Perencanaan dan Pengendalian Produksi

INTRO

Production Planning & Control

Concerning management of all activities from material and component acquisition to fabrication and assembly processes and up to delivery and distribution to customers

Production Planning &

Control (PPC)

Planning activities for ensuring customer

demand fulfillment in light of resources

constraint

Controlling activities for evaluation of planning implementation and decision making to

overcome implementation

deviation

Manufacturing System• Production

Planning and Control (PPC) performed in a manufacturing system

• What is manufacturing system ?

PRODUCTION PLANNING

PRODUCTION CONTROL

MANUFACTURING PRODUCTION

PRODUCTION MANAGEMENT SYSTEM

PRODUCTION SYSTEM

DESIGN MARKETING

QUALITY ASSURANCE

MANUFACTURING SYSTEM

ENTERPRISE SYSTEM

HUMAN RESOURCE

MANAGEMENT

GENERAL MANAGEMENT

SYSTEM

FINANCIAL SYSTEM

Material FlowMaterial Flow

Definition of Manufacturing

• Manufacturing is defined as (CIRP 1983):A　 Series of interrelated activities and operations involving the design, materials selection, planning, manufacturing production, quality assurance, management and marketing of products of the manufacturing industries.

.

Manufacturing Cycle

Product DesignMarketinng Process

Design

Inventory Control

Production Planning

Design of Work Method, Standard

Time and Productivity Improvement

Inventory Fabrication Process receiving

Custo

mers

Suppl

iers

Quality Control

Production Control

Process Control

Equipment Control

Shipping

Key Performance Indicators for PPC

Quality

Cost

Delivery Time

Examples

Q

C

Examples

D

Framework of PPC• PPC is a process• The framework of

the process can be described as follows:

RESOURCES PLANNING

PRODUCTION PLANNING

DEMAND MANAGEMENT

MASTER PRODUCTION

SCHEDULE

MATERIAL REQUIREMENT

PLANNING

DETAIL CAPACITY PLANNING

MATERIAL AND CAPACITY PLAN

ORDER RELEASE SYSTEM

PURCHASING SYSTEM

SHOP FLOOR ACTIVITY CONTROL

VENDOR CONTROL SYSTEM

FRONTEND

ENGINE

BACKEND

Planning HierarchyStrategic Planning

Tactical Planning

Execution Planning

•What type of product will be manufactured•Manufacturing system design

•Detailing strategic plan•Material and capacity requirement•Planned order release

•Dispatching planned order release•Day-by-day basis•Minimizing manufacturing lead time and work in process

Planning HierarchyPlant Level Aggregate Plan

Department Level Material &Capacity Plan

Machine Level OperationSchedule

PPC and Manufacturing System Management

• PPC is part of bigger manufacturing system management

• Aim for the system or manufacturing enterprise efficiency, productivity and growth

Strategic Planning Cycle- Business planning- Marketing Planning- Manufacturing Planning- Facility location and layout- Product Development- Process technology development

Long Range Planning Cycle- Sales forecast- Aggregate production planning

Medium Range Planning Cycle:- Master Scheduling- MRP- CRP

Short range Scheduling- SFC- Purchasing- Quality cont

Order Response • Define how manufacturing system (producer)

responding customer order• Concept of CODP (Customer Order Decoupling

Point): where customer meet producer

Make to StockAssemble to

Order

Make to Order

Engineer to Order

Some Issues on Order Response

Aspect MTS ATO MTO ETOInterface between consumer-producer

Very far or not exist

Especially in sales process

Engineering and sales process

Very close especially in engineering

processBill of Material (BOM)

Standard BOM

Planning BOM BOM is unique for each order

(customized)

BOM is unique for each order

(customized)Master Production Schedule unit

SalesMajor

component End Product End Product

Basis for production planning

Forecast Forecast and backlog

Backlog and order

Customer order

Measure to face uncertainty

Safety stock Overplanning of component

and subassembly

No control No control

Type of Production System

• Where the raw material and components transformed into product which have added value, quality and competitive cost

Type DescriptionFlow Shop Shop arrange according to the

sequence of fabrication and assembly processes-Small-Batch Line Flow non discrete in low volume, ex: pharmacies-Large-Batch (Repetitive) Line Flow discrete in large volume-Continuous Line Flow fluids, powder,metal, etc

Job Shop Shop arrange according to similarity of process facility

Fixed Shop Product positioned fixed to a certain shop location

JOB SHOP

FLOW SHOP FIXED SHOP

Supply Chain System

Product Documentation

• Bill of Material: shows product structure and its assembly connection and number of part/component required for each assembly

Clipboard

Rivet(2)

IronRod

(3 in.)

Spring(1)

SpringSteel

(10 in.)

Level 0

Level 1

Level 2

Level 3

Bottom Clip(1)

Top Clip(1)

Pivot(1)

SheetMetal(8 in2)

Clip Assembly(10)

SheetMetal(8 in2)

Product Structure Tree

Board(1)

Pressboard(1)

Finish(2oz.)

Have a Nice Day