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Pendekatan Global Pengantar Teknik Industri Semester Genap 2014/2015.

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Presentasi berjudul: "Pendekatan Global Pengantar Teknik Industri Semester Genap 2014/2015."— Transcript presentasi:

1 Pendekatan Global Pengantar Teknik Industri Semester Genap 2014/2015

2 Hasil Pembelajaran Mahasiswa memahami pengaruh teknologi informasi pada disiplin dan praktek teknik industri Mahasiswa memahami aspek global yang mengubah karakteristik sistem integral 2

3 Sistem Manufaktur sebagai Sistem Integral Perusahaan manufaktur adalah yang dimaksud sebagai sistem integral pada saat disiplin teknik industri lahir Namun dalam perkembangannya yang dimaksud sistem integral bisa berupa: –Rumah sakit –Bank –Perusahaan jasa yang lain –Organisasi non-profit 3

4 Pengertian Sistem Manufaktur 4

5 Perkembangan Teknologi Manufaktur 5 Extended manufactur ing system

6 Alasan ekspansi Perusahaan tidak hanya mencari bahan baku Perusahaan mencari pasar global karena pasar lokal sudah jenuh atau kapasitas membesar Penetrasi ke pasar global memerlukan produksi secara global juga Semua dilakukan tetap dalam kerangka mencapai performansi QCD (Quality, Cost, Delivery) dan Flexibility. Disiplin Teknik Industri tetap diperlukan Pasar global juga berarti semakin beragamnya konsumen Diperlukannya performansi fleksibilitas 6

7 Perkembangan 7 Stasiun kerja (Work Station) dan Lantai Produksi (Shop Floor) sebagai sistem integral Perusahaan sebagai sistem integral tertutup Perusahaan sebagai sistem integral terbuka Enterprise sebagai bagian jaringan perusahaan sebagai sistem integral Efisiensi Kualitas Efisiensi Kualitas Fleksibilitas Efisiensi Kualitas Fleksibilitas Environment Globalitas

8 8 Sistem Integral: The whole enterprise. Within a company, this often includes the end-to-end value stream from business capture to product development to manufacturing and assembly to product support to infrastructure (which includes finance, IT and human resources). Industrial Engineering is now concerned with understanding of how all of the elements of an enterprise play together as well as how this understanding can be used to maximize value (Rouse, 2004).

9 Pengaruh global dan networking Kombinasi pengaruh networking dan globalisasi membuat batas sebuah enterprise menjadi semakin tidak jelas 9 Pendekatan sistemik melihat pengaruh lingkungan tempat sistem beroperasi Enterprise menjadi lebih luas: perusahaan – supplier – distributor – customer – stakeholder lain – pesaing

10 Teknologi Informasi: driving force Pendorong utama perubahan adalah teknologi informasi –Teknologi internet –Teknologi telekomunikasi Memungkinkan: –Orang di tempat berbeda dan waktu berbeda bekerja sama –Koordinasi dapat dilakukan dengan lebih mudah 10

11 e-Manufacturing 11

12 Isu-isu dasar dalam sistem enterprise Perancangan, perbaikan dan pemasangan sistem integral sekarang dalam bentuk enterprise yang sangat luas akibat batas enterprise yang kabur Pendekatan dalam disiplin teknik industri yang berbasis pendekatan sistem sangat relevan Beberapa isu yang perlu diperhatikan (Rosue, 2004) 12

13 Isu-isu dasar dalam sistem enterprise 1. Complexity: sistem enterprise sangat rumit sehingga pendekatan sistem diperlukan untuk memudahkan pemahaman sistem dalam bentuk model 2. Uncertainty: ketidakpastian muncul dalam variabel-variabel serta relasi-relasi yang ada dalam sistem dan lingkungannya. Ketidakpastian dapat dipahami dengan mempelajari relasi-relasi ini. 13

14 Isu-isu dasar dalam sistem enterprise 3. Control: pada dasarnya adalah upaya untuk menjamin agar variabel-variabel dan relasi- relasi berada pada karakteristik yang diinginkan. Dalam kaitan ini termasuk (a) pengalokasian sumber daya dan manajemen insentif dan regulasi, (b) atau pembentukan mekanisme pengukuran dan umpan balik untuk pemantauan dan pengambilan keputusan 14

15 Isu-isu dasar dalam sistem enterprise 4. Design: dalam kerangka sistem enterprise maka perancangan berkenaan dengan value stream dan relasi-relasinya dengan karakteristik pasar, rancangan produk, supply chain, proses manufaktur, dan proses delivery layanan. 15

16 Tujuan Dalam operasi enterprise tujuan yang ingin dicapai adalah: –Agility: kemampuan merespon fleksibilitas dan memanfaatkan kesempatan –Security: keamanan operasi –Sustainability: minimasi waste dan konsumsi non-renewable resources 16

17 17 Enterprise Design & Operation Agility Security Sustainability Create high value Disiplin – Pendekatan Teknik Industri

18 Persoalan yang timbul 18 Memahami bagaimana organisasi beradaptasi terhadap perubahan- perubahan Bagaimana organisasi memanfaatkan pembaruan teknologi produk dan proses untuk keunggulan Memahami bagaimana teknologi kolaborasi dan web services dipakai dalam operasi enterprise Memahami aspek perilaku dan sosial organisasi dalam melakukan transformasi

19 ADM (ASTRA DAIHATSU MOTOR) Contoh extended manufacturing: 19 Disampaikan oleh: Budhi Agung Priyanto PT Astra Daihatsu Motor

20 ADM Business Profile ADM is sole agent of Daihatsu in Indonesia and the manufacturer of Daihatsu and Toyota vehicles component and other related business. Daihatsu Motor Co., Ltd. » 61.7 % PT Astra International, Tbk. » 31.9 % Toyota Tsusho Corp. » 6.4 % Man Power 8,379 (as of June 2011) Year of Establishment 1978 Shareholders  Stamping Plant  Engine Plant  Casting Plant  Assy Plant  Part Center 20

21 ADM production contribute 41% of Indonesia automotive market % 45% 36% 35% 30% 20% 42% (x 1,000 u) ‘10 21

22 Town / Lite Ace CBU ADM Production Base T-D Group GranMax & Terios CBU GranMax CBU Terios CKD Avanza CBU Rush CBU ADM Consistently exports CBU to Japan, the high quality standard market in the world 22

23 Automotive industry absorbs a lot of job opportunities ADM Inhouse (24%) Japan Source Part CKD : (9%) Multi Source Part Asian: (6%) Suppliers* No. of Suppliers No. of Manpower First Tier155465,000 Second Tier 85042,500 Total1,005507,000 23

24 ADM’s Overseas First Tier Supplier THAILAND = 34 SUPPLIER INDIA = 1 SUPPLIER PHILIPHINES= 5 SUPPLIER MALAYSIA= 4SUPPLIER JAPAN = 1 SUPPLIER 24

25 Production Process Improvement: Mixed Assembly Line What is Mixed Assembly Line? The assembly process of VARIOUS MODELS or SUFFIXS of vehicles, sequentially in ONE ASSEMBLY LINE. The complexity of logistic is extremely high in this system. ADM implement HEIJUNKA (leveled production) and JUNDATE (mixed sequencing delivery system) and some other logistic innovation to run this MIXED ASSEMBLY LINE SYSTEM. What is Mixed Assembly Line? The assembly process of VARIOUS MODELS or SUFFIXS of vehicles, sequentially in ONE ASSEMBLY LINE. The complexity of logistic is extremely high in this system. ADM implement HEIJUNKA (leveled production) and JUNDATE (mixed sequencing delivery system) and some other logistic innovation to run this MIXED ASSEMBLY LINE SYSTEM. Total 28 Total 137 Mixed Assembly Line Number of Suffix XENIA AVANZA TERIOS AVANZA Benefit for ADM: Producing vehicles as customer required. Benefit for ADM: Producing vehicles as customer required.

26 HEIJUNKA CONCEPT Vehicle 1 Vehicle 2 Vehicle 3 Vehicle 4 Consumers will get & unit at period I & III, & at period II & IV Consumers will get,, & unit at each period. No Finished unit stock © Hery Kurniawan Soekamto, July 2004 Basically Heijunka is needed to set average & balance delivery sequence to each customer equally. But Heijunka also can modified due to customer distance, shipment schedule, etc. Consumers will get unit at period I, at period II, at period III, at period IV There are Finished unit stock at each period. Period IPeriod II Period III Period IV

27 Supply Chain Model on Automotive Mfg. Vertical integration and modular sourcing Features Assembly still in house but greater use of bought in components Complete modules purchased from first tier suppler Features Assembly still in house but greater use of bought in components Complete modules purchased from first tier suppler Criteria Source access to supply fro, superior supplier capabilities Where components and suppliers can readily segmented Criteria Source access to supply fro, superior supplier capabilities Where components and suppliers can readily segmented Source: “Transform Your Supply Chain” John Hughes, Mark Ralf, Bill Michels. 27

28 Supply Chain Practices: Milk Run System What is Milk Run?: Milk Run is a delivery system which deliver parts together from various vendors in one area by same truck What is Milk Run?: Milk Run is a delivery system which deliver parts together from various vendors in one area by same truck MILK RUN SUPPLY SYSTEM IMAGEDIRECT SUPPLY SYSTEM IMAGE Vendor Supply Kanban & Empty Box Grouping Area NOTE: Result Benefit for ADM: Reduce transportation cost & stock. Benefit for ADM: Reduce transportation cost & stock. 28

29 Japan Disaster Impact to Automotive Industry 29

30 Japan Disaster 2011 EARTH QUAKETSUNAMI NUCLEAR POWER PLANT DAMAGE IMPACTS 1. Enormous and widespread disaster 2. Restricted entry area 3. Electrical power shortage  periodical shutdown  change working days to Saturday & Sunday IMPACTS 1. Enormous and widespread disaster 2. Restricted entry area 3. Electrical power shortage  periodical shutdown  change working days to Saturday & Sunday 30

31 Impact to Japan / Global Industries 31

32 Impact to Automotive Industries Critical Impact on Production & Development Activities Shortage supply of electronic components Production volume decreasing 32

33 ADM Recovery Actions Confirm of component stock level Confirm of recovery period from each supplier Adjust factory operations Change production line speed Adopt alternative materials / parts Change product specifications Confirm of component stock level Confirm of recovery period from each supplier Adjust factory operations Change production line speed Adopt alternative materials / parts Change product specifications 33


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