Perencanaan & Pengendalian Produksi - Ub

PERENCANAAN &PENGENDALIAN PRODUKSITIN 4113

Pertemuan 9 Outline:– Master Production Planning / Jadwal ProduksiInduk Referensi:– Smith, Spencer B., Computer-Based Productionand Inventory Control, Prentice-Hall, 1989.

PRODUCTION PLANNINGMASTER PRODUCTION SCHEDULING(JADWAL PRODUKSI INDUK)

Master Production Scheduling Definition:– a statement of what, how much, and when enditems are planned to be produced over planningperiods. It is a disaggregation and implementationof the production plan.

Master Production Scheduling Functions:– It schedules production and purchase orders forMPS items– It is principal input to MRP system– It is the basis for determining resourcerequirements– It provides the basis for making delivery promisesto customers

Product Level vs Production PlanningFamilyProduction (Aggregate)PlanningItemMaster ProductionSchedulingComponent/MaterialMaterial RequirementPlanning

SOP vs. MPSPROCESSSales & OperationsPlanningMasterSchedulingObjectiveSupply Rate by ProductFamilyAnticipated Build ScheduleItem PlannedProduct FamilyEnd item or Planning Bill ofMaterialsPlanning HorizonLongest Lead TimeResource Plant andEquipmentLongest Cumulative LeadTime for End ItemsConstraintsResource CapacityCritical WorkcentersTime PeriodsMonthlyWeekly or DailyPlanning FocusProduct VolumeProduct MixProcess OutputProduction PlanMaster ProductionSchedule

Production Plan Relationship to MPSProduct Family AJulyAugustSeptemberOctoberNovemberWorking Days/ Month2221232019Approved ProductionPlan from S&OP22,00021,00023,00020,00019,000MPS Week40414243Product A11,0001,0001,0001,000Product A25001,0001,5002,000Product A31,5005005001,500Product A42,0002,5002,000500Total5,0005,0005,0005,000

The Components of MRP IIMarketing PlanForecast DemandProduction PlanResource PlanningMaster ProductionSchedulingRough-CutCapacity PlanningMaterial RequirementsPlanningCapacity RequirementPlanningDistribution PlanOrdersBill of MaterialInventoryRoutingToolProductionAny changes?Reports

Master Production Scheduling Inputs:1. Production PlanMPS must be reconciled with Production Plan2. Demand data Sales forecast Customer orders Safety stocks Field warehouse requirements3. Inventory status4. Ordering policy

Master Production Scheduling Planning Bills:– BOM yang digunakan untuk memfasilitasikemudahan dalam melakukan peramalanpenjualan, perencanaan MPS, menentukan safetystock dan FAS– Jenis-jenis Planning Bills:1. Modular Bills2. Super Bills

Master Production Scheduling Modular BillContoh: sebuah mobil dapat dirakit dengan pilihan:– Transmisi: Manual atau Otomatis (2)Single BOMV-6DieselV-6Diesel– Mesin: V6 atau diesel (2)ManualOtomatisManualOtomatisM01M11M21M31Modular BOM- A01- A01- A01- A01- B10- B10- B11- B11- C20- C10- C20- C10- D01- D11- D21- D31Semua MobilMesinV-6Mesin C10E01F01F11G01G11

Master Production Scheduling Super BillSuper Bill forBOM ModulesP101P102P103P104P104- A01- B10- B11- C20- C10- E01- F01- F11- G01- G11Screw DriversA100Super Bill forProduct 01Slotted1/4"A102Slotted5/16"A103PhillipsNo. 0A104PhillipsNo. 1A105PhillipsNo. 2A106PhillipsNo. 3A107

Master Production Scheduling Memilih Item:– Menentukan efisien tidaknya pelaksanaan pembuatanMPS– Pertimbangan:1.2.3.4.5.Jumlah item sedikit untuk memudahkan dalam pembuatan dan evaluasiMPSItem harus dapat diramalkan (pada MTS) sehingga karakteristikpermintaan item dapat dianalisisSetiap item harus punya BOM sehingga MPS dapat digunakan sebagaidasar pembuatan MRPKapasitas yang dibutuhkan dari item-item yang akan diproduksi harusdapat dihitungItem dalam MPS harus mudah diterjemahkan sebagai produk yangdiminta customer

BOM Structures and FAS, MPS LevelProductsMaterialsPyramid MTO and MTSProductsProductsMaterialsHourglass ATO and MTSProductsMPS levelMaterialsInverted Pyramid MTOMaterialsInverted Pyramid MTSFAS level

BOM Structures and FAS, MPS LevelProducts Pyramid BOM, Sistem Produksi MTO Produk akhir jenisnya sedikit dan tidak distockkarena harganya relatif mahal (mis: pesawatterbang, supercomputer) dimana produk dibuatsesuai spesifikasi yang diinginkan oleh kustomer MPS sama dengan Jadwal Perakitan Akhir (FAS) Cummulative Lead Time dapat dipercepatdengan cara melakukan peramalan permintaandan MPS dibuat jangka waktu yang lebihpanjang lagi sehingga pengadaan material danfabrikasi dapat dilakukan lebih awal Pada kasus MPS yang belum sepenuhnya pastidapat dinyatakan dalam satuan yang cocokseperti jam mesin, jam orang dllMaterials

BOM Structures and FAS, MPS LevelProductsMaterials Pyramid BOM, Sistem Produksi MTS Digunakan untuk produk yang standard (TV,Radio, dsb) MPS dan FAS sama Bila variasi produk sedikit maka produkproduk tersebut bisa langsung dijadualkandalam MPS. Untuk variasi produk banyak, sebaiknyaMPS dinyatakan dalam keluarga produk(super bills). MPS dibuat dalam 2-level,pertama adalah tingkat produk family dankedua adalah produk-produk itu sendiri

BOM Structures and FAS, MPS LevelProductsMaterials Hourglass BOM, Sistem Produksi ETO Tersedia banyak variasi produk akhir yangdapat diminta kustomer dimana setiap pilihandirakit dari sejumlah komponen/subassembly(modul) dengan kombinasi yang berbedabeda (contoh: mobil, PC) MPS dibuat dengan pilihan-pilihanSubassembly level 1, komponen atau modul Bila modul cukup banyak, gunakan super billsdengan MPS Two-level dengan Level-1 adalahproduk generik, dan Level-2 adalah modulmodul pilihan. Komponen dan Subassembly tingkat satupada MPS ini kemudian dirakit menjadiproduk jadi yang sebenarnya dengan FAS

Master Production Scheduling Planning ative Lead TimePlanning HorizonVisibility3 – 6 months

Master Production Scheduling Planning Horizon:The length of each path is the sum of the lead timesE E-B-A 6 4 2 12L L-H-C-A 8 9 8 2 27F F-B-A 2 4 2 8I I-D-A 12 3 2 17G G-C-A 7 8 2 17J J-D-A 5 3 2 10K K-H-C-A 3 9 8 2 22

Master Production Scheduling Planning Horizon:

Master Production Scheduling Manufacturing StrategiesCumulative Order Lead ctShipTYPE OF STRATEGYDelivery to Customer Lead TimeMAKE TO STOCKINVENTORYINVENTORYDelivery Lead TimeINVENTORYINVENTORYCAPACITYCAPACITYASSEMBLE TO ORDERDelivery Lead TimeINVENTORYINVENTORYCAPACITYCAPACITYMAKE TO ORDERDelivery Lead TimeINVENTORYINVENTORYCAPACITYCAPACITYENGINEER TO ORDER

Master Production Scheduling Time Fences0DTFZONE 1Proyeksi Permintaan vsPersediaanJenis orderReschedulingPermintaan aktualPlanningHorizonPTFZONE 2ZONE 3Kombinasi antara permintaan aktual denganperamalanORDERFIRM PLANNEDORDERPLANNED ORDERMP Scheduling ManajemenMP SchedulerSistemAssemblylead timeCummulative lead time

Master Production Scheduling Planned orderPlanned order is an order for future execution which iscalculated automatically by the system Firm planned order (FPO)FPO is an order authorized by master scheduler butnot yet release to manufacturing OrderOrder is production order that have been release tomanufacturing

Master Production Scheduling Content: Header : Item part number, item description, lead time, safety stock, order quantity policy,DTF and PTFBody : information for each time bucket through the planning horizon:–––––Forecast forecast of independent demandProduction forecast the calculated dependent demandActual demand promised customer ordersMPS the scheduled receipts of orders and FPOsProjected available balance a projection of the on-handinventory less any allocations or back orders– Available to Promise (ATP) the quantity from the currentbalance and from each MPS order that has not already beenpromised to customer and is, therefore, available to promise– Planned orders by period in which they are scheduled to bereceived

The Example of MPSMPS for an MTS Product (1)Item no: X1736Lead time: 3 periodsOrder Quantity : 3 periods netrequirementsDescriptionSafety stockDTFPTF: Generator: 3 unit: 0 period: 5 -13-23Production forecastActual demandMPSProjected available balance15149613Available to promisePlanned order16For periods 6, 7, and 8 the net requirements is Demand Safety stock – Starting projected available balance (5 8 4) 3–4 16This will be the planned order to be received in period 6 and to be released in period 310

The Example of MPSMPS for an MTS Product (2)MPS might look one period later. Demand in period 1 was actually 7 (forecast 5), so theprojected available balances for periods 1 through 5 are lower by 2 units. The forecast forperiods 2 through 9 is unchanged, but period 10 has been added with a demand of 7Item no: X1736Lead time: 3 periodsOrder Quantity : 3 periods netrequirementsDescriptionSafety stockDTFPTF: Generator: 3 unit: 0 period: 5 4Production forecastActual demandMPSProjected available balance157411189215Available to promisePlanned order17

The Example of MPSMPS for an MT0 Tidak akan ada ramalan/proyeksi stok karena produksi hanya dilakukan setelah adapesanan langsung dari kustomer DTF dan PTF jatuh pada waktu yang sama Pesanan yang jatuh tempo di luar PTF dialokasikan sebagai Planned Order, sedangkanyang berada pada daerah PTF dialokasikan pada MPSItem no: Y750Lead time: 5 periodsOrder Quantity : Lot for LotDescription : Digital ControllerSafety stock : 0 unitDTF/PTF: 6/6 periodDTFPTFPeriod1234567Actual demand5573421MPS557342ForecastProduction forecastProjected available balanceAvailable to promisePlanned order189

The Example of MPSMPS for an MTO/MTS Product (1) Hybrid system Produk akhir terlalu mahal untuk di stok, tetapi harus tersediasebelum ada permintaan MPS berdasarkan forecast, dan permintaan customer dipenuhisesuai sesuai waktu yang dijanjikan Biasanya karakteristik produk hampir standard (minorcustomizing) sehingga MPS bisa dibuat berdasarkan ramalansebelum pesanan kustomer benar-benar diterima

The Example of MPSMPS for an MTO/MTS Product (2)Item no: Z438Lead time: 3 periodsOrder Quantity : 4 periods netrequirementsDescriptionSafety stockDTFPTF: Electronics microscope: 0 unit: 3 periods: 6 5321101-14Production forecastActual demandMPSProjected available balanceAvailable to promisePlanned order1811711141028927162514Avaible to Promise (ATP) stok awal – total permintaan aktual dan permintaansebelum MPSATP (Period 1) 11 – 4 – 6 1ATP (Period 3) MPS (Period 3) – Actual demands (Period 3 and 4) 18 – 5 – 3 10

The Example of MPSMPS for an MTO/MTS Product (3)The MPS for one period later :Item no: Z438Lead time: 3 periodsOrder Quantity : 4 periods netrequirementsDescriptionSafety stockDTFPTF: Electronics microscope: 0 unit: 3 periods: 6 564211590-15-23Production forecastActual demand18MPSProjected available balanceAvailable to promisePlanned order711417288262123

Master Production Scheduling Metode Disagregasi:– Metode Heuristic– Metode Linear Programming– Metode Family Setup

Pertemuan 10 - Persiapan Materi– Metode Disaggregasi– Material Requirement Planning

Digunakan untuk produk yang standard (TV, Radio, dsb) MPS dan FAS sama Bila variasi produk sedikit maka produk-produk tersebut bisa langsung dijadualkan dalam MPS. Untuk variasi produk banyak, sebaiknya MPS dinyatakan dalam keluarga produk (super bills). MPS dibuat dalam 2-level, pertama adalah tingkat produk family dan