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    FULFILL ORDERFULFILL ORDERManufacturing Process

    Manufacturing System

    Motion and Time Study

    Facilities La out

    Manufaktur ?Manufaktur ?

    RI 1321 Proses Manufaktur - Minggu 1 2

    Definisi ManufakturDefinisi Manufaktur

    Kata-kata manufaktur berasal dari bahasa latin (manus =

    hand, factus =made)

    Definisi manufacturing oleh Random House

    Websters College Dictionary:

    The making of goods or wares by manual labor or by

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 3

    machinery, esp. on a large scale.

    Definisi dari National Science Foundations Workshop:

    The creation and integration of informational and physical

    processes to create economic wealth through the production of

    artifacts. NSF 93-69.

    Contoh Produk ManufakturContoh Produk Manufaktur

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 4

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    Manufaktur (Technology Perspective)Manufaktur (Technology Perspective)

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 5

    Manufaktur (Economic Perspective)Manufaktur (Economic Perspective)

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 6

    Klasifikasi Industri Manufaktur (1)Klasifikasi Industri Manufaktur (1)Berdasarkan North American Industry Classification System (NAICS)Berdasarkan North American Industry Classification System (NAICS)

    Food manufacturing,

    Beverage & tobacco productmanufacturing,

    Textile mills,

    Wood productionmanufacturing

    Paper manufacturing

    Fabricated metal productmanufacturing

    Machinery manufacturing

    Computer and electronicproduct manufacturing

    Electrical equip, appliance &component manufacturing

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 7

    Petroleum and coal productionmanufacturing

    Chemical manufacturing

    Plastic and rubberproduct manufacturing

    Non-metallic mineralmanufacturing

    Primary metalmanufacturing

    Transportation equipmentmanufacturing

    Furniture and related productmanufacturing

    Miscellaneousmanufacturing

    Klasifikasi Industri Manufaktur (2)Klasifikasi Industri Manufaktur (2)

    Primary vs. secondary manufacturing Primary manufacturing adalah industri yang menghasilkan produk berupa

    material yang akan diolah lebih lanjut, seperti steel mill s, textile mills,plastics.

    Secondary manufacturing industri yang menghasilkan komponen atauproduk fungsional.

    Discrete manufacturing vs. continuous manufacturing

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 8

    Discrete manufacturing adalah produsen komponen, part atau singleproduct, seperti gir, mobil, pesawat udara, dll.

    Continuous manufacturing adalah produsen produk yang sifatnyakontinu seperti karet, plastic, sheet metal working, dll.

    Mechanical manufacturing, vs. electronics manufacturingand chemical manufacturing

    Klasifikasi berdasarkan disiplin ilmu

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    Klasifikasi Industri Manufaktur BerdasarkanKlasifikasi Industri Manufaktur Berdasarkan

    Standard ISIC 2 DigitStandard ISIC 2 Digit

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 9

    Proses Vs System ManufakturProses Vs System Manufaktur

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 1 0

    Jenis Material yang dipergunakanJenis Material yang dipergunakan

    Metals Ceramics

    and othersPlastics Composites

    F er ro us No nfer ro us Thermoplastic Thermoset Polymer Matrix

    Metal Matrix

    Ceramic Matrix

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 1 1

    Stainless

    Steels

    Tool and

    Die Steels

    Cast Irons

    Oxides

    Nitrides

    Carbides

    Glasses

    Graphite

    Diamond

    Alumi num

    Copper

    Magnesium

    Titanium

    Polypropylene

    Nylon

    ABS

    PVC

    Epoxy

    Phenolic

    Silicone

    HalHal--hal yang akan dipelajarihal yang akan dipelajari

    Mainly secondary, discrete, and mechanicalmanufacturing processes Casting, Forging, Rolling, Extrusion, Sheet

    Metal Working, Machining, Non-traditional

    Machining, Polymer Processing, Powder

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 1 2

    eta urgy nter ng, rocess ng o eramcsand Composites, and Joining.

    Common aspects of manufacturingprocesses Dimensioning and Tolerance, Engineering

    Metrology, Design of Experiment, ProcessCapability, Statistical Process Control, etc.

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    Manufacturing ProcessManufacturing Process

    1. Subtractive Process

    Machining: Turning, milling, boring, grinding

    Non-traditional machining: EDM, chemicalmilling, waterjet, etc.

    Micro-electronics processes: Primarily etchingtype processes using either masks or beam

    2. Additive Process

    Rapid Prototyping Very flexible to part

    3. Continuous Process

    Pultrusion of composites

    Metal Extrusion Net shape process

    Plastic Extrusion

    Czochralski Crystal Growth

    Continuous Casting

    4. Net shape Process

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 1 3

    s ape; usua y mte n matera c oces; sowrates; fully automated

    Advanced Composites Processes Combination of additive and net shapeprocesses

    Microelectronics Processes Physical andchemical vapor deposition processes andcoating methods

    Joining & Assembly Broad category includeswelding, adhesives, and mechanical assembly

    Solids: Metal Forming, Powders, Others

    Liquids: Casting, Injection Molding, Others

    Mixtures: Infiltration, Viscoelastics, Others

    Characteristics

    Hard tooling

    Solid forming very fast cycle time

    Thermal processes slower and depend uponcooling rate

    Dimensional control is not as good asmachining

    Injection MouldingInjection Moulding

    RI 1321 Proses Manufaktur - Minggu 1 14

    Metal CastingMetal Casting

    RI 1321 Proses Manufaktur - Minggu 1 15

    ForgingForging

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 1 6

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    Sheet Metal StampingSheet Metal Stamping

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 1 7

    Plastic ExtrusionPlastic Extrusion

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 1 8

    Metal ExtrusionMetal Extrusion

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 1 9

    WeldingWelding

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 2 0

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    Blanking and PunchingBlanking and Punching

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 2 1

    MillingMilling

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 2 2

    Water Jet MachiningWater Jet Machining

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 2 3

    ManufakturManufaktur Mengapa penting ?Mengapa penting ?

    Proses manufaktur adalah kegiatan inti dari sebuah perusahaan.

    Adanya kebutuhan terkait dengan Concurrent Enginnering

    Design for X: manufacture, assembly, environment, etc.

    61% alumni Teknik Industri ITS (berdasarkan hasil tracer study 2005 yangmelibatkan 86 responden lulusan dalam 4 tahun terakhir) bekerja di bidangmanufaktur

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 2 4

    esgn ngneers, ro uct ngneers, esearc an eve opment, anuactur ngEngineer, Planning, Safety, Materials, etc.

    6% Dosen/Wiraswasta/Pegawai Pemerintah, dll.

    33% Sektor Jasa Konsultan. Credit Company, Bank, dll

    Di Amerika Serikat Industri menyumbangkan 20% GDP

    Sektor Jasa : 70% U.S. GNP (retail, transportation, banking, education,communication, insurance and government).

    Pertanian, Konstruksi, dan lain-lain : 10%

    Bagaimana dengan peranan industri di Indonesia ?

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    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 2 5

    Proporsi pekerjaan Alumni TI ITS

    33%

    6%

    R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 2 6

    61%

    Manufaktur Jasa Dosen / Wiraswasta

    Responden : 86 orang lulusan periode 2001-2004

    CIMOSA (PRODUK SEBAGAICIMOSA (PRODUK SEBAGAI

    DASAR)DASAR) Sebuah industri manufaktur diawali/didorong oleh

    keberadaan produk yang dihasilkan (dijual) & adanya siklus

    hidup produk

    Industri manufaktur umumnya menghasilkan produk dalam

    jumlah besar dan sebagian part (pembentuk produk) dapat

    berasal dari perusahaan lain.

    Keputusan paling sederhana keputusan buat-beli

    Produk

    Part 1 Part 2

    Part Be li Part Buat

    Part HasilPerakitan

    Part HasilForging

    Part HasilTurning

    ... Part n

    Keputusan buat beli make or buy

    Perkenalan

    Pertumbuhan

    Maturity

    Penurunan

    Inovasi

    CIMOSA (ARSITEKTUR BISNIS DALAMCIMOSA (ARSITEKTUR BISNIS DALAM

    MANUFAKTUR)MANUFAKTUR) Apabila sebuah industri telah berjalan untuk menerima order,

    melakukan produksi dan mengirimkan barang jadi kepada customer

    maka kebutuhan pengaturan menjadi semakin bertambah dan

    kompleks

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    DEFINISI SISTEM PRODUKSIDEFINISI SISTEM PRODUKSI

    Serangkaian peralatan, prosedur, operator/peopleuntuk menyelesaikan seluruh operasi manufakturdalam sebuah perus