Production Planning & Inventory Control

Wike Agustin Prima Dania, STP, M.Eng

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LITERATURE
INDUSTRIAL ENGINEERING AND PRODUCTION MANAGEMENT, M. TELSANG 2006 OPERATION MANAGEMENT, J HEIZER & B RENDER 2011 DASAR DASAR MANAJEMEN PRODUKSI DAN OPERASI, T H HANDOKO 1999 JOURNAL

 PRODUCTION ACTIVITY: Transformation of material into a desirable output. The efficiency of production system is stated in terms of its ability to produce the product with required quantity and specified quality at predetermined cost and pre-established time. PRODUCTION SYSTEM
quantity quality cost time

PPIC: Direction and coordination of firms resources towards attaining the prefixed goals Helps to achieve un-interupted flow of material through production line by making available the material at the right time and required quantity.

 PRODUCTION PLANNING
Pre-determination of manufacturing requirement such as manpower, materials, machines, and manufacturing process. Problems in production planning:
Non availability of material (due to shortage, etc) Plant, equipment, and machine breakdown Changes in demand and rush orders Absenteeism of workers Lack of coordination and communication between various functional areas of business

PRODUCTION CONTROL
Reviews the progress of the work, and takes corrective steps in order to ensure that programmed production takes place.

Production Planning 1. Production planning is preproduction activity 2. Planning involves the collection, maintenance and analysis of data with respect to time standards, material and their specification, machines and their process capabilities 3. Planning is useful to anticipate the problems 4. Planning is a centralised activity and includes function like material control, tool control, process planning and control 5. Planning sees that all the necessary resources are available to make the production at right quality and time

Production Control 1. Production control will be in action when production activity begins 2. Control is concerned with communication of their information and producing reports like output reports, productivity, rejection rate, etc 3. Control involves in taking correctives steps in case of error to match actual performance against the planned performance 4. Control is a widespread activity 5. Control keeps track of activities and sees whether everything is going as per schedule or not.

NEED FOR PPIC

Effective utilisation of firms resources To achieve the production objectives with respect to quality, quantity, cost and timelines of delivery To obtain the un-interrupted production flow in order to meet customers varied demand with respect to quality and committed delivery schedule To help the company to supply a good quality products to the customer on the continuous basis at competitive rates

OBJECTIVES OF PPIC
Systematic planning of production activities to achieve the highest efficiency in production of goods/services To organise the production facilities (5M) to achieve stated production objectives Optimum scheduling of resources Coordinate with other departments relating to production to achieve regular balanced and uninterrupted production flow To conform to the delivery commitments Material and planning control To be able to make adjustment due to changes in demand and rush orders.

FUNCTION OF PPIC
PRE-PLANNING (macro level) Product Design Flow Design (Lay out) Forecasting Demand Work Station Design PLANNING (micro level) Dispatching Planning Resources Process Planning (Routing) Inspecting CONTROL

Expediting Scheduling Evaluation Estimating

Feedback

Perbedaan sistem produksi dalam menghasilkan output barang dan jasa

Ditinjau dari segi produsen

OUT PUT BARANG KONSUMEN
Tidak ada kontak LANGSUNG

JASA

 Bentuk nyata Tanpa konsumen barang dapat diproduksi, soal laku/tidak masalah lain

Bentuk tidak nyata Harus ada konsumen yang meminta jasa ada output (jasa)

Tdk perlu ada kontak antara produsen dan konsumen

Tidak ada jarak antara produsen dan konsumen

BARANG
- Yang penting adalah barangnya Merupakan tujuan akhir.

JASA
- Yg penting service (pelayanan) Pelayanan merupakan tujuan akhir sehingga tingkat pelayanan merupakan hal yang pokok karena kontak langsung dengan konsumen tinggi. - Lebih sulit mengukur kualitasnya karena banyak hal yang bersifat kualitatif dan tidak rasional, mutu sulit distandarisasi. - Tidak mempunyai persediaan produk akhir, namun hanya mampu membuat persediaan untuk fasilitas - Tidak terjadi transformasi fisik/kimia/alami tetapi yang ada adalah proses pertambahan nilai

- Produktifitas & kualitas bisa diukur secara kuantitatif Mempunyai standarisasi mutu - Mempunyai persediaan produk akhir. - Terjadi transformasi : yaitu : Fisik, kimia, alami

PROSES TRANSFORMASI
DALAM SISTEM PRODUKSI ADA 3 MACAM
1. TRANFORMASI JASA : Tidak terjadi perubahan kimia, fisika, alami tetapi ada pertambahan nilai 2. TRANFORMASI PROSES : Terjadi transformasi kimia/fisik/alami. Contoh : Industri kimia,Pertanian Sifatnya : - Kontinyu Perubahan wujud dari setiap tahap sulit diamati, waktu dan proses tidak dapat dihentikan - Produksi massa (mass Production) Tidak banyak variasi kualitas produksi, bentuk output standar 3. TRANSFORMASI PABRIKASI : Terjadi transfomasi fisik Contoh : Industri manufacturing Meubel, Meubel, Plywood Sifatnya : - Diskrit /intermitten Perubahan wujud dari setiap tahap mudah diamati - Mass Production atau Job order atau Project

TIPE PROSES PRODUKSI

MASS PRODUCTION
Produk Tipe

INTERMITTEN
Kumpulan Tidak pasti Tinggi Pesanan Menengah

PROYEK
Unit tunggal Tidak ada Sangat tinggi Khusus (unik) Unit tunggal

Order Aliran Produk Variasi Produk Tipe Pasar Volume

Tenaga

Kumpulan besar Berurutan Rendah Massa Tinggi

Kerja Ketrampilan Tipe Kegiatan Upah

Kapital Investasi Persediaan Peralatan Sasaran Fleksibilitas Biaya Kualitas PPIC

Rendah Bersifat Pengulangan Rendah

Tinggi Tidak rutin Tinggi

Tinggi Tidak rutin Tinggi

Tinggi Rendah Mesin Khusus

Menengah Tinggi Serba guna

Rendah Menengah Serba guna

Rendah Rendah Konsisten Mudah

Menengah Menengah Lebih variabel Sulit

Tinggi Tinggi Lebih variabel Sulit

Membuat jadwal produksi

Melakukan pengaturan dalam

MATERIAL

MESIN

MANUSIA

Pelaksanaan rencana kerja

SIKLUS MANUFACTURING

FEED BACK ( MUNGKIN TERJADI KETIDAK SESUAIAN ANTARA RENCANA & PELAKSANAAN)

Mengantisipasi permintaan konsumen

DEMAND TATA LETAK FASILITAS

I N P U T

PERAMALAN

TRANSFORMASI

SDM BAHAN MESIN MODAL DAN

Analisa Proses & Produk

PENGENDALIAN PRODUKSI PERNC. AGREGAT PERNC. BAHAN PENJADWALAN DAN KAPASITAS DAN PENGENDALIAN
BARANG & JASA

PENJADWALAN PRODUKSI

O U T P U T

PERAWATAN

PENGENDALIAN PERSEDIAAN

PENGENDALIAN MUTU

PENGENDALIAN BIAYA

LINGKUNGAN