lesson 3: PRODUCTION

1. Jelaskan Just in Time dan Kanban metodology (cari di sumber lainnya ya)

·         Dalam pengertian luas, JIT adalah suatu filosofi tepat waktu yang memusatkan pada aktivitas yang diperlukan oleh segmen-segmen internal lainnya dalam suatu organisasi.

·         JIT merupakan filosofi pemanufakturan yang memiliki impilkasi penting dalam manajemen biaya. Ide dasarJIT sangat sederhana, yaitu produksi hanya apabila ada permintaan (pull system) atau dengan kata lain hanya memproduksi sesuatu yang diminta dan hanya sebesar kuatitas yang diminta. Filosofi JIT digunakan pertama kali oleh Toyota dan kemudian diadopsi oleh banyak perusahaan manufaktur dijepang .

Sistem Kanban :

·         Memberikan informasi pengambilan dan pengangkatan

·         Memberikan informasi produksi

·         Berlaku sebagai perintah kerja yang ditempelkan langsung pada barang

·         Mencegah produk cacat dengan mengenali proses yang membuat cacat.

·         Mengungkap masalah yang ada dan mempertahankan pengendalian persediaan.

·         Pengendalian visual (visual control)

·         Perbaikan proses dan operasi manual.

·         Alat untuk melakukan improvement

2. Gambarkan proses produksi (delapan tahap)
3. Jelaskan multiple forecasting model and strategy

Can assist you in making the best choice. Models are selected through the system using built-in intelligence, while mySAP ERP continuously checks the validaty of the model.

4. Sales Operation demand

Generates sales plans and/or production plans using forecast values and requirements from the sales information system and costing/profitability analysis as inputs for determining requirements.

5. Demand management

Connects forecasting functionally with production scheduling. Also determines requirement quantities and dates for finished products and assemblies step in the planning process.

6. Master Production Planning

Allows for critical resources to be planned with extra attention. MPS is an optional step in the planning process

7. MRP I

Detailed planning of replenishment schedules for required components. The output of MRP is either a planned order or a purchase requisition.

8. Sales and operation planning

Sales and operations planning (SOP) generates plans and production plans using forecast values and requirements from the sales Information System and costing/profitability analysis as inputs for determining requirements. The requirements are reflected in the system as planned quantities of a product over a given period of time, and are not necessarily created on the basis of a customer requirement.

9. Demand management

In Demand Management forecasting, functionally is connected with production scheduling. Requirements quantities and dates for finished products and assemblies based on the plans from SOP are determined.

10. Master Production Scheduling

Master production Scheduling (MPS) allows for critical resources or top-level items to be planned with extra attention. This procedure ensures that the instabilities in planning are kept to a minimum. MPS is an optional step in the planning process.

11. Master Requirement Planning (MRP)

Material Requirements planning (MRP) is the detailed planning of replenishment schedules for required components. The output of MRP is either a planned order or a purchase requisition.

12. Manufacturing Execution

Includes several steps: creation and release of a production order, goods issues of components, confirmation of production activity, and goods receipts of the finished goods.

13. Order Settlement

Allocation of costs from the production order to another object (ex. Sales order, cost center, scrap account, etc)

14. Sales and Operation planning

Sales and operations planning (SOP) generates plans and production plans using forecast values and requirements from the sales Information System and costing/profitability analysis as inputs for determining requirements. The requirements are reflected in the system as planned quantities of a product over a given period of time, and are not necessarily created on the basis of a customer requirement.

15. Bill of Material

Explain the reason and result of the Multi-Level MRP run by showing the bill of material for T-F100

16. Production Order

The production order is the central data object in shop floor control and manufacturing execution. The production order contains all data relevant to production objectives, material components, required resources, and costs.

17. Proses dalam production order

You must release production order before you can process it. Once you have set the order status to released, you can print shop floor papers, issue materials from stock, and confirm operations. Before you release a production order, you have to make sure that sufficient manufacturing capacity is available. You can use graphic Planning Table to get an overview of your short-term orders and release production orders.

18. Jelaskan creation and release of a production order

You must release a production order before you can process it. Once you have set the order status to released, you can print shop floor papers, issue materials from stock, and confirm operations. Before you release order, you have to make sure that sufficient manufacturing capacity is available

19. Goods issue of components
20. Confirmation of production activity

Quantity produced by operation, personnel, production dates, goods movements and amount of capacity.

21. Goods receipts of the finished goods

Good receipts to stock can be automatically posted when you confirm the last operation (or any other operation specified) in a production order. Alternatively, you can report them in a separate transaction. You can process goods receipts  for partial delivers from production by posting them directly to available stock or to quality inspection stock.

22. Apa yang dapat dilakukan setelah me-release production order?
23. Jelaskan Graphic planning table
24. Order confirmation

Explain that production order confirmations record internal activities carried out for the order.

25. Jelaskan yang bisa dicatat oleh order confirmation

Quantity produced by operation, personnel, production dates, goods movements and amount of capacity.

26. Jelaskan manfaat dari order confirmation

A confirmation can reduce capacity on the work center, update costs, and/or automatically trigger the GR of the manufactured goods. You confirm production order operations to deliver feedback to sales order processing and shop floor planning.

27. Types of completion confirmation     

·         Milestone completion confirmation

·         Standard completion confirmation

·         Normal completion confirmation

·         Collective completion confirmation

·         Completion confirmations at order header level

28. Milestone completion confirmation

The system confirms operations, including sub-operations, up to the previous milestone. mySAP ERP bases confirmations on reported quantities (yield plus scrap) and standart times.

29. Standard completion confirmation

The operations are confirmed using target values

30. Normal completion confirmation

You conduct individual completion, confirmations, seeing target values as defaults. The system allows you to overwrite all input values so you can report variances in the production process.

31. Collective completion confirmation

The system displays a fast entry screen where you can enter multiple operations to confirm.

32. Completion confirmations at order header level

Order can be confirmed at order header level, which can drive the automatic backflush of material consumption for all operations, If you so choose.

33. Good receipt

Good receipts to stock can be automatically posted when you confirm the last operation (or any other operation specified) in a production order. Alternatively, you can report them in a separate transaction. You can process goods receipts  for partial delivers from production by posting them directly to available stock or to quality inspection stock.

34. Settlement

Of a production ordermeans the actual costs incurred for the order are settled (posted) to one or more receiver cost-objects (for example, to the account for the material produced or to a sales order)