Pengertian Umum Sistem Manufaktur D 0394 Perancangan Sistem

Pengertian Umum Sistem Manufaktur D 0394 Perancangan Sistem Manufaktur Pertemuan I - II

Definisi Manufaktur n n Manufacturing – Suatu kumpulan operasi dan aktifitas yang berkorelasi untuk menghasilkan produk, seperti perancangan produk, pemilihan baku, perencanaan, pemrosesan, inspeksi, dan manajemen. Manufacturing process – Aktifitas manufaktur merubah bentuk suatu produk dengan mesin-mesin seperti, milling, drilling dll. Assembly – Kumpulan dari semua proses dengan mana bermacam komponen dan sub perakitan dibentuk bersamaan untuk membentuk rancangan rakitan atau produk secara geometris secara lengkap. Manufacturing System – Suatu pengorganisasian beberapa proses manufaktur dan perakitan yang saling berinteraksi. Tujuannya adalah untuk menjembatani dengan diluar fungsi produksi berkenaan dengan mengoptimasikan produktifitas kinerja sistem.

Manufacturing – Historical Perspective n n English system (1800 s) – Memperkenalkan mesin-mesin yang digunakan secara umum yang dapat digunakan untuk produk yang bervariasi. American system (1850 s) – Menekankan pada presisi dan kemampuan untuk saling bertukar proses. Berubah dari “best fit” fokus kepada “greatest clearance without loss of functionality”. Scientific management (1900 s) – Prespecified worker motions - Moved the control totally into the hands of management. Process improvement (SPC) (1950 s) – Identical procedures produce different results on same machine at different times. Emphasized outliers instead of mean performance.

Manufacturing – Historical Perspective n n n Numerical control (1970 s) – Combining the versatility of general purpose machines with the precision and control of special-purpose machines. Computer integrated manufacturing (1980 s) – Pervasive use of computers to design products, plan production, control operations, and perform various business-related functions. Agile Manufacturing / Mass Customization (1990 s) – Creation of highly flexible organizational structures that allow systems to produce highly customized product

Manufacturing System Machines Raw Material n Characterized by: – – – Number of machines Number of part types Part routes through the system – Processing times – Machine setups “Finished” Products – Demand patterns – Raw material/component availability – Equipment layout/configuration – Operator availability

Manufacturing System Machines Raw Material n Interested in: – Lead time for products – Cost of processing n Decisions include: – System configuration – Scheduling methods “Finished” Products

Manufacturing System Configurations n Job Shop – Process layout that groups functionally similar machines n Flow Line – Product layout that groups machines based on a product’s flow n Cellular Manufacturing System – Hybrid layout that groups similar parts and the corresponding processing machines – Flexible Manufacturing System is an automated application n Project Shop – Product is fixed and people and equipment brought to it n Continuous Process

Manufacturing System Configurations T T M M M D D G G T G Job Shop Configuration T M M M G G D Flow Line Configurations

Manufacturing System Configurations Cell 1 Cell 2 Cell 4 Cell 3 Cellular Configuration

Product Volume vs. Product Variety High Continuous Flow Line / Transfer Line Cellular / Flexible Mfg. Sys. Volume Low Job Shop Low Variety High

Manufacturing System Design Resource Requirement Resource Lay Out Material Flow Buffer Capacity

Manufacturing System Operation n Operation Decomposition – Planning » Deciding what to do – Scheduling » Deciding when to do what you planned – Execution » Carrying out the planned tasks according to the schedule n Hierarchical System Structure – Shop – Workstation – Equipment

Principles of Manufacturing Systems n Little’s Law – WIP = Production Rate × Throughput Time (L = λ W) Matter is conserved n Larger scope implies reduced reliability n Objects decay n Exponential growth in complexity n – M components, N states ==> NM possible system states

Principles of Manufacturing Systems Technology advances n System components appear to behave randomly n Limits of (Human) rationality n Combining, simplifying, and eliminating save time, money, and energy n

Manufacturing Systems Overview Product Design n Process Planning n Production System Design n Production Planning n Operational Planning n Shop Floor Control n Execution n

Product Design n Idea » Understanding and identifying customer needs » Initial Design » Feasibility study to determine initial functionality n n Prototype Market Research » Market potential, economic analysis, strategic assessment n Design Refinement » Functional specifications n Detailed Specifications » Detailed design considering functions, quality/reliability, manufacturing, etc. Idea Generation (Product Design) Feasibility Study (Performance Specification) Preleminary Design (Prototype) Final Design (Final Design Specification) Process Planning (Manufacturing Specication)

Product Design (Cont. ) n n n Functional analysis – Customer specifications – Product reliability Design for X – Manufacture or Assembly Simplification, standardization, modularization – Testing – Repair – Robustness to variations Concurrent engineering – Consider how product will be manufactured (process and production planning) during design phase Reduce cost and time to market

Product Design (Cont. ) n Computer-Aided Design – Use of computer graphics to assist in the creation, modification, and analysis of a design – Common uses » » n Geometric modeling Automated drafting and documentation Engineering analysis Design analysis CAD/CAM – Generation of manufacturing instructions directly from CAD design data

Product Life Cycle n Product (Consumer) Perspective – – Inception Design Production Use n Production System (Manufacturer) Perspective Ø Ø Ø » Maintenance and repair Ø – Disposal – Reuse, recycle, scrap Design Ramp-up Maturity Decline Sale Time

Production System Life Cycle n Lifecycle – – – n Inception Design Construction Startup Use Closure Relationship to product lifecycle – Typically production system lifecycle is longer than an individual product’s lifecycle – Production system will revert to earlier stages in its lifecycle when new products are introduced » Extent and cost depends on system flexibility