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 Processes

Products &
Materials &
Services
Customers
Planning and Control
Input Output
Production System
 Contoh Organisasi Manufaktur

Chief Executive
Officer

Marketing Engineering Human Information Finance Manufacturing Quality

and Sales Resources Systems

Research and Manufacturing

Development Engineering

Product
Design Production Materials
Management

Industrial
Engineering
Traditional “Silo” Organizations

M P
E A F
R
N R S I
O
G K A N Q
D
I E L A U
U
N T E N A
C
E I S C L
T
E N E I
I
R G T
O
I Y
N
N
G
 II. Manufacturing Strategy

Strategy menentukan delivery lead time Strategy

Lead time
1. Engineer-to-Order
Design Purchasing Manufacture Assemble Ship (ETO)

Lead time

Inventory Manufacture Assemble Ship 2. Make-to-Order

(MTO)
Lead time

Manufacture Inventory Assemble Ship 3. Assemble-to-Order

(ATO)
Lead time
4. Make-to-Stock
Manufacture Assemble Inventory Ship (MTS)
 Lead Time

“A span of time required to perform a process”

—APICS Dictionary
Delivery lead time
ƒ “The time from the receipt of a customer order to the delivery of
the product”
—APICS Dictionary
Cumulative lead time
ƒ “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 masing-

masing 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 Operations Finance
Increase revenue Reduce Increase profit and
Traditional
manufacturing cost cash flow, reduce
Objective
investment
This implies
1 4 7
Customer service

2 5 8
Production efficiency

3 6 9
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
Marketing/ Plan Finance
Sales Plan Plan
Production
Plan Resources
Forecasts Requirements
Plan
Long-Range

Master Rough Cut

Firm Orders Production Capacity
Plan
Plan

Inventory Status

Material Capacity
Medium
BOM Requirements
Requirements Plan (CRP) Range
Planning Data
Planning

EXECUTION OF PLAN
Production Purchasing
Activity
22
Control
23
Capacity
24
JIT
I/O Shor
Line Balance tRange

Final
Assembly FINAL
Schedule
(FAS)
ASSEMBLY
Production Planning & Inventory Control
 Contoh Skema Mekanisme Penerapan PPIC
VENDOR Material flow
Invoices
Mtrls & Paperwork flow
components
Purchase Accounting
5 Invoices
Order (PO)
Receiving 11
4
6 Job cost
Purchasing reports
Inspection CUSTOMER
7
Material to storage Product
Production Planning & Control 10
Material
Planning 3 control Cpltd work & p’chased cmpnnts to final assy
Prepare: Inspection
ƒMtrl requisitions Completed components to storage
ƒBill of Mtrls Mtrl
Status Material to shop 9 Order for
•Route Sheet report 8
product
•Blueprints Release
•Specifications job to Final 1
Scheduling & shop Work Work
•Move tickets assembly
dispatching center 1 center 2
•Mtrls releases shop

Schedule & completion feedback information 2 SALES

 V. Peranan PPIC dalam Supply Chain

S C
U U
P S
P DISTRIBUTION T
MANUFACTURER
L SYSTEM O
I M
E E
R R

Production
Physical
Planning and Physical Distribution
Supply
Control

Dominant Flow of Products and Services

Dominant Flow of Demand and Design Information

 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

Manufacturing Resource Planning (MRP II)

PAC Inventory CRP Purchasing Accounting
MPS Customer Service Order Entry Forecasting

Material Requirements Planning (MRP)

 VIII. PPIC Game

Demo PPIC Game ………………..