an dan perancangan produk

8/3/2019 an Dan Perancangan Produk

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PERENCANAAN DAN

PERANCANGAN PRODUK

Dr. Mohammad Abdul Mukhyi, SE., MM.


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Process Planning and Design

Inputs:

Product/Service Information

Production System Information

Operations Strategy

Process Plannin & Desi n:

Outputs:

Process Technology

Facilities

Personnel Estimates

Select process type Vertical integration studies

Process/Product studies

Equipment studies

Production procedures studies

Facilities studies

2Dr. Mohammad Abdul Mukhyi, SE., MM


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Major Factors AffectingProcess Designs

Nature of product/service demand

Degree of vertical integration

Production flexibility

Degree of automation Product/Service quality



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Tingkat Integrasi Vertikal Integrasi vertikal adalah jumlah dari rantai

distribusi dan produksi yang kepemilikan dikuasaisuatu perusahaan.

Menentukan berapa banyak proses produksi yangdiperlukan untuk direncanakan dan dirancang.

Ke utusan en inte rasian didasarkan ada bia a,

ketersediaan modal, kualitas, kemampuanteknologi, dan sebagainya.

Strategi outsourcing (menurunkan derajat tingkatpengintegrasian) adalah proses outsourcing yangbereaksi lebih cepat dalam mengantisipasiperubahan kebutuhan pelanggan, tindakanpesaing, dan teknologi.



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Fleksibilitas Produksi

Product flexibility -- ability of the

production (or delivery) system toquickly change from producing

to another.

Volume flexibility -- ability to quickly

increase or reduce the volume ofproduct (or service) produced (ordelivered).



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Degree of Automation Advantages of automation

Improves product quality Improves product flexibility

Reduces labor and related costs

Disadvantages of automation Equipment can be very expensive

Integration into existing operations canbe difficult



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Types of Process Designs

Product-Focused

Process-Focused

Group Technology/Cellular

anu ac ur ng



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Product-Focused

(Production Line)

Proses ( konversi) diatur berdasarkan padaurutan operasi untuk menghasilkan suatu produk

atau menyediakan suatu jasa

Dua format umum

Unit terpisah

Proses ( Berlanjut) Contoh

Mobil

Penghisap debu



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Product-Focused Production

22

3311

44

7755

AssembliesAssemblies

Raw MaterialRaw Material ComponentsComponents

Fin. GoodsFin. Goods

Product/Material FlowProduct/Material Flow

Production OperationProduction Operation

PurchasedPurchased

Components,Components,

SubassembliesSubassemblies

66

..



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Process-Focused (Job Shop) Proses (konversi) diatur berdasarkan

pada jenis proses, seperti proses

dikelompokkan bersama-sama Products/Services (pekerjaan) dipindah

dari departemen (kelompok proses) ke

epartemen men asar an pa apekerjaan-pekerjaa tertentu dalammemproses kebutuhan

Contoh Perbaikan body repair

Pekerjaan tukang kayu



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Process-Focused Production

CuttingCutting AssemblyAssembly SandingSanding FinishingFinishingPlaningPlaning ShapingShaping11 55 7722

33

66

22Job AJob A

Custom Woodworking Shop

DrillingDrilling TurningTurning

33

11 66

44Job BJob B

44 55



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Group Technology/CellularManufacturing

Group technology forms parts with

similar processing requirements intopart families or groups.

A manufacturing cell is anarrangement of the

processes requiredto make the partsthat make up the group.



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Group Technology/Cells Advantages (relative to a job shop)

Menyederhanakan proses perubahansistem kerja

Mengurangi variabilitas tugas

e mengara an ru e me a u s s em Peningkatan pengendalian mutu

Perencanaan dan pengendalian

produksi lebih sederhana Otomasi yang lebih sederhana



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Group Technology/Cells

Disadvantages

Duplikasi peralatan

Pemanfaatan peralatan rendah

berkaitan dengan kelompoknya adalahtidak efisien



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Product/Process Design &

Inventory Policy

Standard Products and Produce to Stock

Forecast/orders drive production schedule Maintain pre-determined finished-goods

levels

Custom Products and Produce to Order

Orders set production schedule and drivematerial deliveries

Design time may be required beforeproduction can be scheduled



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Process Design in Services Quasi manufacturing -- produksi barang-

barang berlangsung sepanjang lini

produksi dengan hampir tidak adainteraksi pelanggan

Customer-as-participant tingginya

r rproses meningkatkan ayanan

Customer-as-product -- layanan diberikan

sampai ke pribadi pelanggan



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Deciding Among Processing

Alternatives

Batch Size and Product/Service Variety

Capital Requirements Economic Analysis

Operating leverage - relationship between afirms annual costs and its annual sales

Break-even analysis

Financial analysis



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Process Design Depends on

Product Diversity and Batch Size

ize

ProductFocused,

DedicatedSystems

ProductProductFocused,Focused,

Batch

S

Number of Product Designs

BatchBatchSystemSystem

ProcessProcess--Focused,Focused,

Job ShopJob Shop

CellularCellularManufacturingManufacturing



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Flexible Manufacturing System

10001000

100100

GeneralGeneralpurposepurpose

Work cellsWork cellsCIMCIM

FlexibleFlexible

ProductsProducts

1010

11

11 1010 100100 10001000 1000010000 100000100000 10000001000000

SystemSystem

ocuseocuse

automationautomation

DedicatedDedicatedautomationautomation

VolumeVolume



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Economic Analysis

Cost Function of Processing Alternatives

If capital is not a factor, the process designpreferred depends upon product volume

Operating Leverage Relationship between firms annual costs and

annual sales

If high % firms costs fixed, then high degree ofoperating leverage

Small % change in sales drives large % changein operating income

. . . more



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Economic Analysis Break Even Analysis

Formulas for comparing processes

Cannot incorporate uncertainty, costsassumed over entire range of values,

value of money

Financial Analysis

Incorporate time value of money .... netpresent value, internal rate of return,etc.



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Cost Functions of Processing

Alternatives

Annual Cost of Production ($000)

2,0002,000

100,000100,000 250,000250,000

Units

ProducedPer Year

CellularManufacturing

Preferred

u oma e

Assembly LinePreferred

Job

ShopPreferred500500

1,0001,000

1,5001,500



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Example: Cost Functions

of Processing Alternatives

Three production processes - A, B, and C - have

the following cost structure:

Fixed Cost Variable Cost

A $120,000 $3.00

B 90,000 4.00

C 80,000 4.50

What is the most economical process for avolume of 8,000 units per year?



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Example: Cost Functions

of Processing Alternatives Most Economical Process at 8,000 Units

TC = FC + v(Q)

= =, . , ,

B: TC = 90,000 + 4.00(8,000) = $122,000 per yearC: TC = 80,000 + 4.50(8,000) = $116,000 per year

Process C has the lowest annual cost.



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Deciding Among Processing

Alternatives Bagan perakitan ( Gozinto Tabel)

Pandangan makro bagaimana materialdipersatukan

Titik awal untuk memahami kebutuhan tataruangpabrik, kebutuhan peralatan, kebutuhan latihan

Tabel Proses Rincian bagaimana cara membangun produk

pada masing-masing proses

Meliputi kebutuhan material, jenis aliran prosesproduksi, waktu proses produk sampai masing-masing step



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Stages of a Products Life Cycle

Automobile

Video Recorder

Compact Disc Player

Cell Phone

Introduction Growth Maturity Decline

B&W TVFax Machine

Color Copier



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Product Life Cycle & Sales, Cost, and

Net Revenues

ost&P

ro

fit

SalesRevenue

NetRevenue

Loss

1 2 3 4 5

Introduction Growth Maturity Decline

Sales,

C

TimeTime



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Operations Emphasis in Product Life Cycle

Stage Operations Emphasis

Introductory ResearchProduct developmentProcess modification & enhancement

Growth Capacity determination/enhancement

Maturity High volume production with innovationCost controlReduction in options

Paring down of product lineDecline Termination of production if necessary



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American Approach to Product Design

Research Developmentt

Manufacturing

ProcessDesign

Manufacturing Product



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Japanese Approach to Product Design

Research, Development, and

Manufacturing Process Design

Manufacturing Product



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Product/Service Design

Kapan suatu product/service dirancang:

Karakteristik terperinci produk/jasa adalah

establis Karakteristik produk/jasa yang secara

lan sun mem en aruhi ba aimana

produk/jasa dapat diproduksi/dikirim Bagaimana produk/jasa adalah

diproduksi/dikirim ditentukan disain

produksi/sistem pengiriman.



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Product/Service DesignDesain produk/jasa secara langsungmempengaruhi:

Kualitas produk/jasa

Bia a roduksi/ asa

Kepuasan pelanggan



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Product/Service Design and

Development Sumber.

Mengembangkan produk/jasa baru Membawanya ke pasar lebih cepat.

Meningkatkan produk/jasa sekarang.

Merancang untuk mempermudahproduksi.

Perancangan mutu.

Perancangan dan pengembangan jasabaru.



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Sources of Product/Service

Innovation

Customers

Managers

Marketing

Operations Engineering

Research and Development (R&D)

Basic research

Applied research



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Steps in Designing and

Developing New Products

1. Technical and economic feasibility studies

2. Prototype design3. Performance testing of prototype

4. Market sensing/evaluation and economic

evaluation of the prototype5. Design of production model

6. Market/performance/process testing andeconomic evaluation of production model

7. Continuous modification of production model



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Getting New Products to Market

Faster

Speed creates competitive advantages

Speed saves money Tools to improve speed:

teams Computer-aided design/computer-

aided manufacturing (CAD/CAM)

Simultaneous (concurrent) engineering



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Improving the Design

of Existing Products/Services

Focus is improving performance, quality, andcost

Objective is maintaining or improving marketshare of maturing products/services

Small, steady (continuous) improvements canadd up to huge long-term improvements

Value analysis is practiced, meaning design

features are examined in terms of theircost/benefit (value).



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Designing for Ease of Production

Ease of Production (Manufacturability)

Specifications - Precise information about the

characteristics of the product Tolerances - Minimum & maximum limits on a

dimension that allows the item to function ases gne

Standardization - Reduce variety among a groupof products or parts

Simplification - Reduce or eliminate the

complexity of a part or product



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Designing for Quality

Crucial element of product design is itsimpact on quality

Quality is determined by the customersperception of the degree of excellence of

Covers the principles of designingproducts/services for quality

. . . more



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Designing and Developing New

Services

Three general dimensions of service

design are: Degree of standardization of the

Degree of customer contact indelivering the service

Mix of physical goods and intangibleservices



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Literatur N. Gaither and Frazier, Production and

Operations Management, 8th Edition,

Duxbury Press, NY, NY, 1999. (Road server) Handouts for most classes

.

handouts can be accessed at: _HYPERLINK http://road.uww.edu__http://road.uww.edu_

The handouts are under my name(HOUSEMAJ) and Course #: 250306.

Dr. Mohammad Abdul Mukhyi, SE., MM41

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