3. Manufacturing –– HHiissttoorriiccaall PPeerrssppeeccttiivvee
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.
4. Manufacturing –– HHiissttoorriiccaall PPeerrssppeeccttiivvee
NNuummeerriiccaall ccoonnttrrooll ((11997700ss)
– Combining the versatility of general purpose machines
with the precision and control of special-purpose
machines.
CCoommppuutteerr iinntteeggrraatteedd mmaannuuffaaccttuurriinngg ((11998800ss)
– Pervasive use of computers to design products, plan
production, control operations, and perform various
business-related functions.
AAggiillee MMaannuuffaaccttuurriinngg // MMaassss CCuussttoommiizzaattiioonn ((11999900ss)
– Creation of highly flexible organizational structures
that allow systems to produce highly customized
product
10. PPrroodduucctt VVoolluummee vvss.. PPrroodduucctt
VVaarriieettyy
High
Volume
Low High
Variety
Low
Continuous
Flow Line /
Transfer Line
Cellular /
Flexible Mfg. Sys.
Job Shop
12. MMaannuuffaaccttuurriinngg SSyysstteemm
OOppeerraattiioonn
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
Hierarchical System Structure
– Shop
– Workstation
– Equipment
13. PPrriinncciipplleess ooff MMaannuuffaaccttuurriinngg
SSyysstteemmss
Little’s Law
– WIP = Production Rate × Throughput Time
(L=lW)
Matter is conserved
Larger scope implies reduced reliability
Objects decay
Exponential growth in complexity
– M components, N states ==> NM possible
system states
14. PPrriinncciipplleess ooff MMaannuuffaaccttuurriinngg
SSyysstteemmss
Technology advances
System components appear to behave
randomly
Limits of (Human) rationality
Combining, simplifying, and eliminating
save time, money, and energy
16. PPrroodduucctt DDeessiiggnn
Idea
» Understanding and identifying
customer needs
» Initial Design
» Feasibility study to determine initial
functionality
Prototype
Market Research
» Market potential, economic analysis,
strategic assessment
Design Refinement
» Functional specifications
Detailed Specifications
» Detailed design considering functions,
quality/reliability, manufacturing, etc.
Idea Generation
(Product Design)
Feasibility Study
(Performance Specification)
Preleminary Design
(Prototype)
Final Design
(Final Design Specification)
Process Planning
(Manufacturing Specication)
17. PPrroodduucctt DDeessiiggnn ((CCoonntt..))
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
18. PPrroodduucctt DDeessiiggnn ((CCoonntt..))
Computer-Aided Design
– Use of computer graphics to assist in the creation,
modification, and analysis of a design
– Common uses
» Geometric modeling
» Automated drafting and documentation
» Engineering analysis
» Design analysis
CAD/CAM
– Generation of manufacturing instructions directly from
CAD design data
19. PPrroodduucctt LLiiffee CCyyccllee
Product (Consumer) Perspective
– Inception
– Design
– Production
– Use
» Maintenance and repair
– Disposal
– Reuse, recycle, scrap
Production System
(Manufacturer)
Perspective
Design
Ramp-up
Maturity
Decline
Time
Sale
20. PPrroodduuccttiioonn SSyysstteemm LLiiffee CCyyccllee
Lifecycle
– 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