DAFTAR ISI
HALAMAN JUDUL HALAMAN PENGAKUAN .......................................................................... ii LEMBAR PENGESAHAN PEMBIMBING ............................................... iii LEMBAR PENGESAHAN PENGUJI ......................................................... iv HALAMAN PERSEMBAHAN .................................................................... v MOTTO .......................................................................................................... vi KATA PENGANTAR ................................................................................... vii ABSTRAK ..................................................................................................... ix DAFTAR ISI................................................................................................... x DAFTAR TABEL .......................................................................................... xvi DAFTAR GAMBAR ...................................................................................... xviii BAB I
PENDAHULUAN 1.1
Latar Belakang ......................................................................... 1
1.2
Rumusan Masalah .................................................................... 3
1.3
Batasan Masalah ...................................................................... 3
1.4
Tujuan Penelitian ..................................................................... 4
1.5
Manfaat Penelitian ................................................................... 4
1.6
Sistematika Penulisan .............................................................. 4
BAB II
KAJIAN LITERATUR
2.1
Manajemen Produksi ............................................................... 5
2.2
Perencanaan Produksi.............................................................. 5
2.2.1
Gambaran Umum Perencanaan Produksi ................................ 5
2.2.2
Tujuan Perencanaan Produksi ................................................. 6
2.2.3
Karakteristik Perencanaan Produksi ........................................ 6
2.3
Pengendalian Produksi ............................................................ 7
2.4
Produksi Optimal .................................................................... 8
2.4.1
Pengertian Produksi Optimal .................................................. 8 xi
2.4.2
Faktor-Faktor Yang Membatasi Produksi Optimal .................. 9
2.5
Penjadwalan Produksi ............................................................. 10
2.6
Analisis Biaya dan Laba........................................................... 11
2.6.1 Perilaku Biaya .......................................................................... 11 2.6.2
Pola Perilaku Biaya .................................................................. 12
2.7
Peramalan ................................................................................. 14
2.7.1
Konsep Dasar Peramalan ......................................................... 14
2.7.2
Klasifikasi Teknik Peramalan .................................................. 16
2.7.3
Klasifikasi Metode Peramalan ................................................. 16
2.7.4
Pola Data Peramalan Time Series ............................................ 17
2.7.5
Metode Peramalan Data Time Series ....................................... 18
2.7.6 Akurasi Peramalan ................................................................... 20 2.8
Kualitas .................................................................................... 21
2.8.1 Biaya Kualitas .......................................................................... 21 2.9
Linier Programming................................................................. 23
2.10
Goal Programming .................................................................. 23
2.11
Konsep dan Terminologi Goal Programming ......................... 24
BAB III
METODE PENELITIAN
3.1
Pendahuluan ............................................................................. 28
3.2
Identifikasi Masalah ................................................................. 28
3.3
Menentukan Tujuan Penelitian ................................................. 28
3.4
Data yang Diperlukan .............................................................. 29
3.5
Metode Pengumpulan Data ...................................................... 30
3.6
Metode Pengolahan Data ......................................................... 31
3.7
Solusi Optimal dan Pencapaian Multi Sasaran Perusahaan ..... 34
3.8
Analisa Keseluruhan Kombinasi Produk ................................. 34
3.9
Kesimpulan dan Saran.............................................................. 34
3.10
Diagram Alir Penelitian ........................................................... 35
BAB IV 4.1
PENGUMPULAN DAN PENGOLAHAN DATA Pengumpulan Data ................................................................... 36
4.1.1 Profil Perusahaan ...................................................................... 36 xii
4.1.2
Lokasi Perusahaan .................................................................... 37
4.1.3
Visi dan Misi ............................................................................ 37
4.1.4 Struktur Organisasi................................................................... 38 4.1.5
Data Umum Tenaga Kerja ....................................................... 38
4.1.6 Data Hasil Produksi ................................................................. 39 4.1.7
Bahan Baku .............................................................................. 39
4.1.8 Kapasitas Bahan Baku Maksimal............................................. 41 4.1.9
Proses Produksi ........................................................................ 41
4.1.10 Data Pengamatan Waktu Proses............................................... 44 4.1.11 Data Jenis dan Jumlah Mesin Yang Digunakan ....................... 46 4.1.12 Kapasitas Produksi Maksimal Tiap Mesin ............................... 47 4.1.13 Data Volume Penjualan............................................................ 48 4.1.14 Data Volume Produksi ............................................................. 48 4.1.15 Data Biaya ................................................................................ 49 4.1.16 Biaya Tenaga Kerja .................................................................. 49 4.1.17 Biaya Bahan Baku .................................................................... 50 4.1.18 Biaya Kualitas .......................................................................... 52 4.1.19 Data Harga Jual Produk ........................................................... 54 4.2
Pengolahan Data ....................................................................... 54
4.2.1 Identifikasi Biaya Produksi ...................................................... 54 4.2.2 Perhitungan Biaya Produksi ..................................................... 55 4.2.2.1 Perhitungan Biaya Bahan Baku ................................................ 55 4.2.2.2 Perhitungan Biaya Overhead Pabrik ........................................ 57 4.2.2.3 Hasil Perhitungan Biaya Produksi ........................................... 59 4.2.3 Perhitungan Kapasitas Jam Kerja Tiap Mesin ......................... 59 4.2.4 Perhitungan Kapasitas Maksimal Waktu Proses ...................... 60 4.2.5
Peramalan Permintaan .............................................................. 61
4.2.6
Perumusan Fungsi Batasan ...................................................... 64
4.2.6.1 Batasan Waktu Proses Tiap Satuan Waktu .............................. 64 4.2.6.2 Batasan Bahan Baku ................................................................ 65 4.2.6.3 Batasan Pasar ........................................................................... 65 xiii
4.2.7 Formulasi Model Goal Programming ...................................... 66 4.2.7.1 Sasaran memaksimalkan pendapatan penjualan ...................... 67 4.2.7.2 Sasaran meminimalkan biaya produksi .................................... 67 4.2.7.3 Sasaran meminimalkan biaya kualitas ..................................... 67 BAB V 5.1
PEMBAHASAN Solusi Optimal dan Analisa Keseluruhan Kombinasi Produk...68
5.1.1 Periode Oktober 2010 ............................................................... 68 5.1.1.1 Solution Value .......................................................................... 68 5.1.1.2 Unit Cost or Profit ................................................................... 68 5.1.1.3 Total Contribution .................................................................... 69 5.1.1.4 Reduced Cost ............................................................................ 70 5.1.1.5 Allowable Min-Max .................................................................. 70 5.1.1.6 Objective Function ................................................................... 70 5.1.1.7 Left Hand Side .......................................................................... 71 5.1.1.8 Right Hand Side ....................................................................... 72 5.1.1.9 Slack or Surplus ....................................................................... 73 5.1.1.10 Shadow Price ......................................................................... 74 5.1.1.11 Allowable Min-Max R.H.S ..................................................... 75 5.1.2 Periode November 2010 ............................................................ 76 5.1.2.1 Solution Value .......................................................................... 76 5.1.2.2 Unit Cost or Profit ................................................................... 76 5.1.2.3 Total Contribution .................................................................... 77 5.1.2.4 Reduced Cost ............................................................................ 77 5.1.2.5 Allowable Min-Max .................................................................. 77 5.1.2.6 Objective Function ................................................................... 78 5.1.2.7 Left Hand Side .......................................................................... 78 5.1.2.8 Right Hand Side ....................................................................... 79 5.1.2.9 Slack or Surplus ....................................................................... 80 5.1.2.10 Shadow Price ......................................................................... 81 5.1.2.11 Allowable Min-Max R.H.S ..................................................... 82 xiiii
5.1.3 Periode Desember2010 ............................................................. 83 5.1.3.1 Solution Value .......................................................................... 83 5.1.3.2 Unit Cost or Profit ................................................................... 83 5.1.3.3 Total Contribution .................................................................... 84 5.1.3.4 Reduced Cost ............................................................................ 85 5.1.3.5 Allowable Min-Max .................................................................. 85 5.1.3.6 Objective Function ................................................................... 85 5.1.3.7 Left Hand Side .......................................................................... 86 5.1.3.8 Right Hand Side ....................................................................... 87 5.1.3.9 Slack or Surplus ....................................................................... 88 5.1.3.10 Shadow Price ......................................................................... 89 5.1.3.11 Allowable Min-Max R.H.S ..................................................... 90 BAB VI
PENUTUP
6.1
Kesimpulan ............................................................................ 92
6.2
Saran ...................................................................................... 94
DAFTAR PUSTAKA LAMPIRAN
xivi
DAFTAR TABEL
Tabel 4.1
Jumlah Tenaga Kerja di Setiap Stasiun Kerja............................... 39
Tabel 4.2 Kebutuhan bahan baku utama per unit produk .............................. 40 Tabel 4.3 Kebutuhan bahan baku pendukung per unit produk ...................... 40 Tabel 4.4 Kapasitas Bahan Baku Maksimal Tiap Produk/bulan ................... 41 Tabel 4.5 Jenis dan Fungsi Mesin .................................................................. 44 Tabel 4.6 Data waktu proses per unit produk ................................................ 46 Tabel 4.7 Jenis dan Jumlah Mesin yang digunakan ....................................... 47 Tabel 4.8 Kapasitas Produksi Maksimal Tiap Mesin .................................... 47 Tabel 4.9 Data Volume Penjualan ................................................................. 48 Tabel 4.10 Data Volume Produksi ................................................................... 48 Tabel 4.11 Biaya Tenaga Kerja/unit ................................................................ 50 Tabel 4.12 Data Biaya Bahan Baku Kaos Oblong/pcs .................................... 50 Tabel 4.13 Data Biaya Bahan Baku Kaos Polo/pcs ......................................... 51 Tabel 4.14 Data Biaya Bahan Baku Jumper/pcs.............................................. 51 Tabel 4.15 Biaya Overhead.............................................................................. 52 Tabel 4.16 Biaya Kualitas Kaos Oblong ......................................................... 52 Tabel 4.17 Biaya Kualitas Kaos Polo .............................................................. 53 Tabel 4.18 Biaya Kualitas Jumper ................................................................... 54 Tabel 4.19 Identifikasi Biaya Produksi ............................................................ 54 Tabel 4.20 Total biaya bahan baku Kaos Oblong/pcs ..................................... 55 Tabel 4.21 Total biaya bahan baku Kaos Polo/pcs .......................................... 56 Tabel 4.22 Total biaya bahan baku Jumper/pcs ............................................... 56 Tabel 4.23 Perhitungan Biaya Overhead ......................................................... 57 Tabel 4.24 Hasil Perhitungan Biaya Produksi ................................................. 59 Tabel 4.25 Kapasitas Jam Kerja Tiap Mesin/bulan ......................................... 60 Tabel 4.26 Kapasitas Maksimal Waktu Proses per unit produk...................... 60 Tabel 4.27 Akurasi peramalan produk Kaos Oblong....................................... 63 xvi
Tabel 4.28 Akurasi peramalan produk Kaos Polo ........................................... 63 Tabel 4.29 Akurasi peramalan produk Jumper ................................................ 63 Tabel 4.30 Hasil peramalan ............................................................................. 64
xvii
DAFTAR GAMBAR
Gambar 3.1.Diagram Alir Proses Penelitian .................................................... 8 Gambar 4.1 Struktur Organisasi Inteeshirt ..................................................... 38 Gambar 4.2 Operation Process Chart. ............................................................ 45 Gambar 4.3 Simbol OPC ................................................................................. 46 Gambar 4.4 Plot penjualan produk Kaos Oblong ............................................ 61 Gambar 4.5 Plot penjualan produk Kaos Polo ................................................. 62 Gambar 4.6 Plot penjualan produk Jumper ..................................................... 62
xviii
