Bahan kuliah Otomasi Manufaktur tentang Tinjauan Umum Proses Manufaktur

1. Part I
OVERVIEW OF MANUFACTURING
Chapters:
2. Manufacturing Operations
3. Manufacturing Models and Metrics
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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
a. Manufacturing Industries and Products
b. Manufacturing Operations
c. Production Facilities
d. Product/Production Relationships
e. Lean Production

2. Definisi Manufakturing
Dari Tinjauan Teknologi
Penerapan proses fisik dan kimia untuk mengubah
geometri, sifat, dan tampilan dari sebuah bendakerja asal
menjadi komponen atau produk.
Manufakturing juga termasuk penyambungan terhadap banyak
komponen menjadi produk rakitan
Didukung oleh kombinasi mesin, perkakas, daya dan tenaga
manusia
Hampir selalu dilaksanakan sebagai rangkaian operasi
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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

3. Manufacturing Defined -
Technological Definition
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4. Definisi Manufakturing
Dari Tinjauan Ekonomi
Perubahan bahan menjadi komponen yang bernilai lebih tinggi
dengan melalui satu atau lebih pemrosesan atau perakitan
Manufakturing menambah nilai terhadap bahan
Contoh:
Mengubah biji besi menjadi baja menambah nilai
Mengubah pasir menjadi kaca menambah nilai
Pemurnian minyak menjadi plastik menambah nilai
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

5. Manufacturing Defined -
Economic Definition
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

6. Klasifikasi Industri
1. Industri Primer – mengolah dan mengekploitasi bahan alam
Contoh: pertanian, pertambangan, perikanan, perminyakan
2. Industri Sekunder – mengubah luaran industri primer menjadi
produk
Contoh: manufakturing, pembangkit tenaga, konstruksi,
otomotif, computer, kertas, pemurnian minyak, plastik,
pemrosesan makanan, kayu dan furnitur, logam dasar’
3. Industri Tersier – Sektor Jasa
Contoh: perbankan, pendidikan, pemerintahan, jasa resmi,
perdagangan, transportasi, turisme, grosir, hiburan
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

7. Industri Manufakturing
ISIC Code
Food, beverages, tobacco 31
Textiles, apparel, leather and fur products 32
Wood and wood products, cork 33
Paper, printing, publishing, bookbinding 34
Chemicals, coal, petroleum, & their products 35
Ceramics, glass, mineral products 36
Basic metals, e.g., steel, aluminum 37
Fabricated products, e.g., cars, machines, etc. 38
Other products, e.g., jewelry, toys 39
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
the International Standard Industrial Classification (ISIC) Used by the United Nations

8. Klasifikasi Industri Selanjutnya
Industri Proses, mis, kimia, petroleum, logam dasar, makanan
dan minuman, pembangkit tenaga
Produksi Kontinyu
Produksi Batch (Kelompok)
Produk diskret (dan komponen), mis. Mobil, pesawat terbang
peralatan rumah tangga, permesinan, dan komponennya
Produksi Kontinyu
Produksi batch (kelompok)
Produksi Kontinyu  jika peralatan hanya dikhususkan untuk
yang diberikan dan luaran produk tidak dapat diberhentikan
Produksi Batch jika bahan diproses dalam jumlah terbatas.
Jumlah kelompok tersebut disebut batch, baik pada proses diskret
maupun kontinyu

9. Industri Proses dan
Industri Manufakturing Diskret
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10. Operasi Manufakturing
Ada aktivitas dasar tertentu yang harus dilaksanakan pada
sebuah pabrik untuk mengubah bahan mentah menjadi produk
Untuk produk diskret:
1. Operasi pemrosesan dan perakitan
2. Pemindahan bahan
3. Inspeksi dan pengujian
4. Koordinasi dan kendali
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

11. Klaisifikasi
proses
manufakturing
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

12. Operasi Pemrosesan
Operasi pengubahan bentuk
1. Proses pembekuan
2. Particulate processing
3. Proses Deformasi
4. Proses pembuangan bahan (tatal)
Operasi perbaikan sifat- (perlakuan panas)
Operasi pemrosesan permukaan
Perlakuan dan pembersihan permukaan
Pelapisan dan Deposisi lapisan film tipis
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

13. Operasi Perakitan
Proses penyambungan
Pengelasan
Brazing and soldering
Adhesive bonding
Penyambungan Mekanis
Sambungann berulir (mur-baut, sekrup)
Keling
Interference fits (e.g., press fitting, shrink fits)
Lainnya
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

14. Operasi Pabrik lainnya
Pemindahan bahan dan peryimpanan
Inspeksi dan Pengujian
Koordinasi dan kendali
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

15. Material Handling
Transport bahan
Kendaraan, mis. forklift trucks, AGVs, monorails
Conveyors
Hoists and cranes
Sistem penyimpanan
Unitizing equipment (Peralatan Penakaran)
Automatic identification and data capture
Bar codes
RFID (radio frequency identification)
Other AIDC (automatic identification and data capture)
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

16. Waktu yang Dihabiskan untuk
Material Handling
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

17. Inspeksi (inspection) dan Pengujian (Testing)
Inspeksi – pengujian produk dan komponennya untuk menentukan
apakah mereka sesuai dengan spesifikasi desain
Inspeksi untuk variabel - pengukuran
Inspeksi untuk atribut – gaging (pembandingan)
Pengujian – pengamatan produk (komponen, bahan, sub perakitan)
selama operasi sesungguhnya atau keadaan yang mungkin
terjadi selama operasi
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

18. Koordinasi dan Pengendalian
Aturan pemrosesan individu dan operasi perakitan
Kendali Proses
Kendali Mutu
Manajemen aktivitas level pabrik
Production planning and control (PPC)
Kendali Mutu
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

19. Fasilitas Produksi
Sebuah perusahaan manufakturing mencoba untuk menata
fasilitas dengan cara yang paling efisien untuk mencapai misi
perusahaan.
Tipe perusahaan tertentu dikenali sebagai memiliki cara yang
paling sesuai untuk mengelola tipe manufakturing tertentu.
Tipe yang paling sesuai bergantung pada:
Tipe produk yang dibuat
Jumlah produksi
Varitas Produk
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

20. Kuantitas Produksi
Jumlah unit komponen atau produk yang mampu dibuat oleh pabrik
setiap tahun
Tiga batas jumlah:
1. Produksi Rendah: 1 sd.100 unit
2. Produksi Medium: 100 sd. 10,000 unit
3. Produksi Tinggi: 10,000 - jutaan unit
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

21. Varitas Produk
Merujuk ke jumlah produk atau komponen yang berbeda
yang didesain atau dibuat pada sebuah pabrik.
Hubungan terbalik antara jumlah dan varitas produk pada
operasi pabrik
Varitas produk lebih rumit daripada jumlah produk
Hard product variety – produk sangat berbeda
Komponen yang tidak umum pada perakitan
Soft product variety – sedikit perbedaan antar produk
Kebanyakan komponen yang umum pada perakitan
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

22. Varitas Produk vs. Kuantitas Produk
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

23. Kuantitas Produk Rendah
Job shop – membuat produk dengan jumlah sedikit dengan
kekhususan dan penyesuaian terhadap pesanan.
Produk biasanya kompleks (mis. mesin-mesin khusus, prototip,
kapsul untuk ruang angkasa (space capsules)
Peralatan untuk keperluan umum
Tata letak pabrik:
Posisi tetap (Fixed position)
Tata letak proses (Process layout)
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
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24. Fixed-Position Layout
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25. Process Layout
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26. Kuantitas Produksi Menengah
1. Batch production – sebuah kelompok (batch) dari produk tertentu
dibuat, kemudian fasilitas diubah jika hendak mengganti dengan
produk lain.
Pengubahan memakan waktu – set-up time (waktu persiapan)
Tata letak yang umum – process layout
Hard product variety
2. Cellular manufacturing – produk-produk campuran dibuat tanpa
perubahan yang signifikan di antara pergantian produk
Tata letak yang umum – cellular layout
Soft product variety
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
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27. Cellular Layout
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28. Produksi Tinggi
1. Kuantitas Produksi – Peralatan dipersiapkan untuk membuat
produk tunggal
Mesin Standar dilengkapi perkakas untuk produksi tinggi
(mis. stamping presses, molding machines)
Tata letaknya – process layout
2. Flow line production – Multiple workstations disusun secara
berurutan
Produk memerlukan langkah yang panjang pemrosesan
atau perakitan
Tata letak produk yang paling umum dipakai
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

29. Tata Letak Produk (Product Lay out)
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30. Hubungan antara Tata Letak
dan Tipe Fasilitas Produk
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31. Hubungan Produk/Produksi
Jumlah Total Unit Produk = Qf = ∑Qj
j =1
Varitas Produk
Hard product variety = beda antar produk
Soft product variety = beda model di antara produk
Kompleksitas Produk dan Komponen
Kompleksitas produk np = jumlah komponen dalam produk
Kompleksitas Komponen no = jumlah operasi per komponen
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
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P
Qf=jumlah tahunan model j,
Qi= jumlah total komponen atau produk dibuat di pabrik
Contoh 2.1

32. Model Operasi Pabrik
Penyederhanaan untuk tujuan konseptualisasi:
Jumlah total unit produk Qf = PQ
Jumlah total komponen yang diproduksi npf = PQnp
Jumlah operasi total nof = PQnpno
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
Contoh 2.2

33. Keterbatasan dan Kemampuan
Sebuah Pabrik Manufakturing
Kapabilitas manufakturing – keterbatasan dari segi teknik dan fisik
dari sebuah pabrik manufakturing dan masing-masing bagiannya
Tiga dimensi kapabilitas manufakturing:
1. Kapabilitas Pemrosesan scr Teknologi – ketersediaan
rangkaian proses manufakturing
2. Ukuran fisik dan bobot produk
3. Kapasitas produksi (kapasitas pabrik) – jumlah produksi
yang dapat dibuat pada waktu tertentu
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

34. Lean Production
Pengoperasian pabrik dengan sumber daya yang minimum namun tetap
mendapatkan jumlah pekerjaan yang dapat dicakup secara
maksimum.
Sumber daya meliputi: buruh, peralatan, waktu, ruang dan bahan
Juga bermakna penyelesaian produk dengan waktu sesingkat
mungkin untuk mendapatkan tingkat mutu yang memuaskan
konsumen .
Ringkasnya, lean production bermakna bekerja lebih dengan
sesuatu yang terbatas untuk namun hasil dengan mutu tinggi.
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

35. Lean Production dan
Aktivitas Manufakturing
Aktivitas manufakturing dapat dibagi menjadi tiga kategori:
1. Value-adding activities – kontribusi nilai terhadap unit kerja
2. Auxiliary activities – mendukung aktivitas penambahan nilai
3. Wasteful activities – tidak menambah nilai dan juga tidak
mendukung aktivitas penambahan nilai.
Jika tidak dibuat, tidak akan mengurangi nilai produk
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

36. Program yang dikaitkan dengan
Lean Production
Just-in-time delivery of parts
Worker involvement
Continuous improvement
Reduced setup times
Stop the process when something is wrong
Error prevention
Total productive maintenance
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.