Perencanaan & Pengendalian Produksi (Production Planning and Control) Pengantar Pokok Bahasan: I. Kedudukan Planning & Control dalam Keputusan Operasional II. Manufacturing Strategy III. Konflik Sistem Produksi IV. Definisi PPIC V. Peranan PPIC dalam Supply Chain VI. MRP, MRP II, ERP & Beyond ERP VII. Demo PPIC Game Departemen Teknik Industri UI Depok Kuliah Perencanaan & Pengendalian Produksi 2008 Kuliah 1: Intro Rabu, 3 Sep 2008, Reg-S1
I. Kedudukan Planning & Control dalam Keputusan Operasi Marketplace Corporate Strategy Finance Strategy Operations Strategy Marketing Strategy Operations Management Materials & Customers Input People Plants Parts Processes Planning and Control Production System Products & Services Output
Contoh Organisasi Manufaktur Chief Executive Officer Marketing and Sales Engineering Human Resources Information Systems Finance Manufacturing Quality Research and Development Manufacturing Engineering Product Design Production Materials Management Industrial Engineering
Traditional Silo Organizations E N G I N E E R I N G M A R K E T I N G S A L E S P R O D U C T I O N F I N A N C E Q U A L I T Y
II. Manufacturing Strategy Strategy menentukan delivery lead time Lead time Design Purchasing Manufacture Assemble Ship Strategy 1. Engineer-to-Order (ETO) Inventory Lead time Manufacture Assemble Ship Lead time 2. Make-to-Order (MTO) Manufacture Inventory Assemble Ship Lead time Manufacture Assemble Inventory Ship 3. Assemble-to-Order (ATO) 4. Make-to-Stock (MTS)
Lead Time A span of time required to perform a process APICS Dictionary Delivery lead time The time from the receipt of a customer order to the delivery of the product APICS Dictionary Cumulative lead time The longest planned length of time to accomplish the activity in question APICS Dictionary
III. Konflik Sistem Produksi Konflik antar bagian perusahaan terjadi karena tujuan masingmasing bagian berbeda: 1. Tujuan Bagian Marketing (highest revenue through customer satisfaction): - Memiliki persediaan barang jadi dalam jumlah besar - Memproduksi barang yang diminta customer setiap diperlukan - Memperbesar jaringan distribusi dan pergudangan. 2. Tujuan Bagian Keuangan (lowest cost and investment): - Mengurangi investasi persediaan - Mengurangi jumlah pabrik, jaringan distribusi dan pergudangan - Memproduksi dalam jumlah besar untuk pemenuhan permintaan jangka panjang - Memproduksi hanya bila ada pesanan.
Conflicts in Traditional Supply Systems Traditional Objective This implies Customer service Marketing Increase revenue 1 4 Operations Reduce manufacturing cost Finance Increase profit and cash flow, reduce investment 7 Production efficiency 2 5 8 Inventory investment 3 6 9
IV. Definisi PPIC Membuat perencanaan & pengendalian produksi, merancang aliran kerja (workflow) organisasi mulai bahan baku sampai barang jadi, menyusun jadwal sumberdaya dan mengeksekusinya, sehingga dapat memberikan pelayanan yang terbaik bagi customer, serta meminimumkan biaya produksi keseluruhan.
Tujuan PPIC: 1. Memberikan pelayanan yang terbaik bagi customer 2. Mengeluarkan biaya produksi yang terendah 3. Mengeluarkan biaya persediaan yang terendah 4. Mengeluarkan biaya distribusi yang terendah. Profit = Revenue - Expense
Tugas-Tugas PPIC: 1. Perencanaan - Membuat rencana produksi, menyusun dan menetapkan urutan produksi, input material, alat dan mesin, serta pekerja. 2. Perancangan aliran kerja (workflow) organisasi. 3. Penjadwalan - Mempersiapkan order produksi dan jadwalnya (timetables). 4. Pengendalian Memberikan otorisasi untuk memulai kegiatan produksi, memonitor, menindak lanjuti, dan menjaga rencana dilaksanakan.
Tahapan Perencanaan Produksi BUSINESS Plan PLANNING Marketing/ Sales Plan Manufacturing Plan Finance Plan Forecasts Production Plan Resources Requirements Plan Long-Range Firm Orders Master Production Plan Rough Cut Capacity Plan Inventory Status BOM Planning Data Material Requirements Planning Capacity Requirements Plan (CRP) Medium Range EXECUTION OF PLAN Production Activity 22 Control 23 Capacity JIT 24 I/O Line Balance Purchasing Shor trange Final Assembly Schedule (FAS) FINAL ASSEMBLY Production Planning & Inventory Control
Contoh Skema Mekanisme Penerapan PPIC Purchase Order (PO) 4 VENDOR Purchasing Production Planning & Control 5 Mtrls & components Receiving Invoices 6 Inspection 7 Material to storage Accounting Job cost reports Invoices Material flow Paperwork flow 11 Product 10 CUSTOMER Planning 3 Prepare: Mtrl requisitions Bill of Mtrls Route Sheet Blueprints Specifications Move tickets Mtrls releases Material control Mtrl Status report Scheduling & dispatching Cpltd work & p chased cmpnnts to final assy Completed components to storage Material to shop 8 Release job to shop Work center 1 Work center 2 Final assembly shop Inspection 9 Order for product 1 Schedule & completion feedback information 2 SALES
V. Peranan PPIC dalam Supply Chain S U P P L I E R MANUFACTURER DISTRIBUTION SYSTEM C U S T O M E R Physical Supply Production Planning and Control Physical Distribution Dominant Flow of Products and Services Dominant Flow of Demand and Design Information
Ciri-ciri dari Supply Chain 1. Supply chain terdiri dari banyak kegiatan dan proses yang mensupply produk dan jasa untuk pelanggan akhir 2. Terdiri dari banyak perusahaan yang terhubung dalam suatu supply chain 3. Pelanggan bisa menjadi pemasok bagi pelanggan lain sehingga supply chain akan terdiri dari sejumlah supplier/customer relationship 4. Supply chain terdiri dari banyak distributor, seperti wholesaler, warehouses dan retailer 5. Produk atau jasa mengalir dari supplier ke customer, sedangkan informasi mengalir ke arah sebaliknya.
Supply Chain Management Mengelola supply chain tidak hanya membutuhkan pemahaman tentang jaringan supplier dan customer, tapi juga merencanakan material dan aliran informasi sepanjang supply chain sehingga dapat memaksimumkan efisiensi biaya, efektivitas, delivery dan flexibility.
Physical Supply/Distribution Movement of goods from suppliers to the beginning of the production process and from the end of the production process to consumers Activities Transportation Distribution inventory Warehousing Packaging Materials handling Order entry
PPIC & Supply Chain: Penjadwalan produksi dalam PPIC terintegrasi dengan supply chain: Demand forecasts mempengaruhi keseluruhan supply chain dandiperlukanolehparasuppliers. Demand berpengaruh pada kebutuhan pengadaan dan persediaan dalam supply chain. Keputusan yang terkait dengan lokasi pabrik sangat strategis dan mempengaruhi supply chain. Keputusan available-to-promise (ATP) untuk pengadaan material dan komponen yang dibutuhkan dapat dicek ke suppliers. Jadi, penjadwalan produksi atau PPIC terintegrasi dalam supply chain, bukan bereaksi terhadap supply chain.
VII. MRP, MRP II, ERP & Beyond ERP Beyond ERP SCM CPFR SRM AIDC BPM CRM Enterprise Resource Planning Manufacturing Eng. HR R&D Maintenance QC S&OP APS EDI Marketing Log/Dist Demand Mgt. Strategy DSS Manufacturing Resource Planning (MRP II) PAC Inventory CRP Purchasing Accounting MPS Customer Service Order Entry Forecasting Material Requirements Planning (MRP)
VIII. PPIC Game Demo PPIC Game..