DAFTAR ISI
HALAMAN JUDUL.............................................................................................. i HALAMAN PENGESAHAN PEMBIMBING.....................................................ii HALAMAN PENGESAHAN PENGUJI..............................................................iii HALAMAN PERNYATAAN KEASLIAN..........................................................iv HALAMAN PERSEMBAHAN............................................................................. v KATA PENGANTAR........................................................................................... vii DAFTAR ISI...........................................................................................................ix DAFTAR GAMBAR............................................................................................. xv DAFTAR TABEL.................................................................................................. xviii ABSTRAKSI...........................................................................................................xxi
BAB I
PENDAHULUAN.................................................................................. 1
1.1. Latar Belakang......................................................................................... 1 1.2. Tinjauan Pustaka...................................................................................... 10 1.2.1. Tinjauan Proses Produksi Garment............................................. 10 1.2.2. Sistem Produksi Garment............................................................. 12 1.2.3. Prinsip Pemilihan Sistem Produksi............................................. 16
BAB II PERANCANGAN PRODUK................................................................. 18 2.1. Spesifikasi Produk................................................................................... 18 2.2. Spesifikasi Bahan.....................................................................................26
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2.2.1.
Kain .......................................................................................... 26
2.2.2.
Interlining.................................................................................... 36
2.2.3.
BenangJahit................................................................................ 36
2.2.4.
Jarum Jahit.................................................................................. 38
2.2.5
Webbing (bag handle).................................................................40
2.2.6
Redsleting.................................................................................... 42
2.2.5.
Asesoris....................................................................................... 43
2.2.6.
Bahan Pembantu.......................................................................... 46
2.3. Pengendalian Kualitas.............................................................................. 49
BAB III PERANCANGAN PROSES...................................................................58 3.1. Uraian Proses ........................................................................................... 58 3.1.1. Quality Control............................................................................ 60 3.1.2. Sampling Department.................................................................. 61 3.1.3. Pattem Making Department........................................................63 3.1.3.1. Quality Control dan Monitoring pada Pattem Making Departement....................................................63 3.1.4. Cutting Department.....................................................................64 3.1.4.1. Quality Control dan Monitoring pada Cutting Departement................................................. 67 3.1.5. Sewing Department......................................................................68 3.1.5.1. Quality Control dan Monitoring pada Sewing Departement....................................................70
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3.1.6.
Finishing Department.................................................................. 70 3.1.6.1. Quality Control pada Finishing Department.............. 72
3.2. Spesifikasi Alat/ Mesin Produk...............................................................73 3.2.1. Mesin di Departemen Sample dan Pattern Making....................73 3.2.2. Mesin di Departemen Cutting.....................................................75 3.2.3. Mesin di Departemen Sewing.....................................................80 3.2.4. Mesin di Departemen Finishing..................................................84 3.3. Perencanaan Produksi.............................................................................. 85 3.3.1. Departemen Sampel dan Pattern Making................................... 85 3.3.2. Departemen Sewing....................................................................86 3.3.3. Departemen Cutting.................................................................... 92 3.3.4. Departemen Finishing.................................................................93 3.4. Perhitungan Kebutuhan Bahan Baku.......................................................94 3.4.1. Kebutuhan K ain..........................................................................95 3.4.2. Kebutuhan Benang Jahit.............................................................96 3.4.3. Kebutuhan Perekat......................................................................97 3.4.4. Kebutuhan Redsleting.................................................................98 3.4.5. Kebutuhan Webbing....................................................................98 3.4.6. Kebutuhan Buckle.......................................................................99 3.4.7. Kebutuhan Kertas Pola................................................................99 3.4.8. Kebutuhan Interlining................................................................. 100 3.4.9. Kebutuhan Label......................................................................... 101 3.4.10. Kebutuhan Karton Box .............................................................. 101
XI
3.4.11. Kebutuhan Plastik Packing......................................................... 102
BAB IV PERANCANGAN PABRIK.................................................................. 103 4.1. Lokasi Pabrik............................................................................................ 103 4.2. Tata Letak Pabrik (Plant Layout)............................................................ 104 4.3. Tata Letak Mesin/ Alat Proses (Machines Layout)................................ 108 4.3.1. Departemen Sampel dan Pattern Making................................... 109 4.3.2. Departemen Cutting.................................................................... 112 4.3.3. Departemen Sewing.................................................................... 114 4.3.4. Departemen Finishing................................................................. 116 4.3.5. Ruang Kantor.............................................................................. 119 4.4. Pelayanan Teknik (Utilitas)..................................................................... 120 4.4.1. Unit Penyediaan Air.................................................................... 120 4.4.2. Unit Penyediaan Listrik............................................................... 121 4.4.3. Bahan Bakar................................................................................ 122 4.4.4. Sarana Penunjang Produksi......................................................... 123 4.4.5. Perhitungan Kebutuhan Utilitas.................................................. 126 4.4.5.1. Perhitungan Kebutuhan Listrik untuk Penerangan.... 126 4.4.5.1.1. Kebutuhan Listrik Penerangan di Ruang Produksi..................................... 126 4.4.5.1.2. Kebutuhan Listrik Penerangan di Ruang Non Produksi............................. 135
XII
4.4.5.1.3. Perhitungan Kebutuhan AC dan Kipas Angin........................................ 143 4.4.5.1.4. Perhitungan Pemakaian Listrik untuk Kebutuhan Mesin Produksi............ 145 4.4.5.1.5. Perhitungan Pemakaian Listrik untuk Kebutuhan Mesin Non Produksi.... 150 4.4.6. Perhitungan Kebutuhan Bahan Bakar........................................ 155 4.4.6.1. Perhitungan Kebutuhan Bahan Bakar untuk Generator........................................................... 155 4.4.6.2. Perhitungan Kebutuhan Bahan Bakar untuk T ransportasi........................................................ 156 4.4.7. Perhitungan Kebutuhan Air......................................................... 158 4.5. Organisasi Perusahaan............................................................................. 161 4.5.1. Bentuk Perusahaan dan Permodalan.......................................... 161 4.5.2. Struktur Organisasi...................................................................... 162 4.5.3. Desain Kerja................................................................................ 167 4.5.4. Ketenagakerjaan.......................................................................... 175 4.5.4.1
Penggolongan Jumlah Karyawan............................... 175
4.5.4.2
Jumlah Karyawan......................................................... 176
4.5.4.3
Waktu Kerja Karyawan................................................ 185
4.5.4.4
Sistem Gaji karyawan.................................................. 186
4.5.4.5
Rekruitmen Karyawan................................................ 186
4.5.4.6
Fasilitas Karyawan....................................................... 190
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4.5.4.7
Riset dan Pengembangan Perusahaan......................... 193
4.6. Evaluasi Ekonomi................................................................................... 195 4.6.1. Analisa Marketing........................................................................ 195 4.6.1.1. Analisa SWOT............................................................. 195 4.6.1.2. Analisa Daur Hidup Produk (product life cycle)....... 196 4.6.2. Strategi Pemasaran (Marketing Strategy).................................. 197 4.6.3.
Analisa Finansial......................................................................... 200 4.6.3.1. Modal Investasi............................................................ 200 4.6.3.2
Biaya Operasional........................................................203
4.6.3.3. Sumber Pembiayaan.....................................................221 4.6.3.4. Analisis Break Event Point (BEP).............................. 223 4.6.3.5. Analisa Keuntungan.....................................................225 4.6.3.6. Analisa Shut Down Point ( SDP ) ............................... 226 4.6.4. Analisis Kelayakan Ekonomi......................................................228 4.6.4.1. Return On Investment (ROI)....................................... 228 4.6.4.2. Pay Out Time (POT)....................................................228
BABV PENUTUP
.......................................................................................... 231
5.1. Kesimpulan........................................................ ............................ 231
DAFTAR PUSTAKA
232
DAFTAR GAM BAR Gambar 2.1.
Visualisasi produk las......................................................................... 18
Gambar 2.2.
Detail spesifikasi produk tas...............................................................20
Gambar 2.3.
Pola dasar tas bagian badan................................................................23
Gambar 2.4.
Pola dasar tas bagian tutup.................................................................24
Gambar 2.5.a. Jarum jahit Regular Sharp Point........................................................ 39 Gambar 2.5.b. Jarum jahit Ball Point......................................................................... 39 Gambar 2.5.C. Jarum jahit Wedge P o in t....................................................................39 Gambar 2.6.
Webbing nylo n .................................................................................... 41
Gambar 2.7.a. Metal Zipper skala 1:1........................................................................ 42 Gambar 2.7.b. Polyester Zipper skala 1:1.................................................................43 Gambar 2.8.
Perekat.................................................................................................. 44
Gambar 2.9.
Buckle................................................................................................... 45
Gambar 2.10. Desain label tas.................................................................................... 46 Gambar 2.11. Setting posisi potongan pola di atas kertas pola..............................47 Gambar 2.12. Setting posisi potongan pola di atas kain, 1 rapot menghasilkan 3 p c s ...............................................................48 Gambar 3.1.
Flow chart proses produksi tas canvas.............................................59
Gambar 3.2.
Flow chart proses kerja pada Departement S am pel....................... 62
Gambar 3.3.
Flow chart proses kerja pada Departement C utting.......................67
Gambar 3.4.
Flow chart proses kerja pada Departement Sew ing.......................69
Gambar 3.5.
Flow chart proses keija pada Departement Finishing....................72 xv
Gambar 3.6.
Visualisasi printer patem m aking......................................................74
Gambar 3.7.
Visualisasi mesin Cutting tipe CZD 160-3...................................... 76
Gambar 3.7.a. Bagian-bagian mesin Cutting tipe CZD 160-3................................76 Gambar 3.8.
Visualisasi mesin Cutting RC-10 0 ....................................................79
Gambar 3.9.
Visualisasi table patem ....................................................................... 79
Gambar 3.10. Visualisasi mesin jahit tipe LK-1942-HA ....................................... 82 Gambar 3.11. Visualisasi mesin jahit tipe D U -1181............................................... 83 Gambar 3.12. Visualisasi mesin jahit tipe LH-3128 S ............................................83 Gambar 3.13. Visualisasi mesin label....................................................................... 84 Gambar 3.14. Lay out mesin sewing 1 line...............................................................90 Gambar 3.15.a. Visualisasi potongan-potongan kain yang akan dijahit dalam 1 rapot........................................................ 95 Gambar 3.15.b. Visualisasi potongan -potongan pola pada kain taslan............... 100
Gambar 4.1.
Lay out pabrik garment tas canvas kapasitas 33.124 pcs/bln....... 107
Gambar 4.2.
Lay out departemen sampel dan patem making pabrik garment tas canvas kapasitas 33.124 pcs/bln..................... I l l
Gambar 4.3.
Lay out departemen cutting pabrik garment tas canvas kapasitas 33.124 pcs/bln.................................................................... 113
Gambar 4.4.
Lay out departemen sewing pabrik garment tas canvas kapasitas 33.124 pcs/bln.................................................................... 115
Gambar 4.5.
Lay out departemen finishing pabrik garment tas canvas kapasitas 3 3.124 pcs/bln.................................................................... 118
Gambar 4.6.
Lay out kantor pabrik garment tas canvas kapasitas 33.124 pcs/bln.................................................................... 119 XVI
Gambar 4.7.
Struktur organisasi perancangan pabrik garmen tas canvas dengan kapasitas 33.124 pcs/bln...................................................... 163
Gambar 4.8.
Struktur organisasi bagian produksi perancangan pabrik garmen tas canvas dengan kapasitas 33.124 pcs/bln..................... 164
Gambar 4.9.
Struktur organisasi bagian teknik dan perencanaan perancangan pabrik garmen tas canvas dengan kapasitas 33.124 p cs/b ln......... 165
Gambar 4.10. Struktur organisasi bagian umum perancangan pabrik garmen tas canvas dengan kapasitas 33.124 pcs/bln..................... 166 Gambar 4.11. Flow chart pengembangan dan kemampuan SDM karyawan pabrik garment tas canvas dengan kapasitas 33.124 pcs/bln........ 189 Gambar 4.12. Flow chart rekruitmen karyawan pabrik garment tas canvas dengan kapasitas 33.124 pcs/bln...................................................... 190 Gambar 4.13. Grafik hubungan analisis BEP dan SDP terhadap kapasitas produksi..............................................................................229
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DAFTAR TABEL
Tabel 1.1.
Proyeksi jumlah penduduk Indonesia usia 15-29............................ 7
Tabel 1.2.
Data perkembangan produksi tas kain tenun skala nasional..........8
Tabel 1.3.
Data perhitungan ramalan kebutuhan produk tas kain ten u n ........ 9
Tabel 1.4.
Data hasil perhitungan ramalan kebutuhan tas kain tenun dari tahun 2003-2007......................................................................... 10
Tabel 2.1.
Ukuran standar tas kantor....................................................................22
Tabel 2.2.
Syarat mutu canvas cotton...................................................................28
Tabel 2.3.
Standart nilai evaluasi tahan luntur w a m a ....................................... 35
Tabel 2.4.
Syarat penggunaan benang ja h it.........................................................38
Tabel 2.5.
Syarat penggunaan jarum ja h it........................................................... 39
Tabel 2.6.
Evaluasi setiap tahapan proses produksi ta s..................................... 49
Tabel 3.1.
Spesifikasi mesin spreading PB -2400............................................... 75
Tabel 3.2.
Spesifikasi mesin cutting tipe CZD 160-3....................................... 77
Tabel 3.3.
Spesifikasi mesin cutting RC-10 0 ......................................................79
Tabel 3.4.
Spesifikasi mesin jahit tipe LK-1942 H A .........................................81
Tabel 3.5.
Spesifikasi mesin jahit tipe DU-1181................................................ 82
Tabel 3.6.
Spesifikasi mesin jahit tipe LH -3128 S ............................................. 83
Tabel 3.7.
Jenis mesin yang digunakan uhtuk setiap tahapan proses dan waktu proses................................................................................87
Tabel 3.8.
Tipe dan jumlah mesin di ruang sewing............................................91
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Tabel 3.9.
Tipe dan jumlah mesin di ruang cutting..........................................93
Tabel 3.10.
Tipe dan jumlah mesin di ruang finishing.......................................94
Tabel 4.1.
Kebutuhan listrik penerangan di ruang non produksi...................135
Tabel 4.2.
Kebutuhan listrik mesin produksi dan non produksi..................... 153
Tabel 4.3
Rencana penyediaan kran hydrant................................................... 159
Tabel 4.4.
Jumlah tenaga kerja di departemen sampel dan patem m aking... 177
Tabel 4.5.
Jumlah tenaga kerja di departemen cutting.................................... 178
Tabel 4.6.
Jumlah tenaga keija di departemen sew ing.................................... 179
Tabel 4.7.
Jumlah tenaga kerja di departemen finishing................................. 180
Tabel 4.8.
Jumlah tenaga kerja di departemen quality control....................... 181
Tabel 4.9.
Jumlah tenaga kerja di departemen maintenance dan utilitas...... 182
Tabel 4.10.
Jumlah tenaga kerja di departemen gudang.................................... 183
Tabel 4.11.
Jumlah tenaga kerja di ruang non produksi.................................... 184
Tabel 4.12.
Jenjang jabatan karyawan berdasarkan tingkat pendidikan.......... 187
Tabel 4.13.
Rincian dan total harga tanah, bangunan, pemasangan instalasi, taman dan jalan................................................................................... 200
Tabel 4.14.
Rincian dan total biaya notaris, modal kerja, biaya training, sampel produksi dan izin usaha........................................................ 201
Tabel 4.15.
Rincian dan total harga mesin produksi dan utilitas...................... 201
Tabel 4.16.
Rekapitulasi modal investasi pabrik tas kanvas............................ 203
Tabel 4.17.
Rincian biaya asuransi....................................................................... 204
Tabel 4.18.
Rincian biaya perawatan pabrik tas canvas.................................... 205
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Tabel 4.19 .
Total biaya penyusutan...................................................................... 206
Tabel 4.20.
Dafitar gaji karyawan berdasarkan jenjang jabatan........................ 207
Tabel 4.21.
Rincian biaya fixed cost (biaya tetap) ............................................ 210
Tabel 4.22.
Total biaya kebutuhan bahan baku utama, bahan pembantu dan bahan untuk packing...................................................................220
Tabel 4.23.
Rincian biaya Variable cost (biaya tidak te ta p ).............................220
Tabel 4.24.
Sumber dana dan modal perusahaan............................................... 222
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