DEPOK

Manajemen Operasi

Pemahaman Supply Process

Baca :
1). Chapter 3 Understanding the Supply Process: Evaluating
Process Capacity (pp. 32-55).
Textbook: Matching Supply with Demand, by Cachon &
Terwiesch- McGraw-Hill, 2009..(

2). Chapter 11. Process Design & AnalysisOperations and Supply Chain Management;
Chase et.al; Irwin McGraw-Hill; 14th Ed., 2014

Video: Mass production Hot Dogs in a Factory

Manop/Kuliah -4-yad/3 Mar-2015

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Kuliah ke-4:
Selasa, 3 Maret 2015
Jam: 13-15
Ruang: A-101

Basic Process Vocabulary

Inventory: The number of flow units in the system

Activity times: how long does the worker spend on the task?
Capacity =1/activity time: how many units can the worker make per unit of time
If there are m workers at the activity: Capacity=m/activity time
Bottleneck: process step with the lowest capacity
Process capacity: capacity of the bottleneck
Flow rate = Minimum{Demand rate, Process Capacity)
Utilization = Flow Rate / Capacity
Flow Time: The amount of time it takes a flow unit to go through the process
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I. Process Flow Diagram - Pembuatan hot dogs

Grind
trimmings

Inspection

Mix
ingredients

Peeler

Stuffing

Cook and
flavor

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Diketahui: Data proses

2 grinders
22,000 dogs per
batch
5 minutes to load
1
and grind

Grind
trimmings

Inspection

6 mixers
22,000 dogs per
batch
1/3 hour to mix

Mix
ingredients

Peeler

3 machines
3
2,300 dogs per
minute per machine

Stuffing

Cook and
flavor

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17 inspection
stations
Each inspector
requires only 1/6th of
6
a second to inspect
each dog

8 peelers
700 dogs per minute
per peeler

5 ovens
Each oven holds
15,000 dogs
Each dog spends 15
minutes in process

Perhitungan Capacity grind, mix, , dst

Hitung capacity tiap langkah proses, yang merupakan maximum flow
rate (R) melalui langkah proses. Satuannya harus sama dan konsisten.
Misalnya dogs/min, dogs/day, lbs/second) Pilih satuan dogs / min.
1.

Grind:
Each grinder = 22,000 dogs / 5 min = 4,400 dogs / min
2 grinders x 4,400 dogs / min = 8,800 dogs / min

2.

Mix:
Each mixer = 22,000 dogs/ (1/3 hour x 60 min / hour) = 1,100
dogs / min
6 mixers x 1,100 dogs / min = 6,600 dogs / min

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Perhitungan Capacity stuff, cook, peel, inspect

3.

Stuff:
3 stuffers x 2,300 dogs / min = 6,900 dogs / min

4.

Cook and flavor:

To find R, use Littles Law, R = I / T
I = 15,000 dogs, T = 15 min
R = 15,000 dogs / 15 min = 1,000 dogs / min
5 ovens x 1,000 dogs / min = 5,000 dogs / min

5.

Peeler
8 peelers x 700 dogs / min = 5,600 dogs / min

6.

Inspection
1/6 sec / dog = 6 dogs / sec
17 stations x 6 dogs / sec x 60 sec / min
= 6,120 dogs / min
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Capacity keseluruhan proses

Kapasitas suatu proses adalah minimum capacity dari sub proses:

Proses ini tidak dapat memproduksi lebih dari 5,000 dogs / min
Sub proses yang menjadi kendala (constrains) bagi keseluruhan proses
disebut bottleneck.

8800 dogs / min

Grind
trimmings

Inspection

6600 dogs / min

Mix
ingredients

Peeler

6120 dogs / min

5600 dogs / min

The bottleneck
6900 dogs/ min

Stuffing

Cook and
flavor
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5000 dogs / min

Capacity keseluruhan proses (lanj.)

Untuk proses ini, the flow rate, R, is 5,000 dogs / min

Dalam satuan hour proses dapat memproduksi
5,000 dogs / min x 60 min / hour = 300,000 dogs/ hour

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CONTOH SOAL (Prob. 8, p 9, Chase, 2011)

Problem: Wallys Widget Warehouse takes orders from 7 a.m to 7 p.m. The
manager wants to analyze the process and has provided the process flow
diagram shown below. There are three steps required to ship a customer
order. The first step is to take the order from a customer. The second step is to
pick the order for the customer, and then they have to pack the order ready
for shipping. Wally promises that every order placed today gets shipped
tomorrow. That means that the picking and packing operations must finish all
orders before they go home.
Customers

Customer Orders

Pick Orders

Order
Taker

Pick
Orders

100 Customers/
hour

80 Customers/
hour

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Wait for Shippers

Pack
Orders
60 Customers/
hour

Questions:
Wally wants to figure out the following:
a. What is the current maximum output of the process
assuming that no one works overtime?
b. How long will the picking and packing operations have to
work if we have a day where the order taker works at his
maximum capacity?
c. Given b, what is the maximum number of order waiting to
be picked?
d. Given b, what is the maximum number of order waiting to
be packed?
e. If we double the packing capacity (from 60 to 120 orders per
hour), what impact does this have on your answers in parts
b, c, and d?
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