PERENCANAAN &

PENGENDALIAN PRODUKSI
Asep Anwar, S.T., M.T.
 Pertemuan
• Outline:
– Master Production Planning / Jadwal Produksi
Induk

• Referensi:
– Smith, Spencer B., Computer-Based Production
and Inventory Control, Prentice-Hall, 1989.
PRODUCTION PLANNING

MASTER PRODUCTION SCHEDULING

(JADWAL PRODUKSI INDUK)
 Master Production Scheduling
• Definition:
– a statement of what, how much, and when end
items are planned to be produced over planning
periods. It is a disaggregation and implementation
of the production plan.
 Master Production Scheduling
• Functions:
– It schedules production and purchase orders for
MPS items
– It is principal input to MRP system
– It is the basis for determining resource
requirements
– It provides the basis for making delivery promises
to customers
 Product Level vs Production Planning

Family Production (Aggregate)

Planning

Master Production
Item
Scheduling

Material Requirement
Component/Material
Planning
 SOP vs. MPS
PROCESS
Sales & Operations Master
Planning Scheduling
Objective Supply Rate by Product Anticipated Build Schedule
Family
Item Planned Product Family End item or Planning Bill of
Materials
Planning Horizon Longest Lead Time Longest Cumulative Lead
Resource Plant and Time for End Items
Equipment
Constraints Resource Capacity Critical Workcenters

Time Periods Monthly Weekly or Daily

Planning Focus Product Volume Product Mix

Process Output Production Plan Master Production

Schedule
 Production Plan Relationship to MPS

Product FamilyA July August September October November

Working Days/ Month 22 21 23 20 19
Approved Production
22,000 21,000 23,000 20,000 19,000
Plan from S&OP

MPS Week 40 41 42 43
Product A1 1,000 1,000 1,000 1,000
Product A2 500 1,000 1,500 2,000
Product A3 1,500 500 500 1,500
Product A4 2,000 2,500 2,000 500
Total 5,000 5,000 5,000 5,000
 The Components of MRP II
Marketing Plan

Forecast Demand Production Plan Resource Planning

Distribution Plan

Orders Master Production Rough-Cut

Scheduling Capacity Planning
Bill of Material

Inventory Material Requirement s Capacity Requirement

Planning Planning

Routing Tool

Production

Any changes?

Reports
 Master Production Scheduling
• Inputs:
1. Production Plan
MPS must be reconciled with Production Plan
2. Demand data
• Sales forecast
• Customer orders
• Safety stocks
• Field warehouse requirements
3. Inventory status
4. Ordering policy
 Master Production Scheduling
• Planning Bills:
– BOM yang digunakan untuk memfasilitasi
kemudahan dalam melakukan peramalan
penjualan, perencanaan MPS, menentukan safety
stock dan FAS
– Jenis-jenis Planning Bills:
1. Modular Bills
2. Super Bills
 Master Production Scheduling
• Modular Bill
Contoh: sebuah mobil dapat dirakit dengan pilihan:
– Transmisi: Manual atau Otomatis (2) Single BOM
– Mesin: V6 atau diesel (2) V-6 V-6 Diesel Diesel
Manual Otomatis Manual Otomatis

M01 M11 M21 M31

- A01 - A01 - A01 - A01

- B10 - B10 - B11 - B11

- C20 - C10 - C20 - C10

Modular BOM - D01 - D11 - D21 - D31

Semua Mobil Mesin Mesin Diesel Transmisi Transmisi

V-6 Manual Otomatis
A01 B10 B11 C20 C10
E01 F01 F11 G01 G11
 Master Production Scheduling
• Super Bill

Super Bill for P101 P102 P103 P104 P104

BOM Modules
- A01 - B10 - B11 - C20 - C10

- E01 - F01 - F11 - G01 - G11

Screw Drivers
A100 Super Bill for
Product Families

0.12 0.18 0.23 0.16 0.14 0.10 0.07

Slotted Slotted Slotted Phillips Phillips Phillips Phillips

3/16" 1/4" 5/16" No. 0 No. 1 No. 2 No. 3
A101 A102 A103 A104 A105 A106 A107
 Master Production Scheduling
• Memilih Item:
– Menentukan efisien tidaknya pelaksanaan pembuatan
MPS
– Pertimbangan:
1. Jumlah item sedikit untuk memudahkan dalam pembuatan dan evaluasi
MPS
2. Item harus dapat diramalkan (pada MTS) sehingga karakteristik
permintaan item dapat dianalisis
3. Setiap item harus punya BOM sehingga MPS dapat digunakan sebagai
dasar pembuatan MRP
4. Kapasitas yang dibutuhkan dari item-item yang akan diproduksi harus
dapat dihitung
5. Item dalam MPS harus mudah diterjemahkan sebagai produk yang
diminta customer
 BOM Structures and FAS, MPS Level
Products Products

Materials Materials
Pyramid MTO and MTS Hourglass ATO and MTS

Products Products

MPS level
Materials Materials
FAS level
Inverted Pyramid MTO Inverted Pyramid MTS
 BOM Structures and FAS, MPS Level
• Pyramid BOM, Sistem Produksi MTO
Products
 Produk akhir jenisnya sedikit dan tidak distock
karena harganya relatif mahal (mis: pesawat
terbang, supercomputer) dimana produk dibuat
sesuai spesifikasi yang diinginkan oleh kustomer
 MPS sama dengan Jadwal Perakitan Akhir (FAS)
 Cummulative Lead Time dapat dipercepat
Materials dengan cara melakukan peramalan permintaan
dan MPS dibuat jangka waktu yang lebih
panjang lagi sehingga pengadaan material dan
fabrikasi dapat dilakukan lebih awal
 Pada kasus MPS yang belum sepenuhnya pasti
dapat dinyatakan dalam satuan yang cocok
seperti jam mesin, jam orang dll
 BOM Structures and FAS, MPS Level
• Pyramid BOM, Sistem Produksi MTS
Products
 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.
Materials
 Untuk variasi produk banyak, sebaiknya
MPS dinyatakan dalam keluarga produk
(super bills). MPS dibuat dalam 2-level,
pertama adalah tingkat produk family dan
kedua adalah produk-produk itu sendiri
 BOM Structures and FAS, MPS Level
• Hourglass BOM, Sistem Produksi ETO
Products
 Tersedia banyak variasi produk akhir yang
dapat diminta kustomer dimana setiap pilihan
dirakit dari sejumlah komponen/subassembly
(modul) dengan kombinasi yang berbeda-
beda (contoh: mobil, PC)
 MPS dibuat dengan pilihan-pilihan
Subassembly level 1, komponen atau modul
Materials  Bila modul cukup banyak, gunakan super bills
dengan MPS Two-level dengan Level-1 adalah
produk generik, dan Level-2 adalah modul-
modul pilihan.
 Komponen dan Subassembly tingkat satu
pada MPS ini kemudian dirakit menjadi
produk jadi yang sebenarnya dengan FAS
 Master Production Scheduling
• Planning Horizon:

Procurement Fabrication Assemble Packing Visibility

Cumulative Lead Time 3 – 6 months

Planning Horizon
 Master Production Scheduling
• Planning Horizon:

The length of each path is the sum of the lead times

E = E-B-A = 6+4+2 = 12 L = L-H-C-A = 8+9+8+2 = 27
F = F-B-A = 2+4+2 = 8 I = I-D-A = 12+3+2 = 17
G = G-C-A = 7+8+2 =17 J = J-D-A = 5+3+2 = 10
K = K-H-C-A = 3+9+8+2 = 22
 Master Production Scheduling
• Planning Horizon:
 Master Production Scheduling
• Manufacturing Strategies
Cumulative Order Lead Time

Purchase Manufacture Assemble hip

TYPE OF STRATEGY
Materials Parts
S Product
Delivery to Customer Lead Time
INVENTORY
INVENTORY MAKE TO STOCK

Delivery Lead Time

INVENTORY
INVENTORY CAPACITYCAPACITY ASSEMBLE TO ORDER

Delivery Lead Time

INVENTORY
INVENTORY CAPACITY
CAPACITY MAKE TO ORDER

Delivery Lead Time

INVENTORY
INVENTOR CAPACITY
CAPACITY ENGINEER TO ORDER
Y
 Master Production Scheduling
• Time Fences Planning
0 DTF PTF Horizon

ZONE 1 ZONE 2 ZONE 3

Proyeksi Per- Kombinasi antara permintaan aktual dengan

mintaan vs Permintaan aktual peramalan
Persediaan

FIRM PLANNED
Jenis order ORDER PLANNED ORDER
ORDER

MP Scheduling +
Rescheduling MP Scheduler Sistem
Manajemen

Assembly
lead time

Cummulative lead time

 Master Production Scheduling
• Planned order
Planned order is an order for future execution which is
calculated automatically by the system

• Firm planned order (FPO)

FPO is an order authorized by master scheduler but
not yet release to manufacturing

• Order
Order is production order that have been release to
manufacturing
 Master Production Scheduling
• Content:
• Header : Item part number, item description, lead time, safety stock, order quantity policy,
DTF and PTF
• Body : information for each time bucket through the planning horizon:
– Forecast  forecast of independent demand
– Production forecast  the calculated dependent demand
– Actual demand  promised customer orders
– MPS  the scheduled receipts of orders and FPOs
– Projected available balance  a projection of the on-hand
inventory less any allocations or back orders
– Available to Promise (ATP)  the quantity from the current
balance and from each MPS order that has not already been
promised to customer and is, therefore, available to promise
– Planned orders  by period in which they are scheduled to be
received
 The Example of MPS
MPS for an MTS Product (1)
Item no : X1736 Description : Generator
Lead time : 3 periods Safety stock : 3 unit
Order Quantity : 3 periods net DTF : 0 period
requirements PTF : 5 periods
PTF
Period 1 2 3 4 5 6 7 8 9
Forecast 5 3 8 2 7 5 8 4 10
Production forecast
Actual demand
MPS 15
Projected available balance 14 9 6 13 11 4 -1 -9 -13 -23
Available to promise
Planned order 16 10

For periods 6, 7, and 8 the net requirements is

= Demand + Safety stock – Starting projected available balance
= (5 + 8 + 4) + 3 – 4
= 16
This will be the planned order to be received in period 6 and to be released in period 3
 The Example of MPS
MPS for an MTS Product (2)
MPS might look one period later. Demand in period 1 was actually 7 (forecast = 5), so the
projected available balances for periods 1 through 5 are lower by 2 units. The forecast for
periods 2 through 9 is unchanged, but period 10 has been added with a demand of 7

Item no : X1736 Description : Generator

Lead time : 3 periods Safety stock : 3 unit
Order Quantity : 3 periods net DTF : 0 period
requirements PTF : 5 periods
PTF
Period 2 3 4 5 6 7 8 9 10
Forecast 3 8 2 7 5 8 4 10 7
Production forecast
Actual demand
MPS 15 18
Projected available balance 7 4 11 9 2 15 7 3 -7 -14
Available to promise
Planned order 17
 The Example of MPS
MPS for an MT0
 Tidak akan ada ramalan/proyeksi stok karena produksi hanya dilakukan setelah ada
pesanan langsung dari kustomer
 DTF dan PTF jatuh pada waktu yang sama
 Pesanan yang jatuh tempo di luar PTF dialokasikan sebagai Planned Order, sedangkan
yang berada pada daerah PTF dialokasikan pada MPS
Item no : Y750 Description : Digital Controller
Lead time : 5 periods Safety stock : 0 unit
Order Quantity : Lot for Lot DTF/PTF : 6/6 period
DTF
PTF
Period 1 2 3 4 5 6 7 8 9
Forecast
Production forecast
Actual demand 5 5 7 3 4 2 1
MPS 5 5 7 3 4 2
Projected available balance
Available to promise
Planned order 1
 The Example of MPS
MPS for an MTO/MTS Product (1)

 Hybrid system
 Produk akhir terlalu mahal untuk di stok, tetapi harus tersedia
sebelum ada permintaan
 MPS berdasarkan forecast, dan permintaan customer dipenuhi
sesuai sesuai waktu yang dijanjikan
 Biasanya karakteristik produk hampir standard (minor
customizing) sehingga MPS bisa dibuat berdasarkan ramalan
sebelum pesanan kustomer benar-benar diterima
 The Example of MPS
MPS for an MTO/MTS Product (2)

Item no : Z438 Description : Electronics microscope

Lead time : 3 periods Safety stock : 0 unit
Order Quantity : 4 periods net DTF : 3 periods
requirements PTF : 6 periods
DTF PTF
Period 1 2 3 4 5 6 7 8 9
Forecast 7 8 3 5 10 11 6 9 15
Production forecast
Actual demand 4 6 5 3 2 1
MPS 18 28
Projected available balance 11 7 1 14 9 27 16 10 1 -14
Available to promise 1 10 25
Planned order 14

Avaible to Promise (ATP) = stok awal – total permintaan aktual dan permintaan
sebelum MPS
ATP (Period 1) = 11 – 4 – 6 = 1
ATP (Period 3) = MPS (Period 3) – Actual demands (Period 3 and 4)
= 18 – 5 – 3 = 10
 The Example of MPS
MPS for an MTO/MTS Product (3)

The MPS for one period later :

Item no : Z438 Description : Electronics microscope

Lead time : 3 periods Safety stock : 0 unit
Order Quantity : 4 periods net DTF : 3 periods
requirements PTF : 6 periods
DTF PTF
Period 2 3 4 5 6 7 8 9 10
Forecast 8 3 5 10 11 6 9 15 8
Production forecast
Actual demand 6 5 6 4 2 1
MPS 18 28
Projected available balance 7 1 14 8 26 15 9 0 -15 -23
Available to promise 1 7 21
Planned order 23