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
People
Plants
Parts
Materials & Customers
Processes
Products & Services
Planning and Control Output
Input
Production System
Contoh Organisasi Manufaktur Chief Executive Officer
Marketing and Sales
Engineering
Human Resources
Information Systems
Finance
Research and Development Product Design
Manufacturing
Manufacturing Engineering
Production
Materials Management
Industrial Engineering
Quality
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
Strategy
Lead time Design
Purchasing Manufacture
Assemble
Ship
1. Engineer-to-Order (ETO)
Ship
2. Make-to-Order (MTO)
Lead time Inventory
Manufacture
Assemble
Lead time Manufacture
Inventory
Assemble
Ship
3. Assemble-to-Order (ATO)
Lead time Manufacture
Assemble
Inventory
Ship
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 Marketing Traditional Objective
Increase revenue
Operations
Finance
Reduce Increase profit and manufacturing cost cash flow, reduce investment
This implies
1
4
7
2
5
8
3
6
9
Customer service
Production efficiency
Inventory investment
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 Manufacturing Plan
Marketing/
Finance
Sales Plan
Plan
Production Plan
Forecasts
Resources Requirements Plan
Master Production Plan
Firm Orders
Long-Range
Rough Cut Capacity Plan
Inventory Status
BOM
Planning Data
Material Requirements Planning
Capacity Requirements Plan (CRP)
Medium Range
EXECUTION OF PLAN Purchasing
Production Activity 22 Control
23
Capacity
24
JIT I/O Line Balance
Final Assembly Schedule (FAS)
FINAL ASSEMBLY
Shor tRange
Production Planning & Inventory Control
Contoh Skema Mekanisme Penerapan PPIC Material flow
VENDOR Mtrls & components
Invoices
Paperwork flow Accounting
Purchase Order (PO)
5
Invoices Receiving
4
11 6
Purchasing
Job cost reports
CUSTOMER
Inspection 7 Material to storage
Product
Production Planning & Control Planning 3 Prepare: Mtrl requisitions Bill of Mtrls •Route Sheet •Blueprints •Specifications •Move tickets •Mtrls releases
Material control
10 Cpltd work & p’chased cmpnnts to final assy Inspection
Mtrl Status report Scheduling & dispatching
Completed components to storage Material to shop 8 Release job to Work shop center 1
9
Work center 2
Order for product
Final assembly shop
Schedule & completion feedback information
1
2
SALES
V. Peranan PPIC dalam Supply Chain S U P P L I E R Physical Supply
MANUFACTURER
Production Planning and Control
DISTRIBUTION SYSTEM
Physical Distribution
Dominant Flow of Products and Services Dominant Flow of Demand and Design Information
C U S T O M E R
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 dan diperlukan oleh para suppliers. 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
PAC MPS
Manufacturing Resource Planning (MRP II) Inventory CRP Purchasing Accounting Customer Service Order Entry Forecasting Material Requirements Planning (MRP)
VIII. PPIC Game
Demo PPIC Game ………………..
