Introduction to Manufacturing in Batam and Understanding Basic Concepts of Manufacturing as Requirements to Start a Career in Manufacturing Industry from Engineering Field.

1. THE 9TH AISTSSE 2022
Introduction to Manufacturing in Batam and
Understanding Basic Concepts of Manufacturing
as Requirements to Start a Career in
Manufacturing Industry from Engineering Field.
Romansyah Nst
8 November 2022

2. Self Introduction
01
Manufacturing in Batam
02
Introduction to Manufacturing
03
Skills Needed in Manufacturing
04
Content

3. Self Introduction
THE 9TH AISTSSE 2022

4. Name : Romansyah Nst
Occupation : Process Engineer / Manufacturing Engineer
Education : UNIMED – FMIPA - Chemistry 2013
Domicile : Batam City, Riau Islands
Experience:
1. Manufacturing Engineer
PT. Casco Automotive Group March 2022 - Current
An Amphenol Company – Manufactures connectors electrical systems for cars.
2. Process Engineer
PT. TDK Electronics Indonesia May 2021 – March 2022
Temperature & Pressure Sensors Business Group (NTC Sensors).
3. Process Engineer
PT. Philips Industries Batam April 2018 – May 2021
Manufactures electronics Business Unit Domestic Appliance for Garment Care (Steam Iron Products).
Hello!
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5. PHILIPS
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Finished goods product
Supplier : TDK, Amtek, Prioritas, etc
Customer : General public, Hospital
Garment Care – Steam Iron, Stimmer
Mother & Child care - Baby pacifier
Personal Care - Grooming
Oral Healthcare - Electric toothbrush
Business Unit is an organizational structure such as a department or team
that produces revenues and is responsible for costs.
Unit Bisnis adalah struktur organisasi seperti departemen atau tim
yang menghasilkan pendapatan dan bertanggung jawab atas biaya.
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6. 6
Semi Finished Goods Product
Supplier : Volex, Prioritas,etc
Customer : Philips, Toyota, FORD,
Automotive electronics - Car
Industrial electronics - Industrial Refrigerator, Boiler, etc
Home appliances - Rice cooker, AC, etc
Medical appliances - Health equipment
Temperature Sensor Specialist - NTC (Negative
Temperature Coefficient) dan Thermistor PTC
(Positive Temperature Coefficient).
TDK
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7. 7
Semi Finished Goods Product
Supplier : SP Manufacturing, Goodly, etc
Customer : FORD, GM, FCA, LMC, Volvo, etc
GM - High Voltage
Power Outlets
Volvo – Connectivity USB
FORD – Exterior HVPO
FORD – DC/AC Inverters
An Amphenol Group - Providers of high-technology interconnect, sensor and antenna solutions.
Penyedia solusi interkoneksi, sensor, dan antena berteknologi tinggi.
Markets Served - Automotive, Broadband Communications, Commercial Aerospace, Industrial, etc
Otomotif, Komunikasi Broadband, Ruang Angkasa Komersial, Industri, dll
CASCO
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8. Manufacturing in Batam
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9. Batam City
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10. Industrial Estate in Batam
1. Batamindo Industrial Park
2. Bintang Industrial Park I
3. Bintang Industrial Park II
4. Cammo Industrial Park
5. Citra Buana Industrial Park I
6. Citra Buana Industrial Park II
7. Citra Buana Industrial Park III
8. Dragon Industrial Park
9. Executive Industrial Park I
10. Hijrah Industrial Park
11. Horizon Industrial Park
12. Indah Industrial Park
13. Kabil Integrated Industrial Park
14. Kara Industrial Park
15. Kawasan Industri Sekupang Makmur Abadi
16. Kawasan Industri Wiraraja
17. Latrade Industrial Park
18. Lytech Industrial Park
19. Malindo Industrial Park
20. Mega Cipta Industrial Park
21. Panbil Industrial Estate
22. Puri Industrial Park 2000
23. Sarana Industrial Point
24. Taiwan International Park
25. Tunas Industrial Estate
26. Union Industrial Park
batampos.co.id
26 Industrial
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11. KABIL
Industrial Estate in Batam
SEKUPANG
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12. Type of Manufacturing in Batam
batampos.co.id
1. Miscellaneous Industry 38 companies
2. Electronics and Electrical Industry 98 companies
3. Furniture Industry 12 companies
4. Paper and Cardboard Industry 36 companies
5. Chemical Industry 46 companies
6. Leather, Plastics and Packaging Industry 138 companies
7. Industrial Metal an Machinery 211 companies
8. Food and beverage industry 41 companies
9. Oil and gas industry and supporting 49 companies
10. Tourism and creative industries 36 companies
11. Tobacco processing industry 20 companies
12. Shipping industry and supporting 138 companies
13. Textile and textile products industry 28 enterprises
14. Livestock and fishery industry 7 companies
15. Industrial Services 101 companies
16. Construction Industry Services 118 companies
1.309 Companies
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13. Industrial Estate in Batam
Electronics Industry Chemical Industry Packing Industry
Industrial Metal shipyard Industry Oil & Gas
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14. Manufacturing Related to Chemistry
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15. Introduction to
Manufacturing
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16. Definition of Manufacturing
A system in which raw materials are processed from one form into another, known as a product,
gaining a higher or added value in the process and thus creating wealth in the form of a profit.
Sebuah sistem di mana bahan mentah diproses dari satu bentuk ke bentuk lain, yang dikenal sebagai produk,
memperoleh nilai lebih tinggi atau lebih dalam proses dan dengan demikian menciptakan kekayaan dalam bentuk
keuntungan.
Product
Raw material
Manufacturing
system
Value added
by processing Profit
Basic model of manufacturing system adding value
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17. Inputs and outputs
of a manufacturing system
Inputs and outputs of a manufacturing system
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18. Manufacturing organizational
structures
Forecasting Product
design
Production
planning
Recruitment Buying
Order
processing Research and Quality
development assurance
Plant
maintenance
Training and
development
Industrial
relations
Capital
finance
Vendor
Cost rating
accounting
Market
research Standards and
specifications
Service and
distribution Industrial
engineering
Budgeting
Investment
analysis
Financial
reporting
Data
processing
Manufacturing
engineering
Production
control
Production
Accounts
Finance
marketing
Purchasing
Finance and
accounts
Human
resources
Manufacturing
Engineering
Sales and
Managing
Director
A functional structure
Safety
Logistic
Store
Training
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19. Engineering and Production Team
Direct
Staff / Indirect /
Production Support
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20. Production RM receipt
Inspection
Material
Storage
Production Despatch
Material
OK or Not
?
OK
Send to
supplier
Reject
Are the
parts ok?
Rework
Quality
Alert Note
Scrap Yard
OK
Packaging &
Labelling
Not OK
Scrap Note
as per
packing std
Receiving
Insp. report
Production process occurs.
Tempat terjadinya process produksi.
Production Line
Production Process
Stages of turning raw material
into finished products with the
help of machines and operators.
Tahapan mengubah raw material
menjadi produk jadi dengan
bantuan mesin dan operator.
Process Flow Chart Process Production
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21. Production Line – Main Assy / Assembly line
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22. Production Line – Main Assy / Assembly line
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23. Production Line – Coating
Loading
Unloading
Spray Booth
Curing oven
Conveyor
Jig
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24. Process Manufacturing in Line
Let’s Watch Video Process
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25. Sol-Gel
Coating
How to Produce Steam Iron at Philips
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26. How to Produce Steam Iron at Philips
Deco Printing
Sol-gel Coating Spray Painting
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27. How to Produce Steam Iron at Philips
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28. How to Produce Steam Iron at Philips
Machine Pad Printing
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29. Process Assembly Joining at Casco
Pressing Inserting
Screwing
Testing
Packing
Connecting
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30. Process Assembly Joining at Casco
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31. Product Knowlegde
Part No : 1213600118
Desc : GM T1XX 110V
BOM : Raw material list
Drawing : Specification
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32. Product Knowlegde
1
2
3
3
4
4
5
6
7 8
9
10
9
11
12
13
14
16
15
17
18
18
19
19
3
4
20
21
22
23
18
24
25
1. Main PCBA
2. Terminal Nema 20 (2x)
3. Spring cover (3x)
4. Hinge (3x)
5. Sensor PCBA nema20
6. Supporter
7. Pig tail
8. Connector sensor 1
9. Connector sensor 2
10. Matting CB1
11. Matting CB2
12. Housing
13. Cover storage bin
14. Rubber seal housing
15. Enable button
16. Rear Housing
17. Sensor PCBA nema20+30
18. Terminal Nema 20
19. PIN cover (3x)
20. Terminal Nema 30 (3)
21. Circuit Breaker (2x)
22. Light Guide
23. Cover Outlet nema 20/30 (3x)
24. Rubber Seal Cover (3x)
25. Tapping Screw (33x)
Bill of Materials (BOM) = Material used in making the finish good
Non–BOM = Machine,
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33. Project Release
Customer
Step 1
• Market demand
• Improvement
R&D / Designer
Step 2
• Designing
• Lab scale trial
• BOM & Drawing, etc
NPI
Step 3
• APQP
• Time management
• As a liaison between departments
Engineering
Step 4
• Review,
• Manufactur scale trial
• Release to production
• Documentation (WI, PFMEA, PSW, PPAP)
• Training
Production
Step 5
• Mass production
Role Quality on Production
To ensure quality in :
1. Raw material
2. in process
3. finish good
Customer Complaint
Deviation Process /
Product
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34. Skills Needed in
Manufacturing
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35. Skill Need it
1. Communication
• Meeting
• Email / Chat
2. System Application and Product (SAP)
• Information material & product
3. Lean Manufacturing
• Eliminate waste & sustainably deliver value to the
customer
4. Problem Solving
• Issue
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36. Lean Manufacturing
Lean is an effort to continuously improve by eliminating waste (activities that are not
value added) to provide value to customers.
Lean adalah suatu upaya perbaikan berkesinambungan dengan cara menghilangkan pemborosan/waste
(aktivitas yang tidak bernilai tambah) untuk memberikan nilai kepada pelanggan.
Benefits of elimination of waste:
- Faster leadtime Leadtime lebih cepat
- Improved product quality Kualitas produk meningkat
- Low operating costs Biaya operasi rendah
- Culture of improvement increases Budaya perbaikan meningkat
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37. Value & Waste
Categories of activity in a process:
1. Value-added activity
• add value to the product, paid customers (Assy cover to housing)
menambah nilai produk, dibayar pelanggan
2. Non value-added activity
• does not add value to the product, does not pay customers ( Screening cover OK & Shortmold)
tidak menambah nilai produk, tidak dibayar pelanggan
3. Value enabler
• not paid but other processes required (Add Camera detection printing cover)
tidak dibayar tapi dibutuhkan proses lain
Value-added
Non value-added - Screeing
Value enabler
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38. Value & Waste
Defect / Rework
Defective or reprocessed products will not be paid by customers.
Produk cacat atau pengolahan ulang tidak akan dibayar pelanggan.
Over production
Exceeding demand & Ahead of schedule.
Melebihi permintaan& Lebih awal dari jadwal
Waiting
The waiting process can occur processes that do not flow smoothly.
Proses menunggu bisa terjadi proses yang tidak mengalir lancer
Not utilizing people
Failure to take advantage of the time and intellectuals of personnel leads to
decreased productivity.
Kegagalan memanfaatkan waktu dan intelektual personil menyebabkan produktivitas menurun
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39. Value & Waste
Transportation
Unnecessary or excessive removal/transport.
Pemindahan / pengangkutan yang tidak diperlukan atau berlebihan
Inventory
Excessive inventory will result in: capital increase, use of the room, additional
administration, risk of damage
Inventori berlebihan akan mengakibatkan:penambahan modal, penggunaan ruangan, administrasi
tambahan, resiko kerusakan
Motion
Unnecessary movements for example to search for goods, tools, files.
Gerakan yang tidak diperlukan misalnya untuk mencari barang, alat, file.
Extra processing
The addition of processes that are not needed / do not add value to the
product will burden production costs and result in time/labor inefficiencies.
Penambahan proses yang tidak diperlukan / tidak menambah nilai produk akan membebani biaya
produksi dan mengakibatkan inefisiensi waktu/tenaga.
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40. Prinsip Lean
2. Map the
VALUE STREAM
4. Establish
PULL
5. Seek
PERFECTION
1. Identify
VALUE
3. Create
FLOW
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41. LEAN TOOLS
No Tools Information
1. 5S Arrangement of work areas to eliminate waste caused by poorly organized work areas.
Pengaturan area kerja untuk mengeliminasi pemborosan yang ditimbulkan akibat area kerja
yang kurang terorganisir.
5S = Seiri (Sort), Seiton (Storage), Seiso (Shining), Seiketsu (Standardize), Shitsuke (Self-
Discipline)
2. Andon A visual system that informs the status of the process so that abnormalities can be
detected immediately and action can be taken immediately.
Sistem visual yang menginformasikan status proses sehingga abnormalitas bisa langsung
terdeteksi dan tindakan bisa segera diambil.
3. Gemba Direct observation in the field of the place where the process / activity is carried out to
improve the understanding of the process and its problems.
Pengamatan langsung di lapangan tempat di mana proses/aktivitas dilakukan untuk
meningkatkan pemahaman proses beserta permasalahannya.
4. Heijunka A form of production scheduling that aims to make batches smaller by
sequencing/combining product variants in the same process.
Bentuk penjadwalan produksi yang bertujuan untuk membuat batch lebih kecil dengan
pengurutan/kombinasi varian produk dalam proses yang sama.
5. Hoshin Kanri Alignment between the company's strategy, management planning, and work on the
production floor.
Penyelarasan antara strategi perusahaan, perencanaan manajemen, dan pekerjaan di lantai
produksi.
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42. LEAN TOOLS
6. Jidoka Designing tools that have partial automation capabilities and can stop when defects are
detected.
Perancangan alat yang memiliki kemampuan otomatisasi parsial dan bisa berhenti saat ada
cacat terdeteksi.
7. Kaizen A strategy in which the workers work together proactively to make improvements in the
production process.
Strategi di mana para pekerja bekerja sama secara proaktif untuk melakukan perbaikan dalam
proses produksi.
8. Kanban The method of regulating the flow of goods, both internal and external, by means of signal
cards.
Metode pengaturan aliran barang, baik internal maupun eksternal, dengan menggunakan
kartu sinyal.
9. OEE The technique of measuring the productivity of a process is based on three measures:
availability, performance, and quality.
Teknik pengukuran produktivitas suatu proses berdasarkan tiga ukuran: availabilitas, kinerja,
dan kualitas.
10. Poka Yoke Designing error detection and prevention to achieve zero defects.
Perancangan deteksi dan pencegahan kesalahan untuk mencapai zero defects.
No Tools Information
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43. No Tools Keterangan
11. Single Minute Exchange of
Die
Reduced setup time.
Pengurangan waktu setup.
12. Takt Time The speed of production with customer demand.
Penyeimbangan kecepatan produksi dengan permintaan pelanggan.
13. Total Productive
Maintenance
A comprehensive system/machine maintenance approach that is proactive and
preventive to maximize system/machine uptime.
Pendekatan pemeliharaan sistem/mesin yang menyeluruh yang bersifat proaktif dan
preventif untuk memaksimalkan waktu operasional sistem/mesin.
14. Visual Management Visual indicators or controls that are used in production premises to improve the
delivery of information.
Indikator atau kontrol visual yang digunakan di tempat produksi untuk
meningkatkan penyampaian informasi.
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44. A problem is defined as a discrepancy (gap) between the way something is (current
state or actual) and the way you want it to be (desired state, standard, goal, etc.)
Masalah adalah kesenjangan antara cara sesuatu (keadaan saat ini atau aktual) dan cara yang Anda
inginkan (keadaan yang diinginkan, standar, tujuan, dll.)
A solid problem statement must have four elements:
Goal/Standard,Actual,Gap,Trend (behavior over time)
Current
Condition
Target
Condition
Gap = Problem
Problem Solving is a structured sequence of team based activities that you apply to bridge
the gap between a current and a target condition.
Pemecahan Masalah adalah urutan terstruktur dari aktivitas berbasis tim yang Anda terapkan untuk menjembatani
Current Condition kesenjangan antara kondisi saat ini dan kondisi target
Problem Solving
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45. Process Problem Solving
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