Kuliah 4
LSiPro – FT Untirta
Muhammad Adha Ilhami
3 rd Edition 2014
Muhammad Adha Ilhami

• Mahasiswa mampu menggunakan teknik disagregasi
• Mahasiswa mampu menyusun Master
Production Schedule (MPS) atau Jadwal Induk
Produksi (JIP).
Muhammad Adha Ilhami

• Section of a production facility where all task associated with a particular process (such as assembling, painting, welding) are performed.
• It usually has more than one machine.
Sumber: http://www.businessdictionary.com/ definition/work-center.html#ixzz11xhyQTXS
Muhammad Adha Ilhami

WELDING
CUTTING
MACHINE
WELDING
CIRLING
MACHINE
SAFETY
EQUIPMENT
Welding Work Center
Muhammad Adha Ilhami
Main
Assembly
Table
Support
Assembly
Table
Boxes
Assembly Work Center

• Assigned location for an employee to perform his or her job, and which is equipped with all the required tools and facilities.
• It usually has one main working component.
• It is specifically dedicated to one employee only.
• Workstations are commonly networked together.
Muhammad Adha Ilhami

Incoming
WIP
Main
Machine
Outgoing
WIP
Muhammad Adha Ilhami

Takt Time = Total Daily Operating Time / Total Daily Customer Requirements
Where Operating Time does not include TPM, 5S, meeting times, breaks, etc…
So… Takt time is calculated and not measured. It can help to determine process capabilities
Contoh:
Customer A requires 5000 pieces per week or 1000 pieces per day.
Operating time is 8 hours – breaks = 7,5 hours/shift
Tak time = (7,5 hours x 3600 seconds/hours) / (1000 pieces)
= 27 seconds/piece
Muhammad Adha Ilhami

• the rate of output from an OM system per unit of time
• the rate at which the firm withdraws work from the system
• Jumlah masukan sumberdaya-sumberdaya yang tersedia relatif untuk kebutuhan keluaran pada waktu tertentu.
• Satuan unit : jumlah/waktu atau waktu/unit
Muhammad Adha Ilhami

• In general, production capacity is the maximum production rate of an organization (or maximum conversion rate of a production system) in any given period.
• Sustainable practical capacity is the greatest level of output that a plant can maintain:
 within the framework of a realistic work schedule
 taking account of normal downtime
 assuming sufficient availability of inputs to operate the machinery and equipment in place
Muhammad Adha Ilhami

Definisi Macam-Macam Kapasitas (1)
 Design Capacity : tingkat keluaran per satuan untuk mana pabrik dirancang.
 Rated Capacity ; tingkat keluaran per satuan waktu yang menunjukkan bahwa fasilitas secara teoritik mempunyai kemampuan memproduksi.
 Standard capacity : tingkat keluaran per satuan waktu yang ditetapkan sebagai sasaran pengoperasian bagi manajemen, supervisi dan para operator mesin, dapat digunakan sebagai dasar bagi penyusunan anggaran.
Muhammad Adha Ilhami

Definisi Macam-Macam Kapasitas (2)
 Actual dan atau operating capacity : tingkat keluaran rata-rata per satuan waktu selama periode waktu yang telah lewat = kapasitas standar ± cadangan-cadangan, penundaan, tingkat sisa nyata.
 Peak capacity : jumlah keluaran per satuan waktu yang dapat dicapai melalui maksimisasi keluaran dengan kerja lembur, menambah tenaga kerja, mengurangi jam istirahat dan sebagainya.
Muhammad Adha Ilhami

 Level of output of a plant or system is dependent on how it is organized
 capacity in sequence: linear operations, is based on the operation with the lowest amount of capacity
 capacity in parallel:
 multiple alternative operations
 any machine can be used
Muhammad Adha Ilhami

 capacity in sequence: linear operations, is based on the operation with the lowest amount of capacity.
 Contoh:
 Operasi 1 : 20 unit/jam
 Operasi 2 : 10 unit/jam
 Operasi 3 : 15 unit/jam
 Maka kapasitas sistem adalah 10 unit/jam
Muhammad Adha Ilhami

Dalam 1 jam menghasilkan
20 unit
Meski ada inputan 20 unit dalam 1 jam.
Stasiun ini hanya mampu menghasilkan
10 unit
Meski mampu menghasilkan 15 unit dalam 1 jam.
Namun karena hanya ada inputan 10 unit maka dalam 1 jam hanya menghasilkan 10 unit
20/jam 10/jam 15/jam
Dalam satu jam hanya akan dihasilkan
10 unit
Muhammad Adha Ilhami

 capacity that is based on the sum of the capacities of the various machines that make up the operation.
 Contoh:
 Operation 3 has 4 machines
 machine 1 - 90 pieces per minute
 machine 2 - 110 pieces per minute
 machine 3 -120 pieces per minute
 machine 4 - 80 pieces per minute
 Total capacity for operation 3 = 400 pieces/min
Muhammad Adha Ilhami

90/menit
Dalam satu menit dihasilkan
90 unit
110/menit 110 unit
90 + 110 + 120
+ 80 = 400 unit/menit
120 unit
120/menit
80 unit 80/menit
Muhammad Adha Ilhami

90/menit
110/meni t
120/meni t
80/menit
100/meni t
80/menit
150/meni t
50/menit
70/menit
60/menit
135/meni t
90/menit
Berapa Kapasitas Produksi Sistem ini dalam 1 jam?
Muhammad Adha Ilhami
?

Disagregasi diperlukan jika peramalan dilakukan dalam unit aggregate, namun jika peramalan tidak dilakukan dalam unit aggregate maka disagregasi tidak diperlukan.
Sementara peramalan dalam unit aggregate dilakukan atas dasar simplifikasi (filosofi dari
aggregate plan)
Muhammad Adha Ilhami

Alur Proses Pengolahan Data –
Peramalan – Rencana Agregat
Item Family Family
Agregasi Disagregasi
Data Produk
A
Data
Data Produk
B
Agregasi
Peramalan
Family
Data Produk
C
Agregasi
Perancangan
Agregat
Family
Disagregasi
MPS
Disagregasi
Data
Data family
A
Agregasi
Peramalan
Family
Perancangan
Agregat
Family
Disagregasi
Data family
B
Agregasi
Data family
C
Peramalan
Family
Perancangan
Agregat
Family
Disagregasi
MPS
Agregasi
Peramalan
Family
Muhammad Adha Ilhami
Perancangan
Agregat
Family
Disagregasi

Perhitungan Persentase
(dengan nilai penjualan)
Periode
Family X
(hasil forecast 2010)
Jan
200
Feb
250
Mar
400
Apr
210
Mei
450
Jun
255
Data Penjualan Terdahulu (2009)
Periode Jul Agu Sept Okt Nov Dec
Produk A 100.00
80.00
65.00
180.00
90.00
150.00
Demand
Records
Produk B 80.00
65.00
50.00
100.00
50.00
80.00
Produk C 120.00 115.00
85.00
120.00
100.00
110.00
Family X 300 260 200 400 240 340
Muhammad Adha Ilhami

Perhitungan Persentase
(dengan nilai penjualan)
Perhitungan Persentase
Produk
Harga
Produk
A 100.00
B
C
200.00
150.00
Periode
Demand
Records
Produk A
Produk B
Jul
10,000.00
Agu
8,000.00
Sept Okt
6,500.00 18,000.00
Nov Dec
9,000.00 15,000.00
16,000.00 13,000.00 10,000.00 20,000.00 10,000.00 16,000.00
Total
66,500.00
85,000.00
Produk C 18,000.00 17,250.00 12,750.00 18,000.00 15,000.00 16,500.00 97,500.00
Persentase
0.27
0.34
0.39
Family X 44,000.00 38,250.00 29,250.00 56,000.00 34,000.00 47,500.00 249,000.00
Disagregasi Hasil Peramalan
Periode Jan Feb Mar Apr Mei Jun
Family X 200 250 400 210 450 255
Produk A 53.41
66.77
106.83
56.08
120.18
68.10
Demand
Forecast
Produk B 68.27
85.34
136.55
71.69
153.61
87.05
Produk C 78.31
97.89
156.63
82.23
176.20
99.85
Example : MPS Januari (Produk A) = 200 x 0,27 = 53,41
MPS Januari (Produk B) = 200 x 0,34 = 68,27
MPS Januari (Produk C) = 200 x 0,39 = 78,31
Muhammad Adha Ilhami

Disagregasi Menggunakan Teknik Persentase
(dengan pertimbangan nilai conversion)
Data Penjualan Terdahulu
Periode Jul Agu Sept
Produk A 100.00
80.00
65.00
Demand
Records
Produk B 80.00
65.00
50.00
Produk C 120.00 115.00
85.00
Family X 300 260 200
Okt
180.00
100.00
120.00
400
Nov
90.00
Dec
150.00
50.00
80.00
100.00
110.00
240 340
Perhitungan Persentase
Produk
Waktu
Proses
Conversi on
A 74.34
0.61
B
C
62.32
0.51
121.38
1.00
Periode
Produk A
Demand
Records
Produk B
Produk C
Jul Agu Sept Okt Nov Dec Total %
61.25 49.00 39.81 110.24 55.12 91.87 407.28 0.32
41.07 33.37 25.67 51.34 25.67 41.07 218.21 0.17
120.00 115.00 85.00 120.00 100.00 110.00 650.00 0.51
Family X
222.32 197.37 150.48 281.59 180.79 242.94 1,275.49
Muhammad Adha Ilhami

Disagregasi Menggunakan Teknik Persentase
(dengan pertimbangan nilai conversion)
Disagregasi (Persentase dari nilai penjualan)
Periode
Family X
Demand
Forecast
Jan
200
Feb
250
Mar
400
Produk A 63.86
79.83
127.73
Produk B 34.22
42.77
68.43
Produk C 101.92
127.40
203.84
Apr
210
67.06
35.93
107.02
Mei
450
143.69
76.98
229.32
Jun
255
81.43
43.62
129.95
Example : MPS Januari (Produk A) = 200 x 0,32 = 63,86
MPS Januari (Produk B) = 200 x 0,17 = 34,22
MPS Januari (Produk C) = 200 x 0,51 = 101,92
Muhammad Adha Ilhami

Hasil Disagregasi (MPS/JIP)
Master Production Schedule / Jadwal Induk Produksi
Periode Jan Feb
Demand
Forecast
Produk A 64
Produk B 35
80
43
Produk C 102 128
Mar
128
69
204
Apr
68
36
108
Mei
144
77
230
Jun
82
44
130
Muhammad Adha Ilhami