MANUFAKTUR LANJUT

INDUSTRIAL ENGINEERING-UNS
@ Taufiq Rochman, STP. MT.

12/21/15

Introduction to Manufacturing System

Course objective
Memahami konsep mengenai sistem
manufaktur dan keterkaitannya dengan
fasilitas, otomasi, perpindahan material,
pengendalian kualitas dan sistem
pendukung manufaktur.
Memahami dinamika perkembangan
sistem manufaktur yang berpengaruh
terhadap aktivitas produksi perusahaan.
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Introduction to Manufacturing System

Course outline
W1 : Introduction to manufacturing system
W2 : Manufacturing operation
W3 : Mathematical Model of Manufacturing
Operation
W4 : Material transport system
W5 : Manufacturing system
W6 : Manual assembly lines (MAL)
W7 : Mathematical Model of MAL
W8 : Mid exam
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Introduction to Manufacturing System

continuous
W9 : Group Technology
W10 : Flexible Manufacturing System
W11 : Lean Production
W12 : Agile Manufacturing
W13 : Discussion
W14 : Discussion
W15 : Discussion
W16 : Final exam
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Introduction to Manufacturing System

Grading policy
SKENARIO - 1
Tugas 1
: 10%
Tugas 2
: 20 %
UTS
: 30%
UAS
: 40%
SKENARIO 2
KD-1
: 25%
KD-2
: 25%
KD-3
: 25%
KD-4
: 25%

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Introduction to Manufacturing System

Introduction to Production System

What is the production system
It is the collection of people, equipment and
procedures organized to accomplish the
manufacturing operation of a company (or
other organization) (Groover, 2008).
Production system can be divided into two
categories : manufacturing support
systems & factory equipment.
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Introduction to Manufacturing System

PRODUCTION SYSTEM
Input

Conversation
Process

Output

Elemen

Transformation

Useful products

Material

Machines

Products

Data

Interpretation

Knowledge

Energy

Skill

Services

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Introduction to Manufacturing System

KLASIFIKASI SISTEM
PRODUKSI

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Introduction to Manufacturing System

Klasifikasi Sistem Produksi

Sistem
produksi

Output
Proses

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Tujuan
operasi

Introduction to Manufacturing System

Aliran
operasi

Sistem Produksi
Output proses

Continuous
process

Intermitten
process / Discrete
system

Waktu set up rendah

Waktu set up tinggi

Product layout

Process layout

Satu jenis produk

Produk bervariasi

Produksi massal

Batch production

Special purpose
machines

General purpose
machines

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Introduction to Manufacturing System

Repetitive
process
Kombinasi continuous
dan discrete process

10

Sistem Produksi
Tujuan operasi
Engineering to
order (ETO)

Make to Order
(MTO)

Assembly to
Order (ATO)

Make to
Stock (MTS)

Manufacturing Lead time

ETO
MTO
ATO
MTS
Engineering
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Pembelian

Pabrikasi

Introduction to Manufacturing System

Perakitan

Pengiriman
11

Sistem Produksi

Aliran Operasi

Flow shop

Job shop

Volume produksi
tinggi

Volume produksi
rendah

Mass production
Produk standar

Waktu set up
tinggi

Kontinyu &
terputus

Proses terputus/
diskrit

MTS

MTO

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Batch

Seperti flow shop

tetapi standar
produk tidak sama

Introduction to Manufacturing System

Proyek

Satu jenis
produk
Urutan
tugas
terintegrasi

12

Production Quantity
& Product Variety

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13

Production Quantity
Production quantity refers to the number of units of
a given part or product produced annually by the
plant
Product quantities can be classified into three
ranges :
Low production, quantities in the range of 1 to
100 unit annually.
Medium production : 100 to 10.000 unit
High production : 10.000 to 1.000.000 unit

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Introduction to Manufacturing System

14

Product Variety

Product variety

Product variety refers to the different product designs or

types that a produced in a plant.
Product variety is high, production quantity tends to be low.
Production variety is low, production quantity is high.

Low
Medium
High

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100

10.000

1.000.000

Introduction to Manufacturing System

Production
quantity
15

Low quantity production

The type of production facility is job shop

Quantity range of 1 to 100 unit/years
Specialized and customized products
Equipment is general purpose
The labor force is highly skilled
Fixed-position layout, process layout
The product typically complex : space
capsules, aircraft and special machinery.

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Introduction to Manufacturing System

16

Medium quantity production

Depending on product variety

Batch production, set up time/changeover high
Quantity range: 100 10.000 unit annually
Used in make to stock
Process layout
Cellular manufacturing, set up time low
Group of technology, each cell is designed to
produce a limited variety of part configuration.
Cellular layout
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17

High production
Quantity range : 10.000 1.000.000 unit
High demand rate for the product
Mass production can be distinguished : quantity
production & flow line production
Quantity production :
Single part on single pieces of equipment
Standard machines
Process layout
Flow line production
Multiple workstations arranged in sequence
Specialized tool
Product layout
No variation in the product on the line
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Introduction to Manufacturing System

18

Layouts

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19

Types of facilities and layouts

Process Layout
Product Layout
Fixed Position Layout
Cellular Layout

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20

Types of facilities and layouts used for different

levels of production quantity and product variety

Product variety

Fixed
position
layout

Process
layout
Cellular
layout

Batch
production

Job shop

Product
layout

Cellular
manufacturing Quantity

Flow line

Mass production
1

100

10.000

1.000.000

Production quantity
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Introduction to Manufacturing System

21

Definition of Manufacturing
System

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Introduction to Manufacturing System

22

Definisi Sistem Manufaktur

Integrasi peralatan dan sumber daya manusia
yang berfungsi untuk melaksanakan satu atau
lebih operasi perakitan dari bahan baku, part
atau kumpulan part.
Integrasi peralatan meliputi mesin-mesin
produksi, tools, material handling, alat bantu
kerja dan sistem terkomputer.
Penciptaan nilai tambah yang dilakukan pada
part atau produk.

Sistem Manufaktur bagian dari

Sistem Produksi

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Introduction to Manufacturing System

24

Manufacturing
support systems
Production
system
Facilities : Factory
Equipment
Facilities, consist of the factory, the equipment in the
factory and the way the equipment is organized.
Manufacturing support systems, the set of procedure used
by the company to manage production and solve the
technical and logistic problems encountered in ordering
material, moving work and ensuring that product meet
quality standard.
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Introduction to Manufacturing System

25

Enterprise
level

Production
system

Factory
level

Manufacturing
systems

Automaton and
Control
Technologies

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Manufacturing
support
systems

Manufacturing
support systems
Quality
control
system

Material
Handling
technologies

Introduction to Manufacturing System

Facilities

26

Manufacturing system
Single station manufacturing cells
Group technology and cellular
manufacturing
Flexible manufacturing systems
Manual assembly lines
Automated assembly system

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27

Material handling

Material handling system design

Material transport systems
Storage systems
Automatic identification methods

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28

Quality control systems

Traditional and modern quality control

Statistical process control
Inspection principles and practices
Inspection technologies

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29

Manufacturing support systems

Product design and CAD/CAM
Process planning and concurrent
engineering
Production planning and control systems
Lean production and agile manufacturing

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30

Manufacturing support systems

Manufacturing support involves a cycle of
information-processing activities which is
consisting of four functions :
Business function
Product design
Manufacturing planning
Manufacturing control
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31

Information-processing cycle in
manufacturing support systems
Product
design

Customer
order

Bussines
functions

Production System
Facilities

Manufacturing
planning

Manufacturing
Control

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32

Reference
Groover, Mikell P, 2001, Automation,
Production system, and Computer
Integrated Manufacturing, Prentice hall,
New Jersey, USA.
Groover, Mikell P, 2008, Automation,
Production system, and Computer
Integrated Manufacturing, Prentice hall,
New Jersey, USA.
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33