRR, ROE

Industrial System

Labor, Material Infrastructure

Policy Quality Systemic Approach Welfare


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Scientific Management Era


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Sasaran Memahami perkembangan keilmuan dan keahlian serta konsep dan method engineering analysis yang tersedia pada awal teknik industri dikembangkan


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Scientific Management Era • Used Science and Engineering Principle in the

Man-Machine System • Replaced the Old Rule of Thumb Method by

the Scientific Method • Object Integrated System System: » Work Station » Manufacturing System


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Scientific Management Era

Pioneer Era/ Traditionalist •Adam SMITH

Later Traditionalist

Early Modernist

• Carl BATH

• F.W HARRIS

• Henry L. GANTT

•W.A SHEWHART

• H. EMERSON

•GRANT & IRESON

•Henry FORD

•Morris L. COOKE

•Henry TOWNE

•Dwight V. MERRICK

•BARNES, NIEBEL & MUNDEL

•F.W. TAYLOR

• HAWTHORNE

•BOULTON& J. WATT •C. BABBAGE •Eli WHITNEY

•GILBERTH


•MUTTER & APPLE

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Pioneers Of IE • Awareness for the need of IE Discipline • Used Science and Engineering Principle in the

Man-Machine System (Work Station) Scientific Management •

Adam SMITH

Charles BABBAGE

•

•

Eli WHITNEY

•

Henry TOWNE

Frederick W TAYLOR

•

Frank B GILBERTH

• •

Lillian GILBERTH


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Adam SMITH Wealth of Nations (1776) Specialization of Labor – Division of the task in pin making into 4

separate operations increased output by a factor of almost 5 – 10 worker could produce 48.000 pins per day TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Charles BABBAGE On the Economy of Machinery and Manufacture (1832) – motion and time study – division of labor

• Result of factory visit in England and USA(early 1800) • Observed the manufacture of straight pins that: – involve 7 distinct operations – measured the cost and time of performing each operation

Money Could Be Saved Using Woman and Children

• Critics : Do not attempt to improve the work methods

or reduce the operation time TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Eli WHITNEY 1. Manufacturing Interchangeable Part 2. Design and Construction of New Machines Operated by Worker Having Only a Minimal Amount of Training Created the First Mass Production System (Henry FORD) TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Henry TOWNE The Engineer As Economist (1886)

Stressed the Need for Engineers to Be Concerned With the Profitability Effect of Their Decisions


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Frederick Winslow TAYLOR (1856-1915)

• • • • • •

FW Taylor was Influenced by Towne and Wentworth 1874 : Machinist Apprentice in the Hydraulic Work 1983 : Mechanical Engineer From Stevens Institute and Work at Midvale Steel Company 1881 : Began Study of Metal Cutting 1895 : Presented “A Piece Rate System” at ASME Meeting 1903 : Presented “ Shop Management” 1909 : Presented “ Principle of Scientific Management” TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Principle of Scientific Management 1. Develop a science for each element of a man’s work, which replaces the old rule of thumb method 2. Select scientifically and then train, teach, and develop the workman, whereas previously he chose his own work methods and trained himself as best as he could 3. Cooperate heartily with the men so as to ensure that all of the work being done is in accordance with the principles of the science which has been develop 4. There is almost an equal division of the work and the responsibility between management and the workmen. The management takes over all work for which they are better fitted than the workman. TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Frank GILBRETH • Born on 1868 in Maine, USA • Instead of entering MIT, he took a job as

bricklayer’s helper • 30 years old, he was the owner of a profitable construction firm with offices throughout the world • Invented effective method for increasing production rate from 120 bricks laid per worker per hour to 350 by reducing the number of motions from 19 to 5 • He Classified the basic motions into what he called THERBLIG TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Lillian GILBERTH • She was a psychologist graduated from

University of California and Ph.D from Brown University • Made significant analysis of human work

behavior with her husband Frank GILBRETH • Became the most distinguished woman

engineer in USA


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Methods Improvement • Systematic Approach to Finding Easier and

Better Ways to Accomplish a Task • Basic Objective Is to Avoid Any Kind of Waste to increase productivity and efficiency • Procedures: – Selecting Job – Getting and Recording the Fact – Questioning Every Detail – Developing and Testing a Better Method – Installing and Maintaining Improvement TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Tools • Operation Process Chart • Flow Process Chart • Left hand-Right hand Chart • Flow Diagram • Multiple Activity Chart • Gantt Chart


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Operation Process Chart • Chart describe the operation making process

from the beginning ( material input) to the finish (finished good) • ASME symbol: Operation Inspection Operation and Inspection Storage Flow


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Operation Process Chart Plywood

Pipe

5’

4

6’

5

15’

6

3’

7

•Cutting •Circular Saw •Polishing •Grinding •Painting •Sprayer

5’

3’

2’

•Make Screw

1

2

3

•Cutting •Circular Saw •Forming •Press •Make Screw •Drilling

I-1

•Drilling •Assembly &

I-2 10’

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Inspection •Mannual

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Work Measurement Determine the Time It Should Take an Average Standard Time (Normal Time + Allowances) • Normal Time = Actual time x Performance Rating • Performance Rating :

1 for normal worker >1 for slower worker <1 for faster worker


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Methods • Direct Time Study • Time Study Standard • Predetermine Time System • Predetermine Time System Standard Data • Work Sampling


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Flow Process Chart • Similar to OPC, except that more detail that is

shown by including transportation and delay • The objective is to list every detail and to

examine each detail closely – necessary or can be improved ? – can be combined with another? – should the sequence be changed? – is the proper person to be doing this activity ?


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Flow Process Chart- Present Method Process : Prepare Spaghetty Begins : In Storage Charter : Ind. Engineering

Step

Man Ends Date

or Material x Noodles : ready to Serve : 9/16

Symbol

1. Noodle in Shelf

Notes

2. Carried to cooker 3. Cook 4. Placed in Bowl

Washed in Cooker ?

5. Carried to Sink

Very Heavy

6. Washed 7. Bowl Carried to Work Area

Very Heavy

8. Placed in Serving Pans

Six Pans-Full

9. Meat and Sauce Added to Pans

Repeated Six Times

10. Pans Carried to Heater

Repeated Six Times

11. Warned 12. Carried to Serving Line

Repeated Six Times


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Flow Process Chart-Proposed Method Process : Prepare Spaghetty Begins : In Storage Charter : Ind. Engineering

Step

Man Ends Date

or Material x Noodles : ready to Serve : 9/16

Symbol

Notes

1. Noodle in Shelf 2. Carried to cooker 3. Cooked 4. Washed in Cooker

Add a Tap Adjacent to Cooker

5. Meat and Sauce Added to Pans 6. Warmed 7. Placed in Serving Pans

Repeated Six Times

12. Carried to Serving Line

Repeated Six Times


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Principle of Motion Economy List of Thoughts or Concepts That Have Proven Helpful in Designing Efficient Work Methods (MUNDEL) • Elimination • Combination • Rearrangement • Simplification TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Elimination • Eliminate possible job, steps, or motion • Eliminate irregularities in a job so as to facilitate

automaticity • Eliminate the use of hand as holding device • Eliminate awkward or abnormal motion • Eliminate the use of muscle to maintain a fixed position • Eliminate muscular force by using power tools, power

feeds, etc. • Eliminate overcoming of momentum • Eliminate danger • Eliminate idle time unless needed for rest TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Combination • Combine tools • Combine control • Combine motions • Make a maximum of work internal to

the machine cycle


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Rearrangement • Distribute work evenly between two

hands • Shift the work from the hand to eyes • Arrange for a straightforward order of work


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Simplification • Use the smallest muscle group capable of doing

the work • Reduce eyes travel and the number of fixations • Keep work in the normal area • Shorten motion • Adapt handle, levers, pedals, buttons etc to

human dimension and musculatures • Use momentum to build energy in place of the intense application of muscular force • Use the simple combination of therblighs • Reduce the complexity of each therblighs TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Later Traditionalist Extended and Developed the Philosophical Concept of TAYLOR • Developed Graphical Approach • Used In Non Manufacturing Organization • Influenced by Human Behavior •

Carl BARTH

Henry L. GANTT • H. EMERSON • Morris L. COOKE •

•

Dwight V. MERRICK •

HAWTHORNE


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Carl BARTH • TAYLOR’s associate at Midvale Steel • A mathematician • Developed “ Slide Rules”

Henry L GANTT • TAYLOR’s associate • GANNT Chart:Scheduling Production of Equipment • Wage Incentive Plan in 1901 TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Herrington EMERSON • Used TAYLOR’s approach in analyzing labor

effort in the Santa Fe Railroad System, give annual saving $ 1million per year • Wrote a book: “Twelve Principle of

Efficiency”

Morris L. COOKE • Employed Scientific Management on the city

government. • In Cooperation with Phillips MURRAY

published: “Organized Labor and Production” TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Dwight V. MERRICK • Performed a Study of Elemental Times • Developed a Wage Incentive Plan

• HARTHORNE WORK • Study of human performance at Western Electric Co. • Relationship between illumination and Productivity • There was no difference in productivity between

Controlled and Uncontrolled Group HARTHORNE Effect TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Early Modernist Further Development of TAYLOR Philosophical Concept and Scope • Developed Mathematical Model and Analysis • Design and Operation of Manufacturing System

• • • •

F.W HARRIS

W.A SHEWHART GRANT & IRESON

BARNES, NIEBEL & MUNDEL •

MUTTER & APPLE


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F.W HARRIS •

Used Mathematical Model To Solve Inventory Problem •

Introducing Optimization Method

Wilson Formula

W.A SHEWHART •

Used Statistical Principle to Control the Quality Introduce Control Chart

•

Published the first text on Statistical Quality Control in 1931 •

Eugene GRANT of Stanford in 1946 a Publish a Text on QC TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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GRANT & IRESON • Used Mathematical Model in Economy • 1930 Published: Principles of Engineering Economy

BARNES, NIEBEL &MUNDEL • Extended the Method and Time study Efforts of

GILBRETH and TAYLOR Rating Method

MUTHER & APPLE • Used Quantitative Technique and Graphical in

Designing Plant Lay-out TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Administrative And Behavior Management


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Sasaran • Memahami perlunya pendekatan dari sisi

human dalam peningkatan produktivitas dan effisiensi • Memahami perkembangan keilmuan dan

dan pendekatan behavior


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Administrative And Behavior Management

Administrative Management • Henry FAYOL

Human Relation •Hugo MUNSTER •Elton MAYO •Mary P. FOLLET •Oliver SHELDON •Chester BARNARD TI-1101 Pengantar Teknik Industri Evolution of IE Thought

Behavioral Sciences •AGYRIS • MASLOW • Mac GREGOR

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Administrative Management • Grew out of the need to find guidelines for managing •

• • •

complex organization FAYOL as founder of classical management, not because he was the first to investigate managerial behavior but because he was the first to systemize it. AS junior executive in 1860 at CommentryFourchambault and retiring as director in 1918. His success was due not to his personal abilities as a manager but to the methods he used. He believed that management could be taught TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Fayol’s Business Model Financial Commercial

Security Operation Of Business

Technical

Accounting

Managerial • Planning • Organization • Command • Coordination • Control TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Fayol’s 14 Principles Of Management 1. Division of Labor 2. Authority 3. Discipline 4. Unity of Command 5. Unity of Direction 6. Subordination of Individual Interest to the Common Goal 7. Remuneration

8. Centralization 9. The Hierarchy 10. Order 11. Equity 12. Stability of Staff 13. Initiative 14. Esprit de Corps


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Human Relation • Productivity and Efficiency Is Not Exclusively

As Engineering Problem • The classical approach did not achieve

complete production efficiency and workplace harmony • Manager must deal more effectively with the

people side ( sociology and psychology) • Used Scientific Method in the Study of People

in the Work Environment TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Mary Parker FOLLET(1868-1933) • No one could become a whole person except as

a member of a group • Leadership should not come from formal

power of authority but from the manager’s


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Oliver SELDON ( 1894-1951) • Ethics is essential to manage • Published: Philosophy of Management in 1923

Chester BARNARD(1886-1961) • An Enterprise can operate efficiently and survive only

when both the organization’s goals & the aims and needs of the individuals working for it are kept in balance • To ensure its survival , the firm must utilize the informal groups, such as cliques. TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Elton MAYO Study of human performance at Western Electric Co. • Relationship between illumination and Productivity • There was no difference in productivity between Controlled and Uncontrolled Group

HARTHORNE Effect Introduce “social man” motivated by desire to form relationship with others TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Hugo MUNSTERBERG ( 1863-1916)

Psychology and Industrial Efficiency

•

Finding the best person

• Creating the best possible work • Use the psychological influence ( the best possible

effect) to motivate employee


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Behavior Science • Human Relation Is Only One of Several Factor That

Influence Productivity and Efficiency • Self Actualizing Man would more accurate explain human motivations

Abraham MASLOW (Hierarchy of Need) Mac GREGOR ( Theory X and Theory Y) TI-1101 Pengantar Teknik Industri Evolution of IE Thought

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Bagian 2

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