report 6 month final
TRANSCRIPT
Report 6 Month of Management Trainee [25 August’15 – 25 February’16 Period]
Name : Imam Khudori SudibyoNPK : I.4671Position : Production EngineeringGraduation : S1 Udayana UniversityMajoring : Mechanical EngineeringMotto : Be a Honestly Person Will Bring Good
CONTENT : 1. COMPANY PROFILE 2. ORGANIZATION STRUCTURE 3. SCHEDULE & ACTIVITIES DURING 11 MONTH 4. ACHIEVEMENT / JOB RESULT 5. IMPRESSION AND EXPECTATION 6. FUTURE ACTIVITY
1/15
COMPANY PROFILE PT. MEKAR ARMADA JAYA
2/15
PT. Mekar Armada Jaya
Location : Magelang Plant Tambun Plant
Established : 1981Asset amount : US$ 58,000,000Share holder : 100 % local companyEmployees : Tambun Plant : 1289 PersonsMagelang Plant : 620 personsTotal Employees : 1909 PersonsProducts : Stamping part
Assembly part Die, Jig, Checking
fixture
Number of subsidiaries : 46 companies
Founded in 1974 as autobody manufacturer
AUTOMOTIVE TRADING
MULTIFINANCE
MANUFACTURES OTHERS
David Herman Jaya
Chairman of PT. Mekar Armada Jaya
COMPANY LOCATION
3/15
Magelang Plant マゲラン工場
Tambun Plant タンブン工場
ジャカルタ
ジョグジャカルタ
距離 Distance : 530 km 車で約10時間)
PRODUCTION FACILITIES
4/15
HYDRAULIC PRESS MACHINES
4 machines (600 – 2,000 Tons)
ROBOTIC PRESS MACHINES
4 machines (600 – 1,500 Tons)
MECHANICAL PRESS MACHINES
23 machines (350 – 1,000 Tons)
SMALL PRESS MACHINES
44 machines (45 – 300 Tons)
NUT WELDING MACHINES
50 machines
SPOT WELDING MACHINES
80 machines
PRODUCTION FACILITIES
Facility Maker Quantity Capacity
Robotic Tandem Press E Line H&F 1 line 1,500T – 600T – 600T – 600T
Mechanical Press A Line Komatsu 1 line 1,000T – 600T – 600T – 600T
Mechanical Press B Line Komatsu 1 line 800T – 400T – 400T – 400T
Mechanical Press C Line Fukui 1 line 350T – 350T
Mechanical Press D Line Komatsu 1 line 1,000T – 800T – 500T – 500T
Mechanical Press F Line Komatsu 1 line 1,000T – 600T – 600T – 600T
Mechanical Press B Line Sympact 1 line 800T – 600T – 600T – 600T
Mechanical Press Jinan 1 machine 500T
Hydraulic Press Line Lien Chieh 1 line 2,000T – 1,000T – 600T
Small Press (Tandem) Aida, Seyi, Chin Fong 38 machines 45T ~ 150T
Small Press (Progressive) Aida 6 machines 150T ~ 300T
Shearing Machine Amada, Baykal 6 machines Up to 2.3mm thickness
Nut Welding (Static) Chuo, Panasonic, Daiden, Dengensha 50 machines 35 ~ 110 KVA
Spot Welding (Portable) Aro, Dengensha, Obara 80 machines 150 KVA
Magelang Plant & Tambun Plant
5/15
INNER PANELS
Mid Floor Cross Mbr Comp.
Pnl. Reinf. Front Floor
Pillar Comp Qtr.
Stiff. Comp. Center Pillar
Dashboard Lower Comp. Dashboard Upper Comp.
7/15
OUTER PANELS
Roof Panel
Side Body Panel Outer RH/LH
Front Door Panel RH/LH
Rear Door Panel Outer RH/LH
Back Door Panel Outer
Front Fender Panel RH/LH
8/15
CONTENT : 1. PROFILE 2. ORGANIZATION STRUCTURE 3. SCHEDULE & ACTIVITIES DURING 11 MONTH 4. ACHIEVEMENT / JOB RESULT 5. IMPRESSION AND EXPECTATION 6. FUTURE ACTIVITY
1/15
Report 6 Month of Management Trainee [25 August’15 – 25 February’16 Period]
Name : Imam Khudori SudibyoNPK : I.4671Position : Production EngineeringGraduation : S1 Udayana UniversityMajoring : Mechanical EngineeringMotto : Be a Honestly Person Will Bring Good
At this organization structure I assigned as Production System
ORGANIZATION STRUCTURE 2015/2016
9/15
CONTENT : 1. PROFILE 2. ORGANIZATION STRUCTURE 3. SCHEDULE & ACTIVITIES DURING 6 MONTH 4. ACHIEVEMENT / JOB RESULT 5. IMPRESSION AND EXPECTATION 6. FUTURE ACTIVITY
1/15
Report 6 Month of Management Trainee [25 August’15 – 25 February’16 Period]
Name : Imam Khudori SudibyoNPK : I.4671Position : Production EngineeringGraduation : S1 Udayana UniversityMajoring : Mechanical EngineeringMotto : Be a Honestly Person Will Bring Good
FebJanNovSepAug
LocationMileston
e
Activ
ityDec
Production EngineeringTraining On the Job Training Production EngineeringO
peni
ng th
e in
sigh
t of S
afet
y H
ealth
and
Env
ironm
ent,
PKB
Learning About :- Product Knowledge,
- Tools Making
1. Analysis Packaging Delivery Quantity Needed
2. Relayout Inventory Finish Part 3. Calculate Requirement Empty Pallet. 4. Calculate Requirement Packaging Delivery New Project D30D , Release PR & Monitoring Incoming Packaging
TC Stamping , Welding and Tools
- Group I- Group II
SCHEDULE & ACTIVITIES DURING 6 MONTH
10/15Focus on Analysis Packaging Delivery, Layout Area & Schedule Activity
Month
5. Managed Workshop Activity. - Project - Reguler
- Group III
MarOct
- NG in Process- Flow Process,
CONTENT : 1. PROFILE 2. ORGANIZATION STRUCTURE 3. SCHEDULE & ACTIVITIES DURING 11 MONTH 4. ACHIEVEMENT / JOB RESULT 5. IMPRESSION AND EXPECTATION 6. FUTURE ACTIVITY
1/15
Report 6 Month of Management Trainee [25 August’15 – 25 February’16 Period]
Name : Imam Khudori SudibyoNPK : I.4671Position : Production EngineeringGraduation : S1 Udayana UniversityMajoring : Mechanical EngineeringMotto : Be a Honestly Person Will Bring Good
Aspect Objective
M Man power more responsive about abnormality
P Increase productivity
E Line more clean & Neat
13
IMPROVEMENT & ACHIEVEMENT / JOB RESULT
11/15Analyze from several aspect to Relayout Inventory Finish Part
A. Background[Challenge / Strong Point]
1. Inventory finish part area not balance if compared with requirement pallet area, will affect the delivery [Target inventory finish part area must be covering requirement pallet area]
2. Analyze of the pallet quantity needed.[Target calculate requirement pallet must be update base on patan, used to calculate requirement pallet area in IFP]
3. Arrange similar pallet in inventory finish part area.[Target similar pallet must be placed in same column]
Need Improvement to Relayout Inventory Finish Part
B. ObjectivesAspect Objective
Q Built up quality through FIFO System
C Reduce defect cost rust part
D As a sign for suplay finish part not delay
S Maximum height of stack pallet is 3 Meters
IFP Area not balance with pallet area needed, example for pallet C area in IFP is over than
pallet C area needed. But the column pallet C in IFP is less than actual column needed
14
12/15
C. Target
E. Improvement [Data Gathering]
Nov’15 Dec’15
D. Schedule Improvement
Analyze possibility process abnormality by the calculate requirement packaging
Data stock taking opname
Make a team & sharing information about IFP area
Calculate pallet qty needed+area
Gap 104 m²
[Investigation by Flow Process]
Pata
n U
pdat
e
Calc
ulat
e by
act
ual
rang
e sto
ck
Dra
win
g
Fore
cast
Impe
lem
enta
tion
Gap 5 column
Drawing
13/ 15
F. Analysis & Activity ImprovementProblem : Inventory finish part area not balance with requirement pallet area
F.1. Method Why 1 : Calculation requirement pallet must be different Why 2 : Inventory finish part stock is divide by in house Tbn, subcont. Mgl & Subcont. JABABEKA Why 3 : Different stock range between in house Tbn (16 Hours), subcont. Mgl (H-4)& Subcont.JABABEKA (H-3) Why 4 : Calculate distance shipping of vendor to Tbn
Example, calculation pallet subcont Mgl
Purpose to calculate requirement pallet by stock range in house & vendor’s
G. Result of Improvement
14/ 15Inventory Finish Part Area Already Balanced & Covering Requirement Pallet Area
Before Improvement : Not arranged similar pallet location
After Improvement:Similar pallet already in same column
Before Improvement :Can’t implement FIFO System
After Improvement :FIFO System already implemented, cause similar pallet arrange in line in same column
INOUT
Gap 0 m² (Achieved the target)
Gap 0 col. (Achieved the target)
Before Improvement :Line unsightly to look
After Improvement :Line more clean and neat
Before Improvement :Can’t as sign delivery control
After Improvement :As sign delivery control, cause stock already calculate based on stock range
CONTENT : 1. PROFILE 2. ORGANIZATION STRUCTURE 3. SCHEDULE & ACTIVITIES DURING 11 MONTH 4. ACHIEVEMENT / JOB RESULT 5. IMPRESSION AND EXPECTATION 6. FUTURE ACTIVITY
1/15
Report 6 Month of Management Trainee [25 August’15 – 25 February’16 Period]
Name : Imam Khudori SudibyoNPK : I.4671Position : Production EngineeringGraduation : S1 Udayana UniversityMajoring : Mechanical EngineeringMotto : Be a Honestly Person Will Bring Good
MY IMPRESSION :1.Increase analyze skill of root cause, countermeasure, implementation,
standardization and education quickly due the demands of the job (Quick Action).
2.Manage jobs at once and make reports.3. Instill never give up attitude for the key of success.
MY EXPECTATION : 1. I hope accepted as permanent employee to be able continue the uncompleted improvement.
IMPRESSION & EXPECTATION
15/15
CONTENT : 1. PROFILE 2. ORGANIZATION STRUCTURE 3. SCHEDULE & ACTIVITIES DURING 11 MONTH 4. ACHIEVEMENT / JOB RESULT 5. IMPRESSION AND EXPECTATION 6. FUTURE ACTIVITY
1/15
Report 6 Month of Management Trainee [25 August’15 – 25 February’16 Period]
Name : Imam Khudori SudibyoNPK : I.4671Position : Production EngineeringGraduation : S1 Udayana UniversityMajoring : Mechanical EngineeringMotto : Be a Honestly Person Will Bring Good
THANKS FOR YOUR ATTENTION
ATTACHMENT
NEW PROJECT D30D
Already Release PR Pallet Minus to Vendor (Magelang)
NEW PROJECT D30D
Schedule Fabrication & Monitoring Incoming Pallet from Magelang
LAYOUT INVENTORY FINISH PART GROUP 1
New Layout of Inventory Finish Part Group 1, Already Implementation
MONTHLY LOADING vs CAPACITY WORKSHOP
Monthly Loading Workshop Over than Capacity (M/H), Need Additonal MP to Covering
SCHEDULE ACTIVITY WORKSHOP
Schedule Activity Workshop – Project Job
SCHEDULE ACTIVITY WORKSHOP
Schedule Activity Workshop – Reguler Job
LAYOUT EMPTY PALLET
Planning Layout Empty Pallet All Customer
CALCULATION EMPTY PALLET
Calculation Empty Pallet Area ADM Plant 1
PACKAGING DELIVERY QUANTITY NEEDED
Calculation Packaging Delivery Group I – Vendor Magelang
PACKAGING DELIVERY QUANTITY NEEDED
Calculation Packaging Delivery Group II – Vendor Magelang
PACKAGING DELIVERY QUANTITY NEEDED
Calculation Packaging Delivery Group III
TERJEPIT ALAT/MESIN TERTIMPA BENDA BERAT
TERTABRAK ALAT TRANSPORTASI
TERBAKAR / TERSENGAT LISTRIK TERSAYAT BENDA TAJAM
POTENSI & CONTOH KECELAKAAN KERJA
Adalah proses pengolahan barang dari bahan baku (raw material)
menjadi barang hasil stamping (stamping part)
dengan menggunakan alat utama: Dies dan Mesin Press.
RAW MATERIAL
MESIN PRESS
DIE
OPERATOR
SARANA
STAMPING = PRESS
STAMPING PART
PALLETING
PENGENALAN STAMPING
STAMPING = PRESS
PENGENALAN STAMPING
SEBELUM
SESUDAH
Blanking adalah proses persiapan material, material dipotong sesuai dengan yang dibutuhkan. Proses blanking bertujuan agar mendapatkan hasil potongnya atau blank,
sedangkan sisanya akan dibuang sebagai sampah atau disebut scrap
PROSES STAMPING
SEBELUM
SESUDAH
Forming mengacu pada pengertian yang lebih sempit yang artinya adalah deformasi dari sheet metal yang merupakan kombinasi dari proses bending dan flanging. Proses forming menghasilkan bentuk yang sangat
kompleks dengan tekukan-tekukan serta contour part yang rumit.
PROSES STAMPING
SEBELUM
SESUDAH
Drawing adalah forming (kombinasi proses bending dan proses flanging) yang cukup dalam sehingga proses pembentukannya memerlukan blank holder atau stripper dan air cushion / spring untuk mengontrol aliran dari material. Untuk bentuk yang tidak beraturan diperlukan bead untuk menyeimbangkan aliran material. Untuk menghasilkan produk yang baik, sebaiknya digunakan steel sheet khusus proses drawing dan menggunakan
mesin press hidrolik.
PROSES STAMPING
SEBELUM
SESUDAH
Trimming adalah sutu proses pemotongan material pada bagian tepi. Biasanya proses ini adalah lanjutan dari proses sebelumnya seperti draw, stamp dan sebagainya.
PROSES STAMPING
SEBELUM
SESUDAH
PIERCE PROFILE
NOT
CHIN
G
Pierce adalah proses melubangi pada bagian tertentu dari material part sehingga terbentuk pierce profile. Notching adalah proses pemotongan pada bagian pinggir material part, biasanya pada progressive dies. Dengan
pemotongan tersebut, part berangsur terbentuk walaupun masih menempel pada scrap skeleton.
PROSES STAMPING
SEBELUM
SESUDAH
Parting atau separating adalah proses pemisahan suatu part menjadi dua bagian atau beberapa bagian dari sheet metal strip sehingga menghasilkan part yang dikehendaki. Pada proses separating terdapat scrap yang tidak
terpakai.
PROSES STAMPING
NECK
SAMPLE DEFECT PART
SAMPLE DEFECT PART PROSES DRAW
WAVE WAVE
TRIM MINUS BURRY
TRIM MENCUAT
PROSES STAMPING
SAMPLE DEFECT PART PROSES TRIMMING
FLANGE MINUS BARET
SPRING BACK/SPRING GO
PROSES STAMPING
SAMPLE DEFECT PART PROSES FLANGE/BENDING
HOLE TIDAK ADA MENCUAT
HOLE OVAL
PROSES STAMPING
SAMPLE DEFECT PART PROSES PIERCE
TOOLS MAKING
LINE TRY
• PRESS M/C
• CRANE
TRY PRESS
• AIDA 1000 TS
SPOTTING
• TRY M/C
• CRANE
TRY PRESS
• AIDA 1000 TS
MEASURING
• FARO• CF
PART DRAWING
• CF• PPS
DRAWING DIES
• PAMP STAMP
• AUTOCAD
POLY MODEL
• CAM
CASTING
• SAND CASTING
1 2 3 4 5
678910
C/F COST PLANNINGC/F COST PLANNING
PART NAME : EXT-COMPL FDR, RR RH PART NO : 78114 4LC5A
MATERIAL COST
BASE & RESIN BLOCK
RESIN BLOK
PIN & BUSH
1.BUSHING
2.MARKING
PIN
MACHINE COST
MACHINING BASE
1. CNC
MILLING2.
FEELER CNC3.
DRILLING4.
BALNDER
BEAVER5. 02 &
ACYTILE
NE6. HAND
GRINDI
NG
MACHINING
PIN &
BUSH
1. HAND
GRINDING2.
TURNING
3. 02 &
ACYTILENE4.
SURFACE
GRINDING5.
TOOLS
GRINDER
M CLAMP &
LOCATO
R
1. MILLIN
G2.
FEELER CNC
3. BLAND
ER
BEAVER4.
DRILLING5.
HAND
GRINDING
ACCESORIS
1. HAND
GRINDING
HOUSING
BUSH
2. HAND
GRINDING BESI SIKU
CEK
AKURASI
FARO
LABOUR COST
TOTAL C/F COST PLANNING = TOTAL MATEROAL COST + TOTAL MACHINE COST + TOTAL LABOUR COST
QUALITY (NG IN PROCESS)
1. WRINKLE (Kerutan)
ROOT OF CAUSE :Saat material ditekan (bending) dan sampai proses selesai material tidak
kembali ke bentuk sempurna.
COUNTERMEASURE :Bentuk permukaan penahan kerutan,
bentuk punch dan kontur bead dirubah.
IMAGE
IMAGE &
ANIMATION OF
NG
QUALITY (NG IN PROCESS)
2. SHOCK LINE ( Tanda Yang Membekas Pada Sisi Samping Bagian Dinding)
ROOT OF CAUSE :Terjadi tarikan halus pada awal proses
pengerjaan yang menyebabkan penipisan permukaan material.
COUNTERMEASURE :- Menurunkan kecepatan bending
- Memperbesar diameter profil- Menempatkan penahan kerutan
setelah proses awal berjalan.
IMAGE
IMAGE &
ANIMATION OF
NG
QUALITY (NG IN PROCESS)
3. SWELLING (Penggelembungan Pada Sebagian Produk )
ROOT OF CAUSE :Produk dipegang minim oleh bagian dinding dan dilakukan bending dgn
bentuk die bulat.
COUNTERMEASURE :- Menambang tension pada bead /
penahan kerutan.
- Menggunakan cushion pad.
IMAGE
IMAGE &
ANIMATION OF
NG
QUALITY (NG IN PROCESS)
4. FLANGE WRINKLE (Kerutan Bahu)
ROOT OF CAUSE :Saat proses berlangsung terjadi tekanan
pemadatan pada material. Penyebab lainnya adalah pengembangan plastisitas akibat tekanan
pada area miring (shearing stress).
COUNTERMEASURE :- Menurunkan compresed stress dan shearing
stress, memikirkan kembali die-R & posisi bead.- Menambah kekuatan penahan kerutan (wrinkle
holder).
IMAGE
IMAGE &
ANIMATION OF
NG
QUALITY (NG IN PROCESS)
5. SCRATCH / DRAG ( Gloss Mark yang Menyerupai
Bentuk Talirami Serta Menyembul/ Menonjol Keluar)
ROOT OF CAUSE :Goresan akibat terseret (tertarik) da
terkena pada area die-R / bead. Apabila temperatur antara die dan material panas, maka akan terjadi tonjolan pada area tersebut dan
mengakibatkan goresan.
COUNTERMEASURE :- Mengevaluasi material die,
kekerasan, kekasaran, clearance, finishing die.
- Menggunakan pelumas (addition lube).
IMAGE
IMAGE &
ANIMATION OF
NG
QUALITY (NG IN PROCESS)
6. CRACK (Retak)
ROOT OF CAUSE :- Material kurang.
- Tensile stress melebihi batas limit (bending)
COUNTERMEASURE :-Memperlambat kec. drawing.- Mengurangi tenaga penahan
kerutan, menggunakan pelumas.- Sudut R bending diperbesar.- Burry yang terdapat pada
permukaan bekas potongan dibalik ke dalam dan dilakukan bending.
IMAGE
IMAGE &
ANIMATION OF
NG
QUALITY (NG IN PROCESS)
7. WAVE (Gelombang)
ROOT OF CAUSE :Distribusi tekanan pada bagian dalam
material tidak merata.
COUNTERMEASURE :- Die-R dibuat lebih kecil.
- Menambah tegangan (tensile) pada bead maupun kontraksi (step
contraction)
IMAGE
IMAGE &
ANIMATION OF
NG