Manufacturing

System
TI-184414

Manufacturing Systems Laboratory

Department of Industrial Engineering
Institut Teknologi Sepuluh Nopember

© 2023
Course Description

Manufacturing system as important part of modern industry should be designed and controlled
properly to achieve ths strategic objectives, which meet all customer needs, provide high quality
products with shorter delivery time. By following these criteria, the company will be able to sus-
tain and compete optimally. Industrial Engineers have to improve their skills and competencies
for solving real problem, both in manufacture and service industries. This course provides know-
ledge and insight of operations and how to improve it by using appropriate techniques in modern
industry.
Prerequisite

• Engineering Drawing
• Manufacturing Process
• Cost Analysis & Estimation
Course Schedule

Week Date Topic

1 29/8/23 Introduction to Manufacturing System
2 5/9/23 Manufacturing System Architecture, Operational Parameters of a Manufacturing System.
3 12/9/23 Product Design and Development, Assembly & Disassembly.
Material Handling and Storage System.
4 19/9/23
Quality Inspection and Packaging.
5 26/9/23 Guest Lecture
6 3/10/23 Automatic Data Capture.
7 10/10/23 Practicum - 1
8 16-20/10/23 Mid Semester Exam.
9 24/10/23 Single Cell Manufacturing; Automatic Production Line.
10 1/11/23 Cellular Manufacturing, Flexible Manufacturing System.
11 7/11/23 Just in Time, Lean Manufacturing and Toyota Production System.
12 14/11/23 Reconfigurable, Virtual & Intelligent Manufacturing System.
13 21/11/23 Practicum – 2
14 28/11/23 Concept and Application: Industry 4.0.
15 5/12/23 Final Project Presentation.
16 10-15/12/23 Final Semester Exam.
Assessment

No. Type of Evaluation Weight (%)

1 Study Guide (Individual Assignment) 15 %

2 Practicum 1 10 %
3 Practicum 2 10 %
4 Class Assignment and Participation 5%
5 Group Project 20%
6 Mid Semester Exam 20%
7 Final Semester Exam 20%
Assessment
No. CPMK Bobot CPMK Bentuk Assessment Bobot setiap assessment
Individual Assignment week 2 (Study Guide) 1.00%
Individual Assignment week 3 (Study Guide) 1.00%
1 CPMK 1 17.00% Mid Semester Exam 5.00%
Big Assignment 5.00%
Final Semester Exam 5.00%
Individual Assignment week 2 (Study Guide) 1.00%
Individual Assignment week 4 (Study Guide) 1.00%
Individual Assignment week 6 (Study Guide) 1.00%
Practicum Report 1 5.00%
2 CPMK 2 28.50% Mid Semester Exam 5.00%
Individual Assignment week 11 (Study Guide) 0.50%
Practicum Report 2 5.00%
Big Assignment 5.00%
Final Semester Exam 5.00%
Practicum Report 1 5.00%
Mid Semester Exam 5.00%
Individual Assignment week 9 (Study Guide) 1.00%
Individual Assignment week 10 (Study Guide) 1.00%
3 CPMK 3 32.50%
Individual Assignment week 11 (Study Guide) 0.50%
Practicum Report 2 5.00%
Big Assignment 10.00%
Final Semester Exam 5.00%
Individual Assignment week 3 (Study Guide) 1.00%
Individual Assignment week 4 (Study Guide) 1.00%
Guest Lecture Resume 1.00%
Individual Assignment week 6 (Study Guide) 1.00%
Mid Semester Exam 5.00%
4 CPMK 4 22.00%
Individual Assignment week 10 (Study Guide) 1.00%
Individual Assignment week 12 (Study Guide) 1.00%
Individual Assignment week 14 (Study Guide) 1.00%
Class Assignment and Participation 5.00%
Final Semester Exam 5.00%
 Reference
▪ Groover, M.P. 2018, Automation, Production Systems, and Computer Integrated Manufacturing, 5th Edition. Pearson Edu
cation Inc., Canada.

▪ Boothroyd, G. 2005, Assembly Automation and Product Design, 2nd Edition. Boothroyd Dewhurst Inc., New York.
▪ Groover, M.P. 2014, Principles of Modern Manufacturing. John Willey & Sons.
▪ Groover, M.P. 2015, Fundamentals of Modern Manufacturing: Materials, Processes, and System, 6th Edition. John Willey
& Sons.
▪ Hitomi, Katsundo, 2017, Manufacturing Systems Engineering: A Unified Approach to Manufacturing Technology, Produc-
tion Management and Industrial Economics, 2nd Edition. Taylor & Francis.
▪ Liker, J., Meier, D., 2006. The Toyota Way Field-book, Jeffrey Liker and David Meier. McGraw-Hill.
▪ Modrak, V., Pandian, R.S., 2011. Operation Management Research and Cellular Manufacturing Systems: Innovative
Methods and Approach. Business Science USA.
▪ Prasetyawan, Y., Agustiani, E. & Jumayla, S. 2017. Aligning Business Strategy of Incubator Center and Tenants. AIP
Conference Proceedings 1855, 030021 (2017); doi: 10.1063/1.4985491, https://doi.org/10.1063/1.4985491.
▪ Stephens, M.P., Meyers, F.E. 2013, Manufacturing Facilities: Design & Material Handling, 5th Edition, Pearson Education
Inc., Canada.
Class Rules

• Class will be held on Tuesday (10.00 – 12.30).

• Students attend the class on time (students are
expected to come no more than 15 minutes after the
classs begin.
• Students must have and bring at least 1 book or relevant
paper and should read it before attending the class.
• Showing good attitude inside of class.
• Please turn off your mobile phone or other electronic
devices during the class.
• Students may use notebook as instructed by the
lecturer/assistants.
• Any fraud in evaluation will be processed according to
the academic rules.
#01
Introduction & Overview :
Manufacturing System
Outline

Manufacture Manufacturing Manufacturing Global

System Industry Classification Challenge
What is manufacture?
Definition

▪ Manufacture → manus (hand) and factus (make)

▪ “Made by hand” accurately described the fabrication methods that were used
when the English word “manufacture” was first coined around 1567 A.D.

▪ Most modern manufacturing operations are accomplished by mechanized and

automated equipment that is supervised by human workers.
Manufacturing

“Manufacturing” definition (by Random House Webster’s College Dictionary):

– “The making of goods or wares by manual labor or by machinery, esp. on
a large scale.”

Definition by National Science Foundation’s Workshop:

– “The creation and integration of informational and physical processes to
create economic wealth through the production of arti-facts.” — NSF 93-
69.”
Why Does Manufacture Becomes Important?
Manufacturing - Technology Perspective
Manufacturing - Economic Perspective
Manufacturing Process
Manufacturing System

CIRP (International Conference on Production Engineering), 1983:

A series of interrelated activities and operations involving the design, materials selection, plan-
ning, manufacturing production, quality assurance, management and marketing of products of
the manufacturing industries.

Material Products

Energy Services
A complex arrangement of phy
Demand sical elements characterized Information
by measurable parameters.
Information Scrap/defects

Measurable parameters : production rate, work in

process inventory, % defects, % on-time delivery, da
ily/weekly/monthly production volume, total cost
Manufacturing System in Corporate View
Human Resource IT / IS Management Corporate System
Financial System
System System System

Manufacturing System
Production System

Production Production
Product and planning control Market
Process Design Analysis

Production activity

Quality Assurance
Manufacturing Cycle

Marketing Product Design Process Design

Inventory Work Methods Design, Time Mea

Production Planning surement, Productivity
Management
Customers

Suppliers
Storage &
Distribution
Production Process Supply Inspection

Quality Production Process Machine &

Control Control Control Equipment Control
 Industrial Classification

PRIMARY SECONDARY TERTIARY

• Agriculture • Aerospace • Fabricated metals • Banking • Insurance
• Forestry • Apparel • Food processing • Communications • Legal
• Fishing • Automotive • Glass, ceramics • Education • Real estate
• Livestock • Basic metals • Heavy machinery • Entertainment • Repair & maintena
• Quarries • Beverages • Paper • Financial services nce
• Mining • Building-materials • Petroleum refining • Government • Restaurant
• Petroleum • Chemicals • Pharmaceuticals • Health & medical • Retail trade
• Computers • Plastics (shaping) • Hotel • Tourism
• Construction • Power utilities • Information • Transportation
• Consumer-appliances • Publishing • Wholesale trade
• Electronics • Textiles
• Equipment • Tire and rubber
• Wood and furniture
Manufacturing Industry
Discrete Manufacturing
Discrete manufacturing produce
discrete products such as compon-
ents, part or single product like
gear, car, aeroplane etc.
Ex : Dirgantara Indonesia, Boeing,
KAI, Toyota, Honda, Hyundai Motor,
Nissan, Maspion, Paramount,
Maxim, Toshiba, Asus, Apple,
Samsung, Krisbow.
Continuous Manufacturing
Continuous manufacturing produce
continuous products such as plas-
tics, mineral water, intertior and exte
rior wall paint, fertilizer, food and be
verages, etc.
Ex : Indofood, Bogasari, Yakult,
Sosro, Petrokimia Gresik, Semen
Indonesia, Holcim, Danone, Frisian
Flag, Nippon Paint, Total E&P
Indonesie, Pertamina.
 Modern Industry

Challenge Globalization

International Outsourcing

Local outsourcing

Contract manufacturing

Trends

Quality expectation

Operational efficiency
Business Approach

• Automation - automated equipment instead of labor.

• Material handling technologies - because manufacturing usually
involves a sequence of activities.
• Manufacturing systems - integration and coordination of multiple
automated or manual workstations.
• Flexible manufacturing - to compete in the low-volume/high-mix
product categories.
• Quality programs - to achieve the high quality expected by today's
customers.
• CIM - to integrate design, production, and logistics.
• Lean production - more work with fewer resources.
Manufacturing System Components

Heilala et.al. (2010)

Manufacturing Support System
Research & development, design
engineering, prototype shop

Process planning, produc

tion planning, MRP,
capacity planning
Sales & marketing, order
entry, cost accounting,
customer billing

Shop floor control, inventory control, quality control Groover (2018)

Organizing Manufacture

Volume Variety Variation Visibility

Number of products to Related to the kind of Number of demands, Related to how far the
be produced. High volu products, affects pro- related to how to mana costumer getting invol-
me products affects the cess focus. ge the process capacity. ved in manufacturing
process repetition, othe process.
rwise a specific (dedi ca
ted) process.
Volume

Low Quantity Production ➔ In the earliest

manufacturing, a skilled craftsman
created goods one by one.

Number of products to Related to the kind of Number of demands,

be produced. High volu products, affects pro- related to how to mana
me products affects the cess focus. ge the process capacity.
process repetition, othe Medium Quantity Production ➔
rwise a specific (dedi ca
ted) process.
100– 10.000 unit per year

High Quantity Production ➔

10.000 unit per year
Variety
Refers to the number of different products or part
design or types produced in the plant.

Hard Product Variety Soft Product Variety

➔ Products differ greatly. ➔ Small differences between

➔ Few common components
in an assembly.
➔ Transformation process
can be highly complex, and
meets the customer’s spe-
cific needs.
products.
➔Many common components
in an assembly.
➔ Transformation process is
well defined, and requires
standardized processes.

➔ High variety operation lead ➔Low variety in the transform

to high unit costs. ation processes leads to a l
ower unit cost.
Variation

Low Variation High Variation

Operations Operations

✓ The transformation pro- ✓ Operation needs to consi

cessNumber of products to
is stable. Number of demands, der the changing demand
be produced. High volu
✓ The metransformation pro- related to how to mana patterns.
products affects the ge the process capacity. ✓ Operation must be highly
cessprocess
is highly routinely.
repetition, othe
✓ The rwise
demand and output flexible to adapt operatio
a specific (dedi ca
are ted)
predictable.
process.
nal processes, in very sh
✓ There is a relatively high ort notice, to changing de
utilization of inputs. mands.
✓ Low variation leads to ✓ Anticipation of customer
low unit costs. behavior is required.
✓ Organization must be abl
e to change capacity.
 Visibility

Low Visibility Operations High Visibility Operations

➢ There is a short waiting tolerance.
➢ There is a time lag between producti
➢ Service perceptions play a role in the
on and consumption.
quality service.
➢ The transformation process and out
➢ A high degree of customer contact
put from the transformation is highly
skills is required, the customer is
standardized.
closely involved in the transformation
➢ Employees in the transformation pro
process.
cess do not require a high level of
➢ There is a high degree of variety
contact (personal) skills.
present as you do not know what the
➢ There is a high staff utilization as e
customer requires and needs, to ada
mployees concentrate on only a limit
pt to the situation in a moment.
ed number tasks.
➢ The per unit cost is very high as the
➢ The transformation process requires
employee is dedicated to the custom
the centralization.
er for a variety (not standardized) set
➢ Low visibility leads to low unit cost.
of services.
Manufacturing Facility
Wrap Up Question

1. Why does manufacturing becomes important?

2. What is the most challenging part in modern manufactu
ring competition?
3. Please mention the example of process manufacturing.
4. Please explain about world class manufacturing.
5. What is the difference between job shop, batch producti
on, and mass production?