Bagian 5

Departemen Teknik Industri

DESIGN OF MANUFACTURING SYSTEM


Sasaran Mema mahami hami kon k onsep sep dan dan pro p roses ses pera pe ranc nca ang nga an si sist ste em ma manu nufa fakt ktur ur mul mula ai dari pe p eranca rancang nga an pro p rodu duk, k, peranca perancang nga an prose pro ses, s, pemi pemili liha han n lok l oka asi da dan n peranc pera nca ang nga an la l ay ou outt

TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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Sasaran Mema mahami hami kon k onsep sep dan dan pro p roses ses pera pe ranc nca ang nga an si sist ste em ma manu nufa fakt ktur ur mul mula ai dari pe p eranca rancang nga an pro p rodu duk, k, peranca perancang nga an prose pro ses, s, pemi pemili liha han n lok l oka asi da dan n peranc pera nca ang nga an la l ay ou outt


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Wh at Des i g n IE Do ? Int nte egr gra ated Sys ystt em Indu ndust stri ria al Sys yste tem m (Manu nufactu facturi ring ng Sys ystem) tem)

Human Act Activi ivity ty Sy s t em

Mana nage gement ment Cont ontrol rol Sy s t em


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Hum uma an Act A ctiv ivit ity y Sys Syste tem m • Pera ranca ncanga ngan n Syst yste em ngop ope erasi rasia an Sys ystem tem • Peng


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L an g k ah Per an c an g an Si S i s t em An A n al alii s i s Per Perm m i n t aan Peranc ranca ang nga an Pro rodu duk k Dan Pro roses ses Penent nentuan uan Kapasit Kapasita as Pemi mili lihan han Loka Lok asi Per an cang canga an La L ay Out TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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Pengoperasian Sistem TARGET PENJUALAN TARGET PRODUKSI JADWAL PRODUKSI MATERIAL

MESIN

T. KERJA

JADWAL OPERASI PELAKSANAAN EVALUASI TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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Analisis Permintaan

Tujuannya adalah menentukan jenis produk dan menghitung volume permintaan effektifnya


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Analisis Permintaan ANALISIS PELUANG PASAR

PROYEKSI DEMAND POTENTIAL(Do) MARKET SHARE ( S ) PROYEKSI DEMAND EFFEKTIF (De ) De = S.Do TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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Demand Effective

Do

De 10


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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 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 TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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Comparison Scientific Method Vs Design Method Existing Knowledge

State of The Art

Scientific Curiosity

Identification of Need

Hypothesis

Conceptualization

Logical Analysis

Feasibility Analysis

Proof

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 TI-1101 Pengantar Teknik Industri Mnufacturing System 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 TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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Product Design Process Conceptual Design

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

Gather Information

Concept Generation

-Internet -Patent -Trade -Literature

- Brainstorming - Functional Decomposition -Morphological Chart

Evaluation of Concept -Pugh Concept Selection -Decision Matrices

Embodiment Design

Product Architecture

Configuration Design

- Arrangement of Physical Elements to Carry out Function

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

Parametric Design

Detail Design

-Robust Design -Tolerances -Final Dimension -DFM

- 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 TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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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 TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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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 TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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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 Req’ment

6 Relationship Matrix

2 Competitive Assessment

“What?”

3 Importance Rating

7. Absolute Importance 8. Relative Importance 9. Technical Competitive Assessment 10. Technical Difficulty 11. Target Value TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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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 TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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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 TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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Manufacturing Processes • Refining and Alloying • Casting • Metal Forming • Metal Cutting • Welding • Assembly • Finishing TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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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 TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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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 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 accur acy

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 TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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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 TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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Kapasitas Effektif Ce = De/(1-L) Dimana L: loses karena - Kerusakan di gudang - Kerusakan transportasi - Warranty - Sales program TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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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

R > 0.5

• Lag Demand

R < 0.5

• Equal Demand

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

Semen

Fragile

Kertas

Berat

Agro Industri

SERVICES

COST


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Faktor Lokasi 2. Tangible . Transportasi

. Utilitas

. Tenaga Kerja

. Biaya Konstruksi

. Energi

. Pajak

. Tanah

. Bahan Penolong

. Insentif

. 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 TI-1101 Pengantar Teknik Industri Mnufacturing System Design

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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 B

A

C X

D

E

F


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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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Bagian 5

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