Pengertian Umum
Sistem
Manufaktur
D0394 Perancangan
Sistem Manufaktur
Pertemuan I - II
Definisi Manufaktur
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Manufacturing – Suatu kumpulan operasi dan aktifitas yang berkorelasi
untuk menghasilkan produk, seperti perancangan produk, pemilihan bahan
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
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English system (1800s)
– Memperkenalkan mesin-mesin yang digunakan secara
umum yang dapat digunakan untuk produk yang bervariasi.
American system (1850s)
– Menekankan pada presisi dan kemampuan untuk saling
bertukar proses. Berubah dari “best fit” fokus kepada
“greatest clearance without loss of functionality”.
Scientific management (1900s)
– Prespecified worker motions - Moved the control totally
into the hands of management.
Process improvement (SPC) (1950s)
– Identical procedures produce different results on same
machine at different times. Emphasized outliers instead of
mean performance.
Manufacturing – Historical Perspective
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Numerical control (1970s)
– Combining the versatility of general purpose machines
with the precision and control of special-purpose
machines.
Computer integrated manufacturing (1980s)
– Pervasive use of computers to design products, plan
production, control operations, and perform various
business-related functions.
Agile Manufacturing / Mass Customization (1990s)
– Creation of highly flexible organizational structures that
allow systems to produce highly customized product
Manufacturing System
Machines
Raw
Material
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“Finished”
Products
Characterized by:
– Number of machines
– Number of part types
– Part routes through the
system
– Processing times
– Machine setups
– Demand patterns
– Raw material/component
availability
– Equipment
layout/configuration
– Operator availability
Manufacturing System
Machines
Raw
Material
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Interested in:
– Lead time for products
– Cost of processing
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Decisions include:
– System configuration
– Scheduling methods
“Finished”
Products
Manufacturing System
Configurations
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Job Shop
– Process layout that groups functionally similar machines
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Flow Line
– Product layout that groups machines based on a product’s flow
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Cellular Manufacturing System
– Hybrid layout that groups similar parts and the corresponding
processing machines
– Flexible Manufacturing System is an automated application
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Project Shop
– Product is fixed and people and equipment brought to it
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Continuous Process
Manufacturing System
Configurations
T
T
T
T
M
M M
D
D
G
G
G
Job Shop Configuration
T
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
High
Variety
Manufacturing System Design
Manufacturing System
Design
Resource
Requirement
Resource
Lay Out
Material
Flow
Buffer
Capacity
Manufacturing System
Operation
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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
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Hierarchical System Structure
– Shop
– Workstation
– Equipment
Principles of Manufacturing
Systems
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Little’s Law
– WIP = Production Rate  Throughput Time
(L= W)
Matter is conserved
 Larger scope implies reduced reliability
 Objects decay
 Exponential growth in complexity
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– M components, N states ==> NM possible
system states
Principles of Manufacturing
Systems
Technology advances
 System components appear to behave
randomly
 Limits of (Human) rationality
 Combining, simplifying, and eliminating
save time, money, and energy
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Manufacturing Systems
Overview
Product Design
 Process Planning
 Production System Design
 Production Planning
 Operational Planning
 Shop Floor Control
 Execution
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Product Design
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Idea
» Understanding and identifying
customer needs
» Initial Design
» Feasibility study to determine initial
functionality
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Prototype
Market Research
Idea Generation
(Product Design)
Feasibility Study
(Performance Specification)
Preleminary Design
(Prototype)
» Market potential, economic analysis,
strategic assessment
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Design Refinement
» Functional specifications
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Detailed Specifications
» Detailed design considering functions,
quality/reliability, manufacturing, etc.
Final Design
(Final Design Specification)
Process Planning
(Manufacturing Specication)
Product Design (Cont.)
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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.)
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Computer-Aided Design
– Use of computer graphics to assist in the creation,
modification, and analysis of a design
– Common uses
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Geometric modeling
Automated drafting and documentation
Engineering analysis
Design analysis
CAD/CAM
– Generation of manufacturing instructions directly from
CAD design data
Product Life Cycle
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Product (Consumer) Perspective
–
–
–
–
Inception
Design
Production
Use
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Production System
(Manufacturer)
Perspective
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» Maintenance and repair
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– Disposal
– Reuse, recycle, scrap
Design
Ramp-up
Maturity
Decline
Sale
Time
Production System Life Cycle
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Lifecycle
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–
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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