PERENCANAAN AGREGAT

(DISAGREGASI) & TEORI

KAPASITAS
 Tujuan Pembelajaran
• Mahasiswa mampu menggunakan teknik
disagregasi
• Mahasiswa mampu menyusun Master
Production Schedule (MPS) atau Jadwal Induk
Produksi (JIP).
 Definisi Work Center
• Section of a production facility where all task
associated with a particular process (such as
assembling, painting, welding) are performed.
• It usually has more than one machine.

Sumber: 
http://www.businessdictionary.com/definition
/work-center.html#ixzz11xhyQTXS
 Ilustrasi Work Center

WELDING
CUTTING
MACHINE WELDING
CIRLING
MACHINE

Main
SAFETY
Assembly
EQUIPMENT
Table Support
Assembly
Table
Welding Work Center

Boxes

Assembly Work Center

 Workstation
• Assigned location for an employee to perform
his or her job, and which is equipped with all
the required tools and facilities.
• It usually has one main working component.
• It is specifically dedicated to one employee
only.
• Workstations are commonly networked
together.
Workstation Illustration

Main
Machine
Incoming Outgoing
WIP WIP
 Takt Time
Takt Time = Total Daily Operating Time / Total Daily Customer Requirements

Where Operating Time does not include TPM, 5S, meeting times, breaks, etc…

So… Takt time is calculated and not measured. It can help to determine process
capabilities

Contoh:
Customer A requires 5000 pieces per week or 1000 pieces per day.
Operating time is 8 hours – breaks = 7,5 hours/shift

Tak time = (7,5 hours x 3600 seconds/hours) / (1000 pieces)

= 27 seconds/piece
 Definisi Kapasitas
• the rate of output from an OM system per unit of
time
• the rate at which the firm withdraws work from
the system
• Jumlah masukan sumberdaya-sumberdaya yang
tersedia relatif untuk kebutuhan keluaran pada
waktu tertentu.

• Satuan unit : jumlah/waktu atau waktu/unit

 Definisi Kapasitas Produksi
• In general, production capacity is the maximum
production rate of an organization (or maximum
conversion rate of a production system) in any given
period.
• Sustainable practical capacity is the greatest level of
output that a plant can maintain:
within the framework of a realistic work schedule
taking account of normal downtime
assuming sufficient availability of inputs to operate
the machinery and equipment in place
 Definisi Macam-Macam Kapasitas (1)
 Design Capacity : tingkat keluaran per satuan untuk
mana pabrik dirancang.
 Rated Capacity ; tingkat keluaran per satuan waktu
yang menunjukkan bahwa fasilitas secara teoritik
mempunyai kemampuan memproduksi.
 Standard capacity : tingkat keluaran per satuan
waktu yang ditetapkan sebagai sasaran
pengoperasian bagi manajemen, supervisi dan para
operator mesin, dapat digunakan sebagai dasar bagi
penyusunan anggaran.
 Definisi Macam-Macam Kapasitas (2)
 Actual dan atau operating capacity : tingkat
keluaran rata-rata per satuan waktu selama
periode waktu yang telah lewat = kapasitas
standar ± cadangan-cadangan, penundaan,
tingkat sisa nyata.
 Peak capacity : jumlah keluaran per satuan waktu
yang dapat dicapai melalui maksimisasi keluaran
dengan kerja lembur, menambah tenaga kerja,
mengurangi jam istirahat dan sebagainya.

Muhammad Adha Ilhami

 How a plant/system is organized
 Level of output of a plant or system is
dependent on how it is organized
capacity in sequence: linear operations, is
based on the operation with the lowest
amount of capacity
capacity in parallel:
 multiple alternative operations
 any machine can be used
 Capacity in Sequence
capacity in sequence: linear operations, is
based on the operation with the lowest
amount of capacity.
Contoh:
 Operasi 1 : 20 unit/jam
 Operasi 2 : 10 unit/jam
 Operasi 3 : 15 unit/jam
 Maka kapasitas sistem adalah 10 unit/jam
Capacity in Sequence (Illustration)
Meski mampu
menghasilkan 15
unit dalam 1 jam.
Namun karena
Meski ada hanya ada
inputan 20 unit inputan 10 unit
dalam 1 jam. maka dalam 1
Stasiun ini jam hanya
Dalam 1 jam
hanya mampu menghasilkan 10
menghasilkan
menghasilkan unit
20 unit
10 unit
Dalam satu
jam hanya
akan
20/jam 10/jam 15/jam dihasilkan
10 unit
 Capacity in Parallel
capacity that is based on the sum of the capacities
of the various machines that make up the operation.
Contoh:
 Operation 3 has 4 machines
 machine 1 - 90 pieces per minute
 machine 2 - 110 pieces per minute
 machine 3 -120 pieces per minute
 machine 4 - 80 pieces per minute
 Total capacity for operation 3 = 400 pieces/min
Capacity in Parallel (Illustration)
Dalam satu menit
dihasilkan
90/menit 90 unit

90 + 110 + 120
110/menit 110 unit + 80 = 400
unit/menit

120/menit 120 unit

80/menit 80 unit
 How about this one?

100/meni
90/menit 70/menit
t

110/meni
80/menit 60/menit

?
t

120/meni 150/meni 135/meni

t t t

80/menit 50/menit 90/menit

Berapa Kapasitas Produksi Sistem ini dalam 1 jam?

 URGENSI DISAGREGASI
Disagregasi diperlukan jika peramalan
dilakukan dalam unit aggregate, namun jika
peramalan tidak dilakukan dalam unit
aggregate maka disagregasi tidak diperlukan.

Sementara peramalan dalam unit aggregate

dilakukan atas dasar simplifikasi (filosofi dari
aggregate plan)
Alur Proses Pengolahan Data – Peramalan –
Rencana Agregat
Item Family Family

Data Produk Agregasi Disagregasi

A

Agregasi Perancangan Disagregasi

Data Produk Peramalan
Data B Family
Agregat
MPS
Family

Agregasi Disagregasi
Data Produk
C

Agregasi Perancangan Disagregasi

Data family Peramalan
Agregat
A Family
Family

Data family Agregasi Peramalan Perancangan Disagregasi

Data B Family Agregat MPS
Family

Agregasi Perancangan Disagregasi

Data family Peramalan
C Family Agregat
Family
 Perhitungan Persentase
(dengan nilai penjualan)
Periode Jan Feb Mar Apr Mei Jun
Family X 200 250 400 210 450 255
(hasil forecast 2010)

Data Penjualan Terdahulu (2009)

Periode Jul Agu Sept Okt Nov Dec
Produk A 100.00 80.00 65.00 180.00 90.00 150.00
Demand Produk B
80.00 65.00 50.00 100.00 50.00 80.00
Records
Produk C 120.00 115.00 85.00 120.00 100.00 110.00
Family X 300 260 200 400 240 340
 Perhitungan Persentase
(dengan nilai penjualan)
Perhitungan Persentase
Harga
Produk Periode Jul Agu Sept Okt Nov Dec Total Persentase
Produk
A 100.00 Produk A 10,000.00 8,000.00 6,500.00 18,000.00 9,000.00 15,000.00 66,500.00 0.27
Demand Produk B
B 200.00 16,000.00 13,000.00 10,000.00 20,000.00 10,000.00 16,000.00 85,000.00 0.34
Records
C 150.00 Produk C 18,000.00 17,250.00 12,750.00 18,000.00 15,000.00 16,500.00 97,500.00 0.39
    Family X 44,000.00 38,250.00 29,250.00 56,000.00 34,000.00 47,500.00 249,000.00  

Disagregasi Hasil Peramalan

Periode Jan Feb Mar Apr Mei Jun
Family X 200 250 400 210 450 255
Produk A 53.41 66.77 106.83 56.08 120.18 68.10
Demand Produk B 68.27 85.34 136.55 71.69 153.61 87.05
Forecast
Produk C 78.31 97.89 156.63 82.23 176.20 99.85

Example : MPS Januari (Produk A) = 200 x 0,27 = 53,41

MPS Januari (Produk B) = 200 x 0,34 = 68,27
MPS Januari (Produk C) = 200 x 0,39 = 78,31
 Disagregasi Menggunakan Teknik Persentase
(dengan pertimbangan nilai conversion)
Data Penjualan Terdahulu
Periode Jul Agu Sept Okt Nov Dec
Produk A 100.00 80.00 65.00 180.00 90.00 150.00
Demand Produk B
80.00 65.00 50.00 100.00 50.00 80.00
Records
Produk C 120.00 115.00 85.00 120.00 100.00 110.00
Family X 300 260 200 400 240 340

Perhitungan Persentase
Waktu Conversi
Produk Proses on Periode Jul Agu Sept Okt Nov Dec Total %

A 74.34 0.61 Produk A

61.25 49.00 39.81 110.24 55.12 91.87 407.28 0.32
Demand Produk B
B 62.32 0.51
Records 41.07 33.37 25.67 51.34 25.67 41.07 218.21 0.17
C 121.38 1.00 Produk C
120.00 115.00 85.00 120.00 100.00 110.00 650.00 0.51
      Family X 222.32 197.37 150.48 281.59 180.79 242.94 1,275.49
 
 Disagregasi Menggunakan Teknik
Persentase
(dengan pertimbangan nilai conversion)
Disagregasi (Persentase dari nilai penjualan)
Periode Jan Feb Mar Apr Mei Jun
Family X 200 250 400 210 450 255
Produk A 63.86 79.83 127.73 67.06 143.69 81.43
Demand Produk B 34.22 42.77 68.43 35.93 76.98 43.62
Forecast
Produk C 101.92 127.40 203.84 107.02 229.32 129.95

Example : MPS Januari (Produk A) = 200 x 0,32 = 63,86

MPS Januari (Produk B) = 200 x 0,17 = 34,22
MPS Januari (Produk C) = 200 x 0,51 = 101,92
 Hasil Disagregasi (MPS/JIP)

Master Production Schedule / Jadwal Induk Produksi

Periode Jan Feb Mar Apr Mei Jun
Produk A 64 80 128 68 144 82
Demand Produk B 35 43 69 36 77 44
Forecast
Produk C 102 128 204 108 230 130