REPORT 6 MONTH Final

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

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COMPANY PROFILE PT. MEKAR ARMADA JAYA

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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

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Magelang Plant マゲラン工場

Tambun Plant タンブン工場

ｼﾞｬｶﾙﾀ

ｼﾞｮｸﾞｼﾞｬｶﾙﾀ

距離 Distance : 530 km 　車で約１０時間）

PRODUCTION FACILITIES

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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

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INNER PANELS

Mid Floor Cross Mbr Comp.

Pnl. Reinf. Front Floor

Pillar Comp Qtr.

Stiff. Comp. Center Pillar

Dashboard Lower Comp. Dashboard Upper Comp.

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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

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CONTENT : 1. PROFILE 2. ORGANIZATION STRUCTURE 3. SCHEDULE & ACTIVITIES DURING 11 MONTH 4. ACHIEVEMENT / JOB RESULT 5. IMPRESSION AND EXPECTATION 6. FUTURE ACTIVITY

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At this organization structure I assigned as Production System

ORGANIZATION STRUCTURE 2015/2016

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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,


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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


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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

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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


Calculation Packaging Delivery Group II – Vendor Magelang


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


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


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


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


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


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


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

Documents

REPORT 6 MONTH Final