UNIVERSITAS BINA NUSANTARA Program Ganda Teknik Industri – Sistem Informasi Skripsi Sarjana Program Ganda Semester Ganjil 2007/2008
Analisis dan Perancangan Sistem Informasi Pemesanan Bahan Baku dengan Metode MRP Pada Plant A PT.Gajah Tunggal Tbk Yonatan Irwansyah Wibisono 0700700263 ABSTRAK Masalah utama yang dihadapi oleh PT.Gajah Tunggal Tbk adalah perencanaan kebutuhan bahan baku yang kurang tepat dan teratur ditinjau dari waktu pemesanan dan jumlah dalam sekali pemesanan. serta jumlah safety stock yang besar. Hal ini disebabkan karena waktu dan kuantitas pemesanan serta jumlah safety stock yang ditetapkan perusahaan masih bersifat intuitif dan berdasarkan pengalaman, sehingga sering mengakibatkan kelebihan stok bahan baku dan stok ban ketika permintaan kecil. Untuk menyelesaikan masalah tersebut di atas digunakan metode Material Requirements Planning (MRP) dan perhitungan safety stock. Metode MRP mengatur penjadwalan pemesanan bahan baku dengan memperhatikan jadwal induk produksi (MPS) produk sehingga antara jumlah yang dibutuhkan dengan jumlah yang tersedia akan seimbang. Salah satu hal penting dalam metode MRP adalah penentuan teknik lotting. Teknik lotting yang digunakan akan dibandingkan antara Economic Order Quantity (EOQ), Periodic Order Quantity (POQ) dan Lot for Lot (LFL). Kemudian dilakukan perancangan sistem informasi MRP dengan pendekatan berbasis objek (OOAD), sedangkan bahasa pemrograman dibuat dengan menggunakan bantuan bahasa pemrograman PHP, serta pembangunan database dengan MySQL. Dari sistem persediaan bahan baku yang digunakan perusahaan saat ini diperoleh total biaya pesan dan simpan sebesar Rp 26,378,113,- . Sedangkan dari alternatif sistem yang diusulkan, diperoleh total biaya sebesar Rp 22,134,928,- . Terlihat bahwa alternatif sistem yang diusulkan memberikan biaya yang lebih kecil, yang berarti adanya suatu penghematan.
Kata Kunci: Material Requirement Planning (MRP), jadwal induk produksi (MPS), teknik lotting, sistem informasi MRP, OOAD.
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KATA PENGANTAR
Puji Syukur ke hadirat Tuhan yang Maha Esa atas berkat dan rahmat yang dilimpahkan-NYA, serta karunia yang tak terbatas sehingga dapat menyelesaikan penulisan skripsi ini dengan baik sesuai dengan waktu yang telah ditentukan. Skripsi ini diajukan sebagai salah satu syarat untuk gelar kesarjanaan pada Program Ganda Jurusan Teknik Industri dan Sistem Informasi Jenjang Pendidikan Strata-1. Dalam kesempatan ini penulis ingin menyampaikan rasa terima kasih kepada pihak-pihak yang telah membantu dan memberikan dorongan dalam penyusunan skripsi ini. Penulis juga ingin mengucapkan terima kasih kepada: 1. Bapak Prof. Dr. Gerardus Polla, M.App.Sc selaku Rektor Universitas Bina Nusantara. 2. Bapak Iman H. Kartowisastro, Ph.D. selaku Dekan Fakultas Teknik dan Pejabat Sementara Ketua Jurusan Fakultas Teknik Industri Universitas Bina Nusantara. 3. Bapak Ir. Sablin Yusuf, M.Sc, M.Comp.Sc. MM. selaku Dekan Fakultas Ilmu Komputer Universitas Bina Nusantara. 4. Bapak Johan, S.Kom., MM, selaku ketua Jurusan Sistem Informasi Universitas Bina Nusantara. 5. Bapak Wikaria Gazali, S.Si., MT, selaku Ketua Jurusan Ganda Universitas Bina Nusantara. 6. Ibu Siti Nur Fadlilah, ST., MT, dan Bapak Atang Setiawan.S.Teks.,MM selaku dosen pembimbing yang telah bersedia meluangkan waktu untuk memberikan pengarahan dan bimbingan kepada penulis dalam penyusunan skripsi ini. 7. Papa dan Mama serta kedua adik, keluarga tercinta yang telah memberikan dukungan doa dan semangat kepada penulis. 8. Bapak Ridwan, Bapak Joko, Bapak Muchtar, Ibu Endang, Bapak Ahmad, Mas Gusnul, Mas Rurin PPC Plant A yang sangat membantu penulis dalam melakukan penelitian. 9. Bapak Suherman dan Bapak Marjuki selaku Manager dan wakil Manager Dept. Training PT.Gajah Tunggal Tbk 10. AdiPati Laksana Evi, William Emon Arief, Diana Gunawan, Evan Bandar Anthony, Yohannes Ucup Firdian, Ignatius Gracia Harman, Edwin K, Shiane, Kavka A, Merlyana, yang telah memberikan semangat dan dukungan doa kepada penulis dalam penyusunan skripsi ini. 11. Teman–teman jenius 09–PAX angkatan 2003 yang telah memberikan semangat dan persahabatan yang sangat sangat berkesan kepada penulis. 12. Segenap pihak yang tak dapat disebutkan satu persatu, yang telah memberikan dukungan kepada penulis dalam penyusunan skripsi ini.
Skripsi ini dapat selesai dengan segala keterbatasannya sehingga dengan segala kerendahan hati, penulis mengharapkan segala saran dan kritik yang membangun dari
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semua pihak mengenai skripsi ini. Akhir kata, semoga skripsi ini akan bermanfaat bagi pihak yang membutuhkan.
Jakarta, 28 Januari 2008 Penyusun,
Yonatan Irwansyah Wibisono 0700700263
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DAFTAR ISI Halaman Judul Luar ............................................................................................................i Halaman Judul Dalam ....................................................................................................... ii Halaman Pengesahan Hardcover ..................................................................................... iii Persetujuan Dewan Penguji...............................................................................................iv Abstrak ...............................................................................................................................v Kata Pengantar..................................................................................................................vi Daftar Isi ........................................................................................................................ viii Daftar Tabel......................................................................................................................xii Daftar Gambar..................................................................................................................xv Daftar Lampiran ............................................................................................................ xvii
BAB 1 PENDAHULUAN .................................................................................................1 1.1 Latar Belakang ...................................................................................................1 1.2 Identifikasi dan Perumusan Masalah .................................................................3 1.3 Ruang Lingkup...................................................................................................4 1.4 Tujuan dan Manfaat ...........................................................................................5 1.4.1 Tujuan .............................................................................................................5 1.4.2 Manfaat ...........................................................................................................5 1.5 Gambaran Umum Perusahaan ...........................................................................6 1.5.1 Sejarah Berdirinya Perusahaan ........................................................................6 1.5.2 Lokasi Perusahaan ............................................................................................8 1.5.3 Produk ............................................................................................................10 1.5.4 Visi dan Misi Perusahaan ...............................................................................11 1.5.5 Sistem Mutu Produk .......................................................................................12 1.5.6 Struktur Organisasi dan Ketenagakerjaan ......................................................13 1.5.6.1 Struktur Organisasi Perusahaan ..............................................................13 1.5.6.2 Pemberian Tugas dan Wewenang ...........................................................13 1.5.6.3 Organisasi dan Manajemen .....................................................................15 1.5.6.4 Tenaga Kerja ...........................................................................................16 1.5.6.5 Jam Kerja ...............................................................................................17 1.5.6.6 Fasilitas Kerja .........................................................................................18 1.5.6.7 Sistem Pengupahan .................................................................................18 1.5.7 Bahan Baku dan Produksi ...............................................................................19 1.5.7.1 Bahan Baku ............................................................................................19 1.5.7.2 Proses Produksi .......................................................................................19 1.5.7.3 Jumlah Mesin dan Peralatan ...................................................................26 1.5.7.4 Teknologi ................................................................................................26 1.5.8 Petunjuk Pembacaan Kode Ukuran Ban .....................................................27
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BAB 2 LANDASAN TEORI...........................................................................................29 2.1 Teknik Industri .................................................................................................29 2.1.1 Peramalan.................................................................................................29 2.1.2 Fungsi Persediaan ....................................................................................34 2.1.3 Biaya-Biaya Persediaan ...........................................................................35 2.1.4 Safety stock...............................................................................................35 2.1.5 Penjadwalan Produksi ..............................................................................37 2.1.6 Master Production Schedule (MPS).........................................................42 2.1.7 Metode Petersen Silver ............................................................................46 2.1.8 Material Requirement Planning (MRP ) ..................................................46 2.1.8.1 Pengertian MRP ...........................................................................46 2.1.8.2 Tujuan dan Manfaat Sistem MRP ................................................47 2.1.8.3 Mekanisme Dasar dari Proses MRP.............................................................49 2.1.8.4 Prosedur Sistem MRP ..................................................................................51 2.1.8.4.1 Netting.......................................................................................51 2.1.8.4. Lotting .........................................................................................52 2.2 Sistem Informasi ..............................................................................................54 2.2.1 Analisa Problem Domain .........................................................................60 2.2.2 Analisa Application Domain....................................................................66 2.2.3 Desain Arsitektur .....................................................................................70 2.2.4 Komponen Model ...................................................................................76 BAB 3 METODOLOGI PENELITIAN..........................................................................77 3.1 Model Rumusan Masalah dan Pengambilan Keputusan..................................77 3.2 Teknik Pengumpulan Data dan Penentuan Parameter .....................................87 BAB 4 HASIL DAN PEMBAHASAN............................................................................90 4.1 Pengumpulan Data ...........................................................................................88 4.1.1 Data bahan baku.......................................................................................88 4.1.2 Data sisa persediaan bahan baku..............................................................89 4.1.3 Data Penggunaan Bahan Baku Per Produk .............................................89 4.1.3.1 LT 5.50-13 8PR SU .....................................................................89 4.1.3.2 LT 6.50-14 8PR SU[Exp ] ...........................................................90 4.1.3.3 LT 7.00-14 8PR SU KB ...............................................................90 4.1.4 Data Penjualan Produk.............................................................................90 4.1.5 Kalender kerja ..........................................................................................92 4.1.6 Kebutuhan Bahan Baku Secara Historis ..................................................92 4.1.6.1 Pemakaian Bahan Baku LT 5.50-13 8PR SU ..............................92 4.1.6.2 Pemakaian bahan baku LT 6.50-14 8PR SU[Exp].......................93 4.1.6.3 Pemakaian bahan baku LT 7.00-14 8PR SU KB .........................................93 4.2 Pengolahan Data ..............................................................................................99 4.2.1 Peramalan...............................................................................................100 4.2.1.1 LT 5.50-13 8PR SU ..........................................................................100 4.2.1.2 LT 6.50-14 8PR SU[Exp] ..................................................................103 4.2.1.3 LT 7.00-14 8PR SU KB ....................................................................106 4.2.2 Master Production Schedule (MPS) ......................................................109 ix
4.2.2.1 LT 5.50-13 8PR SU ..........................................................................110 4.2.2.2 LT 6.50-14 8PR SU[Exp] ..................................................................112 4.2.2.3 LT 7.00-14 8PR SU KB .....................................................................113 4.2.2.4 Perhitungan Safety Stok Usulan ........................................................114 4.2.2.4.1 Safety Stock LT 5.50-13 8PR SU ....................................................116 4.2.2.4.2 Safety Stock LT 6.50-14 8PR SU[Exp] ...........................................117 4.2.2.4.3 Safety Stock LT 7.00-14 8PR SU KB..............................................118 4.2.2.5 MPS Usulan ( berdasarkan dari safety stok usulan ) .........................119 4.2.3 Material Requirement Planning .............................................................121 4.2.3.1 Struktur Produk ..................................................................................122 4.2.3.1.1 LT 5.50-13 8PR SU .........................................................................122 4.2.3.1.2 LT 6.50-14 8PR SU[Exp] ................................................................123 4.2.3.1.3 LT 7.00-14 8PR SU KB ...................................................................123 4.2.3.2 BOM ( Bill of Material) .....................................................................124 4.2.3.3 Perhitungan MRP ...............................................................................125 4.2.3.3.1 Penentuan Gross Requirement Bahan Baku Tiap Produk ...............125 4.2.3.3.1.1 LT 5.50-13 8PR SU....................................................................125 4.2.3.3.1.2 LT 6.50-14 8PR SU[Exp] ..........................................................128 4.2.3.3.1.3 LT 7.00-14 8PR SU KB .............................................................130 4.2.3.3.2 Gross Requirement Total .................................................................133 4.2.3.3.3 Pengujian dengan Petersen Silver ....................................................135 4.2.3.3.4 Kalkulasi MRP .................................................................................141 4.2.3.3.4.1 Perhitungan Biaya Simpan dan Biaya Pesan .............................141 4.2.3.3.4.2 Perhitungan Biaya MRP.............................................................147 4.3 Analisis Pengolahan Data ..............................................................................161 4.3.1 Analisis Peramalan.................................................................................161 4.3.2 Analisis Master Production Schedule....................................................162 4.3.3 Analisis Material Requirement Planning ..............................................163 4.3.4 Analisis Biaya ........................................................................................164 4.4 Analisis Sistem Informasi ..............................................................................166 4.4.1 Analisis Sistem Berjalan ........................................................................166 4.4.2 Analisa Proses Bisnis Berjalan ..............................................................168 4.4.3 Analisa Proses Bisnis Usulan.................................................................170 4.4.4 System Definition ...................................................................................172 4.5 Perancangan Sistem Informasi dengan Unified Model Language (UML)) ...175 4.5.1 Problem Domain Analysis......................................................................175 4.5.1.1 Class Candidates dan Clas ................................................................175 4.5.1.2 Event Candidates dan Event...............................................................177 4.5.1.3 Event table..........................................................................................178 4.5.1.4 Class Diagram ...................................................................................179 4.5.1.5 Statechart Diagram............................................................................180 4.5.2 Application Domain ...............................................................................182 4.5.2.1 Use Case Diagram .............................................................................182 4.5.2.2 Function List ......................................................................................189 4.5.2.3 Sequence Diagram..............................................................................190 4.5.2.4 Navigation Diagram ...........................................................................200 4.5.3 Architecture Design ...............................................................................201 x
4.5.3.1 Criteria...............................................................................................201 4.5.3.2 Component Diagram .........................................................................203 4.5.3.3 Deployment Diagram .........................................................................204 4.5.4 Component Design .................................................................................205 4.6 Perancangan database.....................................................................................206 4.7 Pembuatan Program .......................................................................................209 4.8 Usulan Penerapan...........................................................................................221 4.9 Rencana Implementasi ...................................................................................223 BAB 5 KESIMPULAN DAN SARAN .........................................................................225 5.1 Kesimpulan ....................................................................................................225 5.2 Saran...............................................................................................................226
DAFTAR PUSTAKA RIWAYAT HIDUP LAMPIRAN SURAT SURVEY KMK
228 229 230 294 295
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DAFTAR TABEL Tabel 1.1 Jadwal Kerja Shift............................................................................................17 Tabel 2.1 Contoh Tabel MPS...........................................................................................44 Tabel 2.2 Contoh Tabel MRP ..........................................................................................49 Tabel 2.3 Prioritas Kriteria...............................................................................................73 Tabel 4.1 Data Bahan Baku .............................................................................................88 Tabel 4.2 Data Persediaan Bahan Baku ...........................................................................89 Tabel 4.3 Konsumsi Material LT 5.50-13 8PR SU..........................................................89 Tabel 4.4 Konsumsi Material LT 6.50-14 8PR SU[Exp].................................................90 Tabel 4.5 Konsumsi Material LT 7.00-14 8PR SU KB ...................................................90 Tabel 4.6 Data Penjualan Produk.....................................................................................91 Tabel 4.7 Kalender Kerja Bulan Oktober 2007 ...............................................................92 Tabel 4.8 Kalender Kerja Bulan November 2007............................................................92 Tabel 4.9 Kebutuhan Historis Bahan Baku LT 5.50-13 8PR SU.....................................94 Tabel 4.10 Kebutuhan Historis Bahan Baku LT 6.50-14 8PR SU[Exp] .........................95 Tabel 4.11 Kebutuhan Historis Bahan Baku LT 7.00-14 8PR SU KB ............................96 Tabel 4.12 Kebutuhan Historis Bahan Baku total............................................................97 Tabel 4.13 Hasil Perbandingan Peramalan LT 5.50-13 8PR SU ...................................100 Tabel 4.14 Hasil Peramalan LT 5.50-13 8PR SU dengan alpha = 0.6...........................101 Tabel 4.15 Pengujian Ketepatan Peramalan LT 5.50-13 8PR SU .................................102 Tabel 4.16 Konversi Peramalan LT 5.50-13 8PR SU....................................................103 Tabel 4.17 Hasil Perbandingan Peramalan LT 6.50-14 8PR SU[Exp] ..........................104 Tabel 4.18 Hasil Peramalan LT 6.50-14 8PR SU[Exp] dengan alpha = 0.5 .................104 Tabel 4.19 Pengujian Ketepatan Peramalan LT 6.50-14 8PR SU[Exp] ........................105 Tabel 4.20 Konversi Peramalan LT 6.50-14 8PR SU[Exp]...........................................106 Tabel 4.21 Hasil Perbandingan Peramalan LT 7.00-14 8PR SU KB.............................107 Tabel 4.22 Hasil Peramalan LT 7.00-14 8PR SU KB dengan alpha = 0.8 ....................107 Tabel 4.23 Pengujian Ketepatan Peramalan LT 7.00-14 8PR SU KB...........................108 Tabel 4.24 Konversi Peramalan LT 7.00-14 8PR SU KB .............................................109 Tabel 4.25 MPS LT 5.50-13 8PR SU ............................................................................110 Tabel 4.26 MPS Revisi LT 5.50-13 8PR SU .................................................................111 Tabel 4.27 MPS LT 6.50-14 8PR SU[Exp] ...................................................................112 Tabel 4.28 MPS Revisi LT 6.50-14 8PR SU[Exp] ........................................................113 Tabel 4.29 MPS LT 7.00-14 8PR SU KB......................................................................113 Tabel 4.30 MPS Revisi LT 7.00-14 8PR SU KB...........................................................114 Tabel 4.31 Konversi Persen Pelayanan dengan Safety factor........................................115 Tabel 4.32 Safety Stock LT 5.50-13 8PR SU ................................................................116 Tabel 4.33 Safety Stock LT 6.50-14 8PR SU[Exp] .......................................................117 Tabel 4.34 Safety Stock LT 7.00-14 8PR SU KB..........................................................118 Tabel 4.35 MPS Usulan LT 5.50-13 8PR SU ...............................................................119 Tabel 4.36 MPS Usulan LT 6.50-14 8PR SU[Exp] .......................................................120 Tabel 4.37 MPS Usulan LT 7.00-14 8PR SU KB .........................................................120 Tabel 4.38 Perbandingan PAB Perusahaan dengan PAB Usulan ..................................121 Tabel 4.39 Bill of Material LT 5.50-13 8PR SU ...........................................................124
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Tabel 4.40 Bill of Material LT 6.50-14 8PR SU[Exp] ..................................................125 Tabel 4.41 Bill of Material LT 7.00-14 8PR SU KB .....................................................125 Tabel 4.42 Perhitungan MRP LT 5.50-13 8PR SU........................................................126 Tabel 4.43 Perhitungan Gross Requirement Karbon LT 5.50-13 8PR SU ....................126 Tabel 4.44 Perhitungan Gross Requirement Oli LT 5.50-13 8PR SU ...........................127 Tabel 4.45 Perhitungan Gross Requirement Karet LT 5.50-13 8PR SU .......................127 Tabel 4.46 Perhitungan Gross Requirement Bahan Kimia LT 5.50-13 8PR SU...........127 Tabel 4.47 Perhitungan Gross Requirement Nylon LT 5.50-13 8PR SU ......................127 Tabel 4.48 Perhitungan Gross Requirement Kawat LT 5.50-13 8PR SU......................128 Tabel 4.49 Perhitungan MRP LT 6.50-14 8PR SU[Exp]...............................................128 Tabel 4.50 Perhitungan Gross Requirement Karbon LT 6.50-14 8PR SU[Exp] ...........129 Tabel 4.51 Perhitungan Gross Requirement Oli LT 6.50-14 8PR SU[Exp]..................129 Tabel 4.52 Perhitungan Gross Requirement Karet LT 6.50-14 8PR SU[Exp] ..............129 Tabel 4.53 Perhitungan Gross Requirement Bahan Kimia LT 6.50-14 8PR SU[Exp]..130 Tabel 4.54 Perhitungan Gross Requirement Nylon LT 6.50-14 8PR SU[Exp] .............130 Tabel 4.55 Perhitungan Gross Requirement Kawat LT 6.50-14 8PR SU[Exp].............130 Tabel 4.56 Perhitungan MRP LT 7.00-14 8PR SU KB .................................................131 Tabel 4.57 Perhitungan Gross Requirement Karbon LT 7.00-14 8PR SU KB..............131 Tabel 4.58 Perhitungan Gross Requirement Oli LT 7.00-14 8PR SU KB .....................132 Tabel 4.59 Perhitungan Gross Requirement Karet LT 7.00-14 8PR SU KB.................132 Tabel 4.60 Perhitungan Gross Requirement Bahan Kimia LT 7.00-14 8PR SU KB ....132 Tabel 4.61 Perhitungan Gross Requirement Nylon LT 7.00-14 8PR SU KB................132 Tabel 4.62 Perhitungan Gross Requirement Kawat LT 7.00-14 8PR SU KB ...............133 Tabel 4.63 Perhitungan Total Gross Requirement Karbon............................................133 Tabel 4.64 Perhitungan Total Gross Requirement Oli...................................................133 Tabel 4.65 Perhitungan Total Gross Requirement Karet ...............................................134 Tabel 4.66 Perhitungan Total Gross Requirement Bahan Kimia...................................134 Tabel 4.67 Perhitungan Total Gross Requirement Nylon..............................................134 Tabel 4.68 Perhitungan Total Gross Requirement Kawat .............................................134 Tabel 4.69 Tabel data Peterson-Silver Karbon ..............................................................135 Tabel 4.70 Tabel data Peterson-Silver Oli .....................................................................136 Tabel 4.71 Tabel data Peterson-Silver Karet .................................................................137 Tabel 4.72 Tabel data Peterson-Silver Bahan Kimia .....................................................138 Tabel 4.73 Tabel data Peterson-Silver Nylon ................................................................139 Tabel 4.74 Tabel data Peterson-Silver Kawat................................................................140 Tabel 4.75 MRP Karbon dengan LFL............................................................................147 Tabel 4.76 MRP Oli dengan LFL ..................................................................................149 Tabel 4.77 MRP Karet dengan LFL...............................................................................150 Tabel 4.78 MRP Bahan Kimia dengan LFL ..................................................................150 Tabel 4.79 MRP Nylon dengan LFL..............................................................................151 Tabel 4.80 MRP Kawat dengan LFL .............................................................................151 Tabel 4.81 MRP Karbon dengan EOQ ..........................................................................152 Tabel 4.82 MRP Oli dengan EOQ .................................................................................153 Tabel 4.83 MRP Karet dengan EOQ..............................................................................154 Tabel 4.84 MRP Bahan Kimia dengan EOQ .................................................................154 Tabel 4.85 MRP Nylon dengan EOQ ............................................................................155 Tabel 4.86 MRP Kawat dengan EOQ ............................................................................155 xiii
Tabel 4.87 MRP Karbon dengan POQ...........................................................................156 Tabel 4.88 MRP Oli dengan POQ .................................................................................157 Tabel 4.89 MRP Karet dengan POQ..............................................................................158 Tabel 4.90 MRP Bahan Kimia dengan POQ .................................................................159 Tabel 4.91 MRP Nylon dengan POQ.............................................................................159 Tabel 4.92 MRP Kawat dengan POQ ............................................................................160 Tabel 4.93 Total Biaya dari Tiap Metode ......................................................................160 Tabel 4.94 Perbandingan PAB.......................................................................................163 Tabel 4.95 Perbandingan Total Biaya............................................................................165 Tabel 4.96 FACTOR......................................................................................................174 Tabel 4.97 Class Candidates .........................................................................................176 Tabel 4.98 Event Candidates .........................................................................................177 Tabel 4.99 Event Table ..................................................................................................178 Tabel 4.100 Use Case Spesification Memasukkan Order..............................................184 Tabel 4.101 Use Case Spesification Melihat Stok Barang Jadi .....................................184 Tabel 4.102 Use Case Spesification Mendata Ban ........................................................185 Tabel 4.103 Use Case Spesification Mendata Bahan Baku ...........................................185 Tabel 4.104 Use Case Spesification Membuat Peramalan.............................................186 Tabel 4.105 Use Case Spesification Mendata BOM......................................................187 Tabel 4.106 Use Case Spesification Menyusun MPS....................................................187 Tabel 4.107 Use Case Spesification Menghitung Pemesanan bahan baku....................188 Tabel 4.108 Use Case Spesification Mencetak MPS .....................................................188 Tabel 4.109 Use Case Spesification Mencetak MRP.....................................................189 Tabel 4.110 Function List ..............................................................................................190 Tabel 4.111 Kriteria Sistem ...........................................................................................201 Tabel 4.112 Tabel bahan baku .......................................................................................206 Tabel 4.113 Tabel Produk ..............................................................................................206 Tabel 4.114 Tabel BOM ................................................................................................207 Tabel 4.115 Tabel Order ................................................................................................207 Tabel 4.116 Tabel Peramalan.........................................................................................207 Tabel 4.117 Tabel MPS .................................................................................................208 Tabel 4.118 Tabel MRP .................................................................................................208 Tabel 4.119 Tabel Total Penjualan ................................................................................208 Tabel 4.120 Rencana Implementasi ...............................................................................223
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DAFTAR GAMBAR Gambar 1.1 Struktur Organisasi Perusahaan ...................................................................13 Gambar 1.1 Proses Produksi ............................................................................................25 Gambar 2.1 Pola Data Permintaan ...................................................................................31 Gambar 2.2 Struktur Produk Pulpen ................................................................................40 Gambar 2.3 Konteks Sistem.............................................................................................57 Gambar 2.4 Siklus Pengembangan dengan OOAD .........................................................58 Gambar 2.5 Aktifitas dalam Memilih Sistem ..................................................................59 Gambar 2.6 Aktifitas dalam Analisa Problem Domain ...................................................61 Gambar 2.7 Aktifitas dalam Memilih Class dan Event....................................................62 Gambar 2.8 Hubungan Asosiasi.......................................................................................64 Gambar 2.9 Hubungan Agregasi......................................................................................64 Gambar 2.10 Hubungan Generalisasi ..............................................................................65 Gambar 2.11 Struktur pada Statechart Diagram ..............................................................65 Gambar 2.12 Aktifitas dalam Analisa Application Domain ............................................66 Gambar 2.13 Aktifitas dalam Tahap Usage .....................................................................66 Gambar 2.14 Aktifitas dalam Tahap Function.................................................................67 Gambar 2.15 Fungsi: Update ...........................................................................................68 Gambar 2.16 Fungsi: Read...............................................................................................68 Gambar 2.17 Fungsi: Compute ........................................................................................69 Gambar 2.18 Fungsi: Signal.............................................................................................69 Gambar 2.19 Aktifitas dalam Tahap Interface.................................................................70 Gambar 2.20 Aktifitas dalam Desain Arsitektur..............................................................71 Gambar 2.21 Aktifitas dalam Menentukan Kriteria.........................................................72 Gambar 2.22 Aktifitas dalam Desain Arsitektur-Component..........................................74 Gambar 2.23 Aktifitas dalam Desain Arsitektur-Process ................................................75 Gambar 3.1 Flowchart Metodologi Pemecahan Masalah Bagian 1 ................................77 Gambar 3.2 Flowchart Metodologi Pemecahan Masalah Bagian 2 ................................78 Gambar 3.3 Flowchart Metodologi Pemecahan Masalah Bagian 3 ................................79 Gambar 4.1 Tingkat Penggunaan Bahan Baku ................................................................98 Gambar 4.2 Grafik Penjualan Produk ..............................................................................99 Gambar 4.3 Struktur Produk LT 5.50-13 8PR SU LT 600 ............................................122 Gambar 4.4 Struktur Produk LT 6.50-14 8PR SU[Exp]................................................123 Gambar 4.5 Struktur Produk 7.00-14 8PR SU KB ........................................................124 Gambar 4.6 Rich Picture Proses Bisnis Berjalan...........................................................167 Gambar 4.7 Rich Picture Proses Bisnis Usulan .............................................................170 Gambar 4.8 Class Diagram ............................................................................................179 Gambar 4.9 Statechart Diagram Bahan Baku................................................................180 Gambar 4.10 Statechart Diagram Ban ...........................................................................180 Gambar 4.11 Statechart Diagram BOM ........................................................................180 Gambar 4.12 Statechart Diagram MPS .........................................................................181 Gambar 4.13 Statechart Diagram MRP .........................................................................181 Gambar 4.14 Statechart Diagram Peramalan.................................................................181 Gambar 4.15 Statechart Diagram Order ........................................................................182 xv
Gambar 4.16 Use Case Diagram...................................................................................183 Gambar 4.17 Sequence Memasukkan Order..................................................................191 Gambar 4.18 Sequence Mendata Ban ............................................................................192 Gambar 4.19 Sequence Mendata Bahan baku................................................................193 Gambar 4.20 Sequence Mengecek Stok.........................................................................194 Gambar 4.21 Sequence Mendata BOM..........................................................................195 Gambar 4.22 Sequence Peramalan.................................................................................196 Gambar 4.23 Sequence Menyusun MPS........................................................................197 Gambar 4.24 Sequence Pemesanan Bahan Baku ...........................................................198 Gambar 4.25 Sequence Mencetak Jadwal Produksi.......................................................199 Gambar 4.26 Sequence Mencetak Pemesanan Bahan Baku ..........................................199 Gambar 4.27 Navigasi Diagram Bagian Marketing.......................................................200 Gambar 4.28 Component Diagram Centralized Data....................................................203 Gambar 4.29 Deployment Diagram Centralized Data ..................................................204 Gambar 4.30 Revised Class Diagram ............................................................................205 Gambar 4.31 Menu Login ..............................................................................................209 Gambar 4.32 Menu Marketing.......................................................................................210 Gambar 4.33 Menu Bagian Gudang ..............................................................................211 Gambar 4.34 Menu Bagian PPC ....................................................................................211 Gambar 4.35 Menu Mendata Ban ..................................................................................212 Gambar 4.36 Menu Mendata Bahan Baku.....................................................................213 Gambar 4.37 Menu BOM ..............................................................................................213 Gambar 4.38 Menu Mengecek Stok Barang ..................................................................214 Gambar 4.39 Grafik Barang(Ban)..................................................................................215 Gambar 4.40 Grafik Bahan Baku...................................................................................216 Gambar 4.41 Menu Peramalan.......................................................................................216 Gambar 4.42 Menu Order ..............................................................................................217 Gambar 4.43 Menu Perencanaan Produksi (MPS) ........................................................218 Gambar 4.44 Menu Pemesanan Bahan Baku (MRP).....................................................219 Gambar 4.45 Menu Cetak Laporan Produksi (MPS) .....................................................220 Gambar 4.46 Menu Pemesanan Bahan Baku (MRP)....................................................220
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DAFTAR LAMPIRAN Lampiran 1 Total Penjualan Ban Luar Mobil pada Plant A PT Gajah Tunggal Tbk Tahun 2006 ............................................................................................... L.1 Lampiran 2 Hasil Peramalan untuk tipe ban LT 5.50-13 8PR SU dengan Metode Single Exponential Smoothing.................................................................. L.3 Lampiran 3 Hasil Peramalan untuk tipe ban LT 5.50-13 8PR SU dengan Metode Double Exponential Smoothing ................................................................ L.4 Lampiran 4 Hasil Peramalan untuk tipe ban LT 5.50-13 8PR SU dengan metode Regresi Linear ......................................................................................... L.22 Lampiran 5 Hasil Peramalan untuk tipe ban LT 5.50-13 8PR SU dengan Metode Triple Exponential Smoothing Brown .................................................... L.24 Lampiran 6 Hasil Peramalan untuk tipe ban LT 6.50-14 8PR SU[Exp] dengan Metode Single Exponential Smoothing ................................................. L.26 Lampiran 7 Hasil Peramalan untuk tipe ban LT 6.50-14 8PR SU[Exp] dengan Metode Double Exponential Smoothing................................................ L.27 Lampiran 8 Hasil Peramalan untuk tipe ban LT 6.50-14 8PR SU[Exp] dengan Metode Regresi linear ............................................................................. L.45 Lampiran 9 Hasil Peramalan untuk tipe ban LT 6.50-14 8PR SU[Exp] dengan Metode Tripple Exponential Smoothing Brown: dengan alpha = 0.5 .... L.47 Lampiran 10 Hasil Peramalan untuk tipe ban LT 7.00-14 8PR SU KB] dengan Metode Single Exponential Smoothing .................................................. L.49 Lampiran 11 Hasil Peramalan untuk tipe ban LT 7.00-14 8PR SU KB] dengan Metode Double Exponential Smoothing................................................. L.50 Lampiran 12 Hasil Peramalan untuk tipe ban LT 7.00-14 8PR SU KB] dengan Metode Regresi Linear............................................................................ L.68 Lampiran 13 Hasil Peramalan untuk tipe ban LT 7.00-14 8PR SU KB] dengan Metode Tripple Exponential Smoothing: dengan alpha = 0.5 ................ L.70 Lampiran 14 Netting Karbon ....................................................................................... L.72 Lampiran 15 Netting Oli .............................................................................................. L.72 Lampiran 16 Netting Karet .......................................................................................... L.73 Lampiran 17 Netting Bahan Kimia .............................................................................. L.73 Lampiran 18 Netting Nylon ......................................................................................... L.74 Lampiran 19 Netting Kawat......................................................................................... L.74
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