Production Planning

&
Inventory Control

MINGGU 1
 KONTRAK PERKULIAHAN
 1. Tugas harus selalu mengumpulkan walaupun tidak masuk (No
extend)
 2. Komponen penilaian:
 UTS 50%
 Quiz 25%
 Tugas 25%
 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 pre-
production 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 organize 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 planning and control
 To be able to make adjustment due to changes in
demand and rush orders.
FUNCTION OF PPIC
PRE-PLANNING PLANNING CONTROL

(macro level) (micro level)

Dispatching
Product Design Planning Resources

Flow Design Process Planning Inspecting

(Lay out) (Routing)

Forecasting Expediting
Demand Scheduling

Work Station Evaluation

Design Estimating

Feedback
Perbedaan sistem produksi dalam
menghasilkan output barang dan jasa

Ditinjau dari segi produsen

OUT PUT

BARANG JASA

KONSUMEN
Tidak ada kontak
LANGSUNG
 Bentuk nyata
 Bentuk tidak nyata
Tanpa konsumen
barang dapat
diproduksi, soal Harus ada
laku/tidak
merupakan masalah konsumen yang
lain meminta jasa ada
output (jasa)
Tdk perlu ada kontak
antara produsen dan Tidak ada jarak
konsumen
antara produsen
dan konsumen
 BARANG
- Yang penting adalah barangnya
Merupakan tujuan akhir.
- Produktifitas & kualitas bisa diukur
secara kuantitatif
Mempunyai standarisasi mutu
- Mempunyai persediaan produk
akhir.
- Terjadi transformasi :
yaitu : Fisik, kimia, alami
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
 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, PLYWOOD
SIFATNYA : - DISKRIT /INTERMITTEN
PERUBAHAN WUJUD DARI SETIAP TAHAP MUDAH DIAMATI
TIPE PROSES PRODUKSI
MASS PRODUCTION INTERMITTEN PROYEK
Produk
Tipe Order Kumpulan besar Kumpulan Unit tunggal
Aliran Produk Berurutan Tidak pasti Tidak ada
Variasi Produk Rendah Tinggi Sangat tinggi
Tipe Pasar Massa Pesanan Khusus (unik)
Volume Tinggi Menengah Unit tunggal

Tenaga Kerja
Ketrampilan Rendah Tinggi Tinggi
Tipe Kegiatan Bersifat Pengulangan Tidak rutin Tidak rutin
Upah Rendah Tinggi Tinggi

Kapital
Investasi Tinggi Menengah Rendah
Persediaan Rendah Tinggi Menengah
Peralatan Mesin Khusus Serba guna Serba guna

Sasaran
Fleksibilitas Rendah Menengah Tinggi
Biaya Rendah Menengah Tinggi
Kualitas Konsisten Lebih variabel Lebih variabel

PPIC Mudah Sulit Sulit

 Mengantisipasi permintaan konsumen

FEED BACK ( MUNGKIN TERJADI

KETIDAK SESUAIAN ANTARA
RENCANA & PELAKSANAAN)
Membuat jadwal produksi

Melakukan pengaturan dalam

MATERIAL MESIN MANUSIA

Pelaksanaan rencana kerja

SIKLUS MANUFACTURING
 DEMAND

TATA LETAK FASILITAS

I PERAMALAN TRANSFORMASI

N Analisa Proses & Produk O

P
SDM
PENGENDALIAN PRODUKSI
U
BAHAN
U MESIN
PERNC. AGREGAT PERNC. BAHAN PENJADWALAN
BARANG
&
T
T MODAL
DAN DAN DAN JASA P
PENJADWALAN KAPASITAS PENGENDALIAN U
PRODUKSI
T
PERAWATAN

PENGENDALIAN PENGENDALIAN PENGENDALIAN

PERSEDIAAN MUTU BIAYA

LINGKUNGAN