Nama : Fajar Lutfi Kelas : 4 MED NIM : 220411010
PROJECT SEMESTER FMS (FLEXIBLE MANUFACTURING SYSTEM)
Penyelesaian :
a) Menentukan Grup Teknologi/Cellular Manufacturing Step 1
101 102 103 104 105 106 107 108 2i
p1 1 1 1 2
p2 1 1 4
p3 1 1 1 1 1 8 p4 1 1 16
p5 1 1 32
p6 1 1 1 64
p7 1 1 1 128
p8 1 1 1 1 256 p9 1 1 1 512
p10 1 1 1 1 1 1024 Wj 230 242 1800 214 1288 1544 1800 1288 Step 2 104 101 102 105 108 106 107 103 2i p1 1 1 1 2
p2 1 1 4
p3 1 1 1 1 1 8 p4 1 1 16
p5 1 1 32
p6 1 1 1 64
p7 1 1 1 128
p8 1 1 1 1 256
p9 1 1 1 512
p10 1 1 1 1 1 1024
Wj 214 230 242 1288 1288 1544 1800 1800
Step 3
104 101 102 105 108 106 107 103 Wj
p1 1 1 1 14
p2 1 1 6
p3 1 1 1 1 1 496 p4 1 1 10
p5 1 1 12
p6 1 1 1 14
p7 1 1 1 14
p8 1 1 1 1 432 p9 1 1 1 448 p10 1 1 1 1 1 496 2i 2 4 8 16 32 64 128 256 Step 4 104 101 102 105 108 106 107 103 Wj p2 1 1 6
p4 1 1 10
p5 1 1 12
p1 1 1 1 14
p7 1 1 1 14
p6 1 1 1 14
p8 1 1 1 1 432
p9 1 1 1 448
p3 1 1 1 1 1 496
p10 1 1 1 1 1 496
2i 2 4 8 16 32 64 128 256
Step 5
104 101 102 105 108 106 107 103
p2 1 1
p4 1 1
p5 1 1 p1 1 1 1 p7 1 1 1 p6 1 1 1 p8 1 1 1 1 p9 1 1 1 p3 1 1 1 1 1 p10 1 1 1 1 1 Waktu Proses Dalam Satuan Menit Load 104 101 102 105 108 106 107 103 Unload p2 4 15 15 4
p4 4 15 35 4
p5 4 16 15 4
p1 4 14 20 14 4
p7 4 20 20 15 4
p6 4 15 15 10 4
p8 4 20 10 10 15 4
p9 4 15 10 10 4
p3 4 25 17 8 5 15 4
p10 4 20 15 10 10 20 4
CELL 1 CELL 2
PART FAMILLY 1
PART FAMILLY 2
LAYOUT MESIN PER CELL
LOAD UNLOAD CELL 1
CELL 2
FR 01
QC 01
GD 01
MK 01
BU 01
FR 02 PC 01 GS 01
c) Hitung Rata-rata produksi setiap produk (produk/jam), dengan frekuensi penggunaan mesin masing-masing 1 kali, palet pada masing-masing mesin 2 buah dan Sistem pemindah memerlukan waktu rata2 transport 4.0 menit dengan 2 carriers.
Tabel Produk
j
Produk Mix Pj
Operation
k Description Station
i
Process
Time Frequency
p1 100
1 Load 100 4 1,0
2 Milling FR01 101 20 1,0
3 Gerinda 102 14 1,0
4 CMM 104 14 1,0
5 Unload 100 4 1,0
p2 100
1 Load 100 4 1,0
2 Milling FR01 101 15 1,0
3 CMM 104 15 1,0
4 Unload 100 4 1,0
p3 100
1 Load 100 4 1,0
2 Bubut 105 25 1,0
3 Milling FR02 108 17 1,0
4 Gerinda Silinder 103 15 1,0
5
Pembersihan
Chip 107 5 1,0
6 Marking Logo 106 8 1,0
7 Unload 100 4 1,0
p4 100
1 Load 100 4 1,0
3 Gerinda Datar 102 35 1,0
4 CMM 104 15 1,0
5 Unload 100 4 1,0
p5 100
1 Load 100 4 1,0
2 Milling 101 16 1,0
3 Gerinda Datar 102 15 1,0
4 Unload 100 4 1,0
p6 100
1 Load 100 4 1,0
2 Milling 101 15 1,0
3 Gerinda Datar 102 10 1,0
4 CMM 104 15 1,0
5 Unload 100 4 1,0
p7 100
1 Load 100 4 1,0
2 Milling 101 20 1,0
3 Gerinda Datar 102 15 1,0
4 CMM 104 20 1,0
5 Unload 100 4 1,0
p8 100
1 Load 100 4 1,0
2 Bubut 105 20 1,0
3 Milling 108 10 1,0
4 Pembersih Chip 107 10 1,0
5 Gerinda Silinder 103 15 1,0
6 Unload 100 4 1,0
p9 100
1 Load 100 4 1,0
2 Gerinda Silinder 103 10 1,0
3 Marking Logo 106 15 1,0
4 Pembersih Chip 107 10 1,0
5 Unload 100 4 1,0
p10 100
1 Load 100 4 1,0
2 Bubut 105 20 1,0
3 Milling 108 15 1,0
4 Gerinda Silinder 103 20 1,0
5 Marking Logo 106 10 1,0
6 Pembersih Chip 107 10 1,0
7 Unload 100 4 1,0
Step 2. Perhitungan rata-rata produksi dalam setiap produk (produk/jam) 1) Menentukan workload
Hitung waktu operasi rata-rata tempat kerja per produk :
L100 = (4+4)(1.0)(0.1 + 0.1 + 0.1 + 0.1 + 0.1 + 0.1 + 0.1 + 0.1 + 0.1 + 0.1) = 8.0 min
L101 = (20)(1.0)(0.1) + (15)(1.0)(0.1) + (16)(1.0)(0.1) + (15)(1.0)(0.1) + (20)(1.0)(0.1) = 8.6 min L102 = (14)(1.0)(0.1) + (35)(1.0)(0.1) + (15)(1.0)(0.1) + (10)(1.0)(0.1) + (15)(1.0)(0.1) = 8.9 min L103 = (15)(1.0)(0.1) + (15)(1.0)(0.1) + (10)(1.0)(0.1) + (20)(1.0)(0.1) = 6.0 min
L104 = (14)(1.0)(0.1) + (15)(1.0)(0.1) + (15)(1.0)(0.1) + (15)(1.0)(0.1) + (20)(1.0)(0.1) = 7.9 min L105 = (25)(1.0)(0.1) + (20)(1.0)(0.1) + (20)(1.0)(0.1) = 6.5 min
L106 = (8)(1.0)(0.1) + (15)(1.0)(0.1) + (10)(1.0)(0.1) = 3.3 min
L107 = (5)(1.0)(0.1) + (10)(1.0)(0.1) + (10)(1.0)(0.1) + (10)(1.0)(0.1) = 3.5 min L108 = (17)(1.0)(0.1) + (10)(1.0)(0.1) + (15)(1.0)(0.1) = 4.2 min
Rata-rata jumlah transport :
nt = (5.0 - 1)(0.1) + (4.0 - 1)(0.1) + (7.0 - 1)(0.1) + (4.0 - 1)(0.1) + (4.0 - 1)(0.1) + (5.0 - 1)(0.1) + (5.0 - 1)(0.1) + (6.0 - 1)(0.1) + (5.0 - 1)(0.1) + (7.0 - 1)(0.1) = 4.2
L109 = (4.2)(4.0) = 16.8 min (part handling station)
Hitung Li/si :
L100/s100 = 8.0/2 = 4.0 L101/s101 = 8.6/2 = 4.3 L102/s102 = 8.9/2 = 4.45 L103/s103 = 6.0/2 = 3.0 L104/s104 = 7.9/2 = 3.95 L105/s105 = 6.5/2 = 3.25 L106/s106 = 3.3/2 = 1.65 L107/s107 = 3.5/2 = 1.75 L108/s108 = 4.2/2 = 2.1
L109/s109 = 16.8/2 = 8.4 (the bottleneck!) ➔ Rmax = 2/16.8 = 0.1190 pc/min (7.14 pc/hr)
2) Production rate for each part:
Rp1 = 7.14 (0.1) = 0.714 pc/hr.
Rp2 = 7.14 (0.1) = 0.714 pc/hr.
Rp3 = 7.14 (0.1) = 0.714 pc/hr.
Rp4 = 7.14 (0.1) = 0.714 pc/hr.
Rp5 = 7.14 (0.1) = 0.714 pc/hr.
Rp6 = 7.14 (0.1) = 0.714 pc/hr.
Rp7 = 7.14 (0.1) = 0.714 pc/hr.
Rp8 = 7.14 (0.1) = 0.714 pc/hr.
Rp9 = 7.14 (0.1) = 0.714 pc/hr.
Rp10 = 7.14 (0.1) = 0.714 pc/hr.
3) Station utilization:
U100 = (8.0/2)(0.1190) = 0.476 ➔ 47.6%
U101 = (8.6/2)(0.1190) = 0.5117 ➔ 51.17%
U102 = (8.9/2)(0.1190) = 0.52955 ➔ 52.955%
U103 = (6.0/2)(0.1190) = 0.357 ➔ 35.7%
U104 = (7.9/2)(0.1190) = 0.47005 ➔ 47.005%
U105 = (6.5/2)(0.1190) = 0.38675 ➔ 38.675%
U106 = (3.3/2)(0.1190) = 0.19635 ➔ 19.635%
U107 = (3.5/2)(0.1190) = 0.20825 ➔ 20.825%
U108 = (4.2/2)(0.1190) = 0.2499 ➔ 24.99%
U109 = (16.8/2)(0.1190) = 1.0 ➔ 100% (Bottleneck)
d) Overall FMS utilization (exclude part handling):
Ū1= [2(0.476) + 2(0.5117) + 2(0.52955) + 2(0.357) + 2(0.47005) + 2(0.38675) + 2(0.19635) + 2(0.20825) + 2(0.2499)]/18 = 0.3762 (37.62%)
e) Optimalisasi Mesin
Set U102 = 100% dan U2 = 1.0 U2 = (L102)(Rmax)/s102, maka 1.0 = L102(0.1190)/2,
L102 = (1x2)/0.1190 = 16.81 min dari yang sebelumnya 8.9 min
Produk p1, p4, p5, p6 dan p7 dikerjakan pada tempat kerja 2
Untuk produk p4 hanya diproses di tempat kerja 2, maka p1, p5, p6 dan p7 sebagai constrained dalam rata-rata waktu produksi oleh tempat kerja lain,
L102 (by p1+p5+p6+p7) = (14)(1.0)(0.1) + (15)(1.0)(0.1) + (10)(1.0)(0.1) + (15)(1.0)(0.1)
= 5.4 min
Jadi dengan penggunaan 100% beban kerja untuk produk p4 meningkat menjadi 16.81 - 5.4 = 11.41 min
dimana sebelumnya 8.9 - 5.4 = 3.5 min, pada utilisasi 52.955%.
L102 (by p4) = (35)(1.0)(0.1) = 3.5 min
Sehingga rata2 produksi untuk produk p4 sekarang bertambah menjadi
Rp4 = (L102 optimum per produk)(Rp4)/L102 (by p4) = (11.41 min)(0.714 pc/hr)/3.5 min = 2.327 pc/hr
Total produksi per jam yang baru adalah (0.714 + 0.714 + 0.714 + 2.327 + 0.714 + 0.714 + 0.714 + 0.714 + 0.714 + 0.714 = 8.753), sehingga part mix berubah menjadi
Part Mix p1 : 0.714/8.753 = 0.081572 Part Mix p2 : 0.714/8.753 = 0.081572 Part Mix p3 : 0.714/8.753 = 0.081572 Part Mix p4 : 2.327/8.753 = 0.265852 Part Mix p5 : 0.714/8.753 = 0.081572 Part Mix p6 : 0.714/8.753 = 0.081572 Part Mix p7 : 0.714/8.753 = 0.081572 Part Mix p8 : 0.714/8.753 = 0.081572
Part Mix p9 : 0.714/8.753 = 0.081572 Part Mix p10 : 0.714/8.753 = 0.081572
Set U102 = 100% dan U2 = 1.0
Pada kasus ini tidak ada produk yang bisa ditambahkan, karena semua produk yang diproduksi melewati bottleneck sehingga produk tersebut tidak dapat dioptimasi lagi atau utilisasi mesin pada kondisi sebelumnya dan sudah optimal.