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Perencanaan dan Pengendalian Produksi

The document discusses industrial engineering and manufacturing systems. It defines industrial engineering as using knowledge from various fields to design integrated systems involving people, equipment, and processes. It discusses the scope of production planning and control, which includes business planning, demand management, inventory management, and shop floor control. Finally, it covers various aspects of manufacturing systems such as production strategies, product positioning, and architectures.

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jordy williams
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30 views38 pages

Perencanaan dan Pengendalian Produksi

The document discusses industrial engineering and manufacturing systems. It defines industrial engineering as using knowledge from various fields to design integrated systems involving people, equipment, and processes. It discusses the scope of production planning and control, which includes business planning, demand management, inventory management, and shop floor control. Finally, it covers various aspects of manufacturing systems such as production strategies, product positioning, and architectures.

Uploaded by

jordy williams
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd

1

Slide 1
Pengantar
Arif Rahman, ST MT

Arif Rahman Perencanaan & Pengendalian Produksi


2

Industrial Engineering
..is concerned with the design,
improvement, and installation of integrated
systems of men, materials, information,
energy, and equipments. It draws upon
specialized knowledge and skill in the
mathematical, physical and social sciences
together with the principles and methods of
engineering analysis and design to specify,
predict and evaluate the result to be
obtained from such systems
Arif Rahman Perencanaan & Pengendalian Produksi
3
Knowledge & Skill

Physical Sciences

Mathematical

Industrial
Engineering
Engineering
Specify
Social Sciences
Predict

Evaluate

Optimal
Result

Design

Integrated
Systems

Improvement Installation

Arif Rahman Perencanaan & Pengendalian Produksi


4

Lingkup Perencanaan&Pengendalian Produksi


SISTEM PERUSAHAAN
SISTEM SISTEM SISTEM
PERSONALIA MANAJEMEN AKUNTING

SISTEM MANUFAKTUR
SISTEM PRODUKSI
SISTEM MANAJEMEN PRODUKSI

SISTEM PERENCANAAN PENGENDALIAN SISTEM


LITBANG PRODUKSI PRODUKSI PEMASARAN

AKTIVITAS
PRODUKSI
SISTEM SISTEM
KUALITAS PERSEDIAAN

SISTEM
PERAWATAN

Arif Rahman Perencanaan & Pengendalian Produksi


5

Perencanaan & Pengendalian Produksi


Business
Planning

Demand Marketing Distribution


Management Planning Requirements
Planning

Aggregate Resource
Inventory
Planning Requirements
Management
Planning

Master Rough Cut


Production Capacity
Scheduling Planning

Bill of Material Capacity


Material Requirements Requirements
Planning Planning

Machine & Labor


Scheduling

Shop Floor
Control

Arif Rahman Perencanaan & Pengendalian Produksi


SISTEM MANUFAKTUR
satu rangkaian aktivitas, proses dan operasi
yang mengolah input meliputi manusia,
material, mesin, modal, lahan, energi,
informasi dan waktu untuk menghasilkan
output berupa komponen atau produk jadi
yang mempunyai nilai tambah.

Arif Rahman Perencanaan & Pengendalian Produksi


Manufaktur sebagai sistem

Arif Rahman Perencanaan & Pengendalian Produksi


Nilai Tambah
Manfaat (benefit) dibandingkan biaya
(cost) baik secara materi maupun
nonmateri.
Hasil yang dikeluarkan (troughput)
dibandingkan yang disimpan (inventory)
Tingkat pengembalian dari usaha yang
telah dikeluarkan.

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Nilai Tambah
Pembeli: fungsi dibandingkan harga
Perusahaan: keberlanjutan dibandingkan
modal
Karyawan: upah dibandingkan tenaga
Manajemen: upah dibandingkan pikiran
Investor : profit dibandingkan investasi
Masyarakat : kesejahteraan dibandingkan
dampak
Pemerintah : pendapatan dibandingkan
kebijakan
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Sistem Manufaktur
PERSEDIAAN Bahan Baku Komponen Produk Jadi

ETO
K
Product O
MTO N
Positioning
Strategy S
ATO
U
M
E
MTS N

AKTIVITAS Perancangan Pengadaan Fabrikasi Perakitan Pengiriman

Arif Rahman Perencanaan & Pengendalian Produksi


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Product Positioning Strategy


ASSEMBLE TO ENGINEER TO
KRITERIA MAKE TO STOCK MAKE TO ORDER
ORDER ORDER

Variasi Produk Sedikit Beberapa Banyak Sangat banyak

Volume Banyak Sedang Sedikit Sedikit

Dasar produksi Peramalan Penerimaan order Penerimaan order Penerimaan order

Persediaan Produk jadi Komponen Bahan Tidak ada

Lead time Minim Cepat Lama Lama

Peralatan Special purpose Special purpose General purpose General purpose

Pekerja Biasa Cukup Terlatih Terlatih

Arif Rahman Perencanaan & Pengendalian Produksi


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Make To Stock

Gudang Gudang Pengiriman


Pabrik Produk Jadi
Bahan Baku

Arif Rahman Perencanaan & Pengendalian Produksi


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Make To Order
Make To Order
Rak Penyimpan
Komponen

Gudang
Bahan Baku Pengolahan Pemindahan Perakitan Pengemasan Pengiriman

Assemble To Order Rak Penyimpan


Komponen

Gudang
Rangka Utama Perakitan Pengemasan Pengiriman

Arif Rahman Perencanaan & Pengendalian Produksi


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Engineer To Order

Desain
Produk & Proses

Rak Penyimpan
Komponen

Gudang
Pengolahan Pemindahan Perakitan Pengemasan Pengiriman
Bahan Baku

Arif Rahman Perencanaan & Pengendalian Produksi


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Diversifikasi/Differensiasi Produk

Arif Rahman Perencanaan & Pengendalian Produksi


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Arsitektur Produk Modular vs. Integral


Modular
Chunk menerapkan salah satu dari beberapa fungsi
keseluruhan. Setiap elemen fungsional terimplementasi tepat
satu chunk secara fisik.
Interaksi antar chunk terdefinisi dengan baik dan fundamental
pada fungsi-fungsi primer produk.
Integral
Elemen-elemen fungsional produk terimplementasi lebih dari
satu chunk
Satu chunk tunggal menerapkan banyak fungsi.
Interaksi antar chunk kurang terdefinisi dengan baik dan
insidental pada fungsi-fungsi primer produk.

Arif Rahman Perencanaan & Pengendalian Produksi


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Sistem Manufaktur
Volume Continuous
Flow Shop

Intermittent
Flow Shop

Batch Process
Production Positioning
Strategy
Job Shop

Project

Variasi Produk

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Process Positioning Strategy


CONTINUOUS INTERMITTENT BATCH
KRITERIA JOB SHOP PROJECT
FLOW SHOP FLOW SHOP PRODUCTION

Variasi Produk Sedikit Sedikit Beberapa Banyak Sedikit

Volume Banyak Banyak Sedang Sedikit Sedikit

Tata letak Product Product Product Process Fixed site

Respon pada Make to stock Make to stock Make to stock Make to order Make to order

pasar

Peralatan Special purpose Special purpose General purpose General purpose General purpose

Pekerja Biasa Biasa Cukup Terlatih Terlatih

Investasi Tinggi Tinggi Menengah Rendah Rendah

Waktu setup Rendah Rendah Sedang Tinggi Rendah

Material handling Fixed Fixed Fixed Flexible Flexible

Aliran proses Tetap Tetap Sedikit variasi Variasi Tunggal / unik

Arif Rahman Perencanaan & Pengendalian Produksi


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Flow Shop
Continuous Flow Shop

Intermittent Flow Shop

Arif Rahman Perencanaan & Pengendalian Produksi


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Job Shop

Arif Rahman Perencanaan & Pengendalian Produksi


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Project

Arif Rahman Perencanaan & Pengendalian Produksi


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Sistem Manufaktur (Aliran Usaha)

Arif Rahman Perencanaan & Pengendalian Produksi


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Sistem Manufaktur (Aliran Material)


Sistem produksi diskrit
(intermittent/discrete production)
Misalnya : industri manufaktur
Sistem produksi kontinyu
(flow/continuous production)
Misalnya : industri kimia

Arif Rahman Perencanaan & Pengendalian Produksi


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Sistem Manufaktur (Pengerjaan Operasi)


Sequential Processing
Overlapped Processing
Concurrent Processing

Arif Rahman Perencanaan & Pengendalian Produksi


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Sistem Manufaktur (kapasitas proses)


Kapasitas berimbang (balanced capacity)
Proses selaras (synchronous processing)
Proses tak selaras (asynchronous
processing)

Arif Rahman Perencanaan & Pengendalian Produksi


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Sistem Manufaktur (paradigma)


Automation & autonomation
Flexible manufacturing
Integrated manufacturing
Lean manufacturing
Agile manufacturing
Green manufacturing
Virtual manufacturing

Arif Rahman Perencanaan & Pengendalian Produksi


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Siklus Pengendalian Produksi (Groover,1987)


Pemasaran & Perancangan Perencanaan
Penjualan Produk Proses

K Metode kerja,
O Pengendalian Perencanaan waktu standar, dan P

N
Persediaan Produksi perbaikan E
produktivitas
S M

U A

M S

E
Penyimpanan Pembuatan Penerimaan O
Pengiriman
N K

Pengendalian Pengendalian Pengendalian Pengendalian


Kualitas Produksi Proses Peralatan
Arif Rahman Perencanaan & Pengendalian Produksi
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Siklus Pengendalian Produksi (Bedworth,1987)


SISTEM PENGENDALIAN PRODUKSI

Penjualan &
Peramalan
Penerimaan Konsumen
Permintaan
Pesanan

Perencanaan Perencanaan Penjadwalan


Kapasitas Kebutuhan & Pengiriman &
Produksi
Jangka Jangka Pengendalian Penerimaan
Panjang Pendek Produksi

Pengendalian
Persediaan Pemasok
Persediaan

Arif Rahman Perencanaan & Pengendalian Produksi


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Siklus Pengendalian Produksi (Uppal,2001)


Perencanaan Perencanaan Perencanaan & Kebutuhan
Penjadwalan
Permintaan Persediaan Material
K Produksi P

O E

N M
Manajemen Pengelolaan Penjadwalan Pengadaan &
S A
Pesanan Persediaan Pabrik Pembelian
U S

M O

E K
Distribusi Pengisian Produksi Penerimaan
N Persediaan Material

Proses Proses Proses Proses


Pelayanan Manajemen Rencana & Jadwal Pengadaan
Permintaan Persediaan Produksi Material

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Perencanaan Produksi
proses yang menyangkut upaya yang
dilakukan menghubungkan evaluasi fakta di
masa lalu dan sekarang serta antisipasi
perubahan dan kecenderungan di masa
mendatang untuk menentukan strategi dan
penjadwalan produksi yang tepat guna
mewujudkan sasaran memenuhi permintaan
pasar secara efektif dan efisien
Produce the right thing by the right man using
right method on the right time at the right place

Arif Rahman Perencanaan & Pengendalian Produksi


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Perencanaan Produksi
WHAT WHO

Product (Quantity+Quality) Resources(Equipment + Labor)

HOW

Method & Technology

WHERE WHEN

Location & Transportation Time (Start + Delivery)

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Pengendalian Produksi
proses yang menyangkut upaya untuk
mengendalikan dan memastikan seluruh
rangkaian aktivitas yang telah
direncanakan agar dilaksanakan sesuai
dengan target dan sasaran yang
ditetapkan sekalipun terdapat beberapa
perubahan dan penyesuaian yang terjadi
No overproduction, no shortage

Arif Rahman Perencanaan & Pengendalian Produksi


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Pengendalian Produksi
Supplier
Procurement

Raw Material
Inventory

Consumption

Work In Process
Inventory

Production

Finished Good
Inventory

Delivery

Customer/Market
Arif Rahman Perencanaan & Pengendalian Produksi
Tuntutan Pelanggan Masalah Efektivitas
Produktivitas (productivity).
Tingkat efektivitas pada produksi dengan efisiensi pada sumber daya.
Kualitas (quality).
Kesesuaian produk memenuhi kebutuhan konsumen dan bebas cacat.
Biaya (cost).
Efisiensi sumber daya dan reduksi pemborosan.
Pengiriman (delivery).
Pengiriman tepat waktu tanpa penundaan, keterlambatan dan pengembalian.
Layanan (service).
Pembinaan hubungan antara konsumen dengan perusahaan.
Moral (morale).
Hubungan sosial perusahaan dengan pekerja, konsumen, masyarakat dan
pemerintah sesuai norma, etika atau peraturan yang ada.
Lingkungan (environment).
Faktor keamanan, kesehatan dan lingkungan (safety, healthy & environment).

Arif Rahman Perencanaan & Pengendalian Produksi


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Effectiveness

Efficiency

Arif Rahman Perencanaan & Pengendalian Produksi


Pemborosan Masalah Efisiensi
Kelebihan produksi (overproduction),
Menunggu (waiting time),
Transportasi (handling & transportation),
Proses pengerjaan tak bernilai tambah
(processing),
Persediaan (inventory),
Pergerakan (motion & movement),
Produk cacat (defect & scrap).
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Pemborosan atau waste atau muda

Arif Rahman Perencanaan & Pengendalian Produksi


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Akhir Perkuliahan

Ada Yang Ditanyakan


Arif Rahman Perencanaan & Pengendalian Produksi

Common questions

Powered by AI

The choice between a continuous flow shop and a batch production system depends on product variation, volume, response to market, equipment purpose, worker skill, investment cost, setup time, material handling, and process flow. Continuous flow shops are suited for high-volume, low-variability scenarios with fixed setups, while batch production offers flexibility in handling variability and moderate volumes but requires general-purpose equipment .

Automation paradigms impact manufacturing by enhancing efficiency through the consistent performance of repetitive tasks, reducing human error, and increasing throughput. Quality improves as automated systems maintain tighter control over production variables, leading to more uniform product quality. Automation supports lean and agile manufacturing, enabling quick adjustments to production variables in response to real-time demands or process changes .

Product positioning strategies differ significantly between 'Make to Stock' and 'Engineer to Order'. 'Make to Stock' typically involves low product variation, high volume, reliance on forecasts, and minimal lead time, with products stored as finished goods. In contrast, 'Engineer to Order' focuses on high product variation with low volume, operates based on received orders, and involves longer lead times using general purpose equipment because products are customized .

Modular product architecture involves each functional element being implemented by one physical chunk, with well-defined interactions between chunks. Integral architecture, however, features functional elements implemented across multiple chunks, with interactions less clearly defined and incidental to primary functions .

Synchronous processing in manufacturing ensures balanced capacity by aligning all processes to operate seamlessly together, which enhances efficiency and productivity. Asynchronous processing, however, may result in imbalances where independent process stages operate at different paces, potentially leading to bottlenecks and inefficiencies in throughput and resource management .

Industrial engineering integrates the design of various systems by drawing upon specialized knowledge and skills from mathematical, physical, and social sciences. It uses engineering principles to specify, predict, and evaluate the outcomes of integrated systems comprising people, materials, information, energy, and equipment . These systems include production, management, and manufacturing systems, all designed to improve efficiency and effectiveness .

The primary considerations for creating value in a manufacturing system include comparing the benefits against costs, both material and non-material. The throughput should be balanced with inventory, and the rate of return from efforts should be optimized. These considerations apply to diverse stakeholders like buyers, companies, employees, management, investors, society, and government, each emphasizing factors like function vs. price or sustainability vs. capital .

Synchronization of production and demand is crucial in effective production planning and control because it ensures that production resources align with market needs, avoiding overproduction or shortages. It allows companies to efficiently satisfy customer demands, minimize inventories, and optimize resource utilization, thus achieving operational efficiency and customer satisfaction .

Inventory management plays a pivotal role in demand management systems by balancing supply with market demand. It involves strategies such as inventory turnover, order scheduling, and re-order points to maintain inventory at optimal levels, ensuring product availability and minimizing holding costs. Effective inventory management supports efficient production scheduling and reduces the risk of stock-outs or excess stock .

Lean manufacturing contributes to reducing waste by focusing on eliminating non-value-added activities such as overproduction, unnecessary transport, waiting times, redundant processing, excess inventories, motion, and defects. Implementing lean principles streamlines processes and resource use, enhancing efficiency and reducing overall production costs .

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