FINAL PPT END OF OJT

Final Presentation Report On The Job Training [February’14 – February’15 Period]

Name : Imam Khudori SudibyoNPK : 2140570Position : Indirect ProductionGraduation : S1 Udayana UniversityMajoring : Mechanical EngineeringMotto : Be a Honestly Person Will Bring Good

PT. TD AUTOMOTIVE COMPRESSOR INDONESIA

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

1/14

Pre Final Presentation Report On The Job Training [February’14 – February’15 Period]




1/14

At this organization structure I assigned as PIC Kaizen Project at Magnetic clutch

ORGANIZATION STRUCTURE 2014/2015

2/14

BAGUS S. Gen Manager

MULYANA DM

ANDRY DM

MAHDI SM

ACEP H SM

IMAM KNT/ KAIZEN PROJECT

JOB & RESPONSIBILITIES1.Quality Up Magnetic Clutch With Reduce NG In Process & Reduce Delivery Claim Cutomer Until Zero Finding2. Cost Down Activity Magnetic Clutch3. Setting Budget Annual Plan 2015/2016 Magnetic Clutch





1/14

LocationMilestone

Activ

ityAugMay Jun Jul Sep Oct Dec Jan FebNov

Magnetic Clutch LineGreen Card On the Job Training Magnetic Clutch OJT

Ope

ning

the

insi

ght o

f w

orki

ng e

nviro

nmen

t1. Learning About

ProductKnowledge, SOP,

NG in Process,

Flow Process, PCC,

Drawing Process

1. Reduce NG In Process

2. Reduce NG Flow Out to Next Process

3. Reduce Delivery Claim Until Zero Finding4. Cost Down Activity Magnetic Clutch

TC Shaft & Swash, assembling, die MTC

- NG Balancing

- NG Voltage Resistance

- NG Slant of Cutting

SCHEDULE & ACTIVITIES DURING 11 MONTH

3/14Enforce to Built Up Quality

Month Feb Mar Apr

5. Setting Budget Annual Plan 2015/2016

- NG Stopper Cushion Abnormal- NG Semitube Exposed

2. Kaizen [ Improvement ]

- NG Run Out Hub





1/14

A

B

Factor Objective

M Man power more responsive about NG scrap

P Increase productivity

E Line more clean

7

IMPROVEMENT & ACHIEVEMENT / JOB RESULT

4/14So Many Benefits while NG Scrap Decrease

A. Background[Challenge / Strong Point]

1.NG scrap rotor line on October can’t achieved the target policy by QA [ Target < 0.39% , Actual 0.55% ]

2.Defect cost rotor line on october due to ng scrap is over the target . [ Target < Rp. 50 Million/month , Actual > Rp. 75 Million/month ]

3.Expense of cutters, jigs and tools on October over than budget due to ng scrap. [ Vol. Adjusment : Rp. 18 Milllion/month, Actual : Rp. 86 Million/month ]

Need Improvement to Reduce NG Un-Balance

B. ObjectivesAspect Objective

Q Reduce NG in process

C1.Reduce defect cost rotor line until < Rp 50 million/month2. Reduce expense of cutters, jigs and tools

D Suplay part [rotor] not delay

Facing

BrokenSlan

t of

Cutting

Appearan

ce

Un-Bala

nce

Item NG Scrap

[Pareto NG Scrap Rotor on October’14]

Taper

Qty

[Pcs

]

Acc

umul

aton

Rat

io [%

]

50

150

100

300

350

250200

400450

500

60

10

30

20

70

5040

80

90

100[495]

[258]

[150]

[74][45]

48.43 %

73.67 %

88.35 %95.59 %

100%

0 0

Rotor Un-Balance

8

5/14

C. Target

E. Improvement [Data Gathering]

Nov’14 Dec’14

Nov ‘14

Sep’14Oct’

14

Aug’14

Month

[Data NG Un-Balance Last 3 Month]

Dec‘14

Qty

[Pcs

]

Rat

io [%

]

50

150100

300

350

250200

400450

500

0.18

0.03

0.090.06

0.21

0.150.12

0.240.27

0.30

[490] [484] [495]

0.25 % 0.24 % 0.25 %

0.12 %

0.06 %

0 0

Before Improvement Target After ImprovementDecrease 50%

Decrease 50%

D. Schedule Improvement

2 CT2 XP

EFC 130LC 40

Model of Rotor

[Pareto NG Un-Balance by Model on October’14]

2 WF

Qty

[Pcs

]

Acc

umul

aton

Rat

io [%

]

10

30

20

60

70

5040

80

90

100

60

10

30

20

70

5040

80

90

100

[94]

[68]

[45]

[21][9]

39.6 %

68.4 %

87.3 %

96.2 % 100%

Analyze possibility process of NG Un-Balance

[Investigation by Flow Process]

<15 gr.cm

15-2

0 gr

.cm

Repair Process

Painting at PT.Surtec

Kariya1 W

Fron

t Fac

ePu

lley

Heatin

g

Cutting

Su

rface

Balanc

ingCa

ulki

ng Fina

l Che

ck

Rear F

ace

Finish Good

Ng Un-Balance by Model

Make a team & sharing information about NG Un-Balance

4M+1E

Cutting Layout Analysis [ Root Cause ] Countermeasure Schedule

Why 1 : Slant of cutting Why 2 : Run out jaw closed to the standard [0.1 mm]

And,

Why 1 : Slant of cutting Why 2 : Air catch sensor not detect part corectly Why 3 : One of holes air catch sensor is clogged

1. Check run out jaw periodically 1/month

If run jaw closed to the standard should be cutting jaw

2. Cleaning air catch sensor periodicallay 1/month [Note]

9

6/14

F. Analysis of NG Un-Balance & Activity ImprovementF.1. Machine [ Rear Face Process , Front Face & Pulley Process ]

No LineNovember’14

I II III IV

1 Mach line 1

2 Mach line 2

3 Mach line 3A

4 Mach line 3B

5 Mach line 4

6 Mach line 5

7 Finish line 1

8 Finish line 2

9 Finish line 3

10 Finish line 5

PlanActual

F.2. Material [ Rotor 1W ]

No ModelNovember’14

I II III IV

1 LC 40

2 EFC 130

3 2 CT

4 2 XP

PlanActual

[ Front Face & Pulley Process ]

[ Rear Face Process ]

Side View of RotorScale 1: 2

U-Position

ID B

earin

g

U-Position

Outside Diameter

Outside Diameter

Drawing Rotor 1W [sample : LC 40 ] Analysis [ Root Cause ] Countermeasure Schedule

Why 1 : Run Out outside diameter, u-position and ID bearing is highWhy 2 : Slant of cutting from supplier

1. Check run out material [ Contur check at CMM ]

[Note]

Illustration of Mastering zero Analysis [ Root Cause ] Countermeasure Schedule

Why 1 : while mastering zero can’t achieved zero point, man power doing compensation runningWhy 2 : Less know about purpose of compensation running

1. Education man power about purpose of compensation.

[Note]

Layout Line Analysis [ Root Cause ] Countermeasure Schedule

Why 1 : Part not precise on base jigWhy 2 : Pressure jaw not maximal [standard 3 Mpa]Why 3 : Jaw is unsteadyWhy 4 : while Dandory, bolt jaw not tightWhy 5 : Not re-tightening bolt corectly while setting with work piece

1. Education man power for tightening bolt of jaws while setting jaws with master or dandory process should be cross between the three jaws and use torque wrench for tighten [ standard torque 22 N]

[Scheddule of educcation]

[Note]

10

7/14

F. Analysis of NG Un-Balance & Activity ImprovementF.3. Method [Rear Face, Front Face & Pulley Process]

No LineNovember’14

I II III IV

1 Mach line 1

2 Mach line 2

3 Mach line 3A

4 Mach line 3B

5 Mach line 4

6 Mach line 5

PlanActual

F.4. Man [ Balancing Process]


I II III IV

1 Finish line 1

2 Finish line 2

3 Finish line 3

4 Finish line 5

PlanActual

jaws

bolt

What’s Purpose of Compensation Running ?

INSERT BEARING

& COULKIN

G

CEK MARRP

OS

BALANCING

NCLA 2 -1 L

NCLA 2 - 1 R

B

BB

NCLA 1-2

NCLA 2-2 R

NCLA 2- 2 L

POS 2POS 1

NCLA1-1

B

LEADER

NCLA 3-1

NCLA 3-2

HEATING 1

LEADER

POS 4 POS 5 POS 7

MIZUZUMAS

HI

MIZUZUMASHI

A

HEATING 8

POS 3 POS 6

B

A

ALL CHECK TAPPER

FINAL CHECK

MACHINING

FINISHING

Rear face Process

Front Face & Pulley Process

Rotor Line 1

0˚4.0V 35˚

0˚

11

8/14

F. Analysis of NG Un-Balance & Activity Improvement [ Compensation Running ]

Eccentricity Axis

Rotor

Spindle

1. Un-Balance of the rotor

2. Un-Balance of the spindle

3. Eccentricity

0˚

90˚270˚

180˚ 5˚

Eccentricity + Spindle weight balancing (c)

Rotor weight balancing (d)= bandul

0˚

180˚

90˚270˚

Marking Un-Balance = c + d = 5˚ + 180˚ = 185˚

Compensation running purpose to make marking on heaviest point of rotor for repair balancing, but before compensation running should be calibration running

[ Calculation of The Calibration Running ]

Voltage amount & phase (a) Unbalance amount & angle (b)Raw Data = b – a = 40˚ - 35˚ = 5˚

Calibration Running purpose to same value of amount and angle of actual un-balance

Vibration Waves Shape

Vibration Waves Shape0 0.5 1 1.5 2

Phase

Amount

40˚Amount = Voltage wave shape

The adjusment work of the calibration becomes necessary to look for the Un-Balance data from the raw data.

[ Data of Repair After Balancing]

Balancing value 15-20 gr.cm Analysis [ Root Cause ] Countermeasure Schedule Nov’14 Why 1 : Marking un-balance not

at heaviest point of rotorWhy 2 : False method while compensation runningWhy 3 : While setting bandul not at heaviest point [V+]Why 4 : Haven’t standard to setting

1. Revisi SOP of Compensation running for setting at [V+]

2. Education man power to corectly compensation running

3. Make marking at [V+] for easily to looks while compensation running

[Note]

Layout Line Analysis [ Root Cause ] Countermeasure Schedule

Why 1 : Mastering zero can’t achieved zero pointWhy 2 : Master part value closed to the standard [actual : 0.9 gr.cm, standard max : 1 gr.cm]Why 3 : deformation of master partWhy 4 : Master part crashed with another material

1. Make master part closed to the zero point with drilling master part at heaviset point.

[Note]

12

9/14

F. Analysis of NG Un-Balance & Activity ImprovementF.5. Machine [ Balancing Process ]

PlanActual

F.6. Method [ Balancing Process]

No ModelDecember’14

I II III IV

1 Finish line 1

2 Finish line 2

3 Finish line 3

4 Finish line 5

PlanActual


I II III IV

1 LC 40

2 EFC 130

3 2 CT

4 2 XP

[OK][NG]

Qty

[Pcs

]

Rat

io [%

]

1200

120

360

240

720

840

600480

960

1080

60

10

30

20

70

5040

80

90

100

[720] [480]

58.33%

41.67%

100 %

0%

[OK][NG]

[1200]

After Repair OK : max 15 gr.cm

Before Improvement

Target

After Repair NG : >15 gr.cm

M/C will automatically mark

in unbalance position

position of drilling for unbalance correction

ROTOR

INSERT BEARING

& COULKIN

G

CEK MARRP

OS

BALANCING

NCLA 2 -1 L

NCLA 2 - 1 R

B

BB

NCLA 1-2

NCLA 2-2 R

NCLA 2- 2 L

POS 2POS 1

NCLA1-1

B

LEADER

NCLA 3-1

NCLA 3-2

HEATING 1

LEADER

POS 4 POS 5 POS 7

MIZUZUMAS

HI

MIZUZUMASHI

A

HEATING 8

POS 3 POS 6

B

A

ALL CHECK TAPPER

FINAL CHECK

MACHINING

FINISHING

Rotor Line 1

Balancing Process

G. Result of Improvement

10/14

0.25 % 0.24 % 0.25 %

0 0

Before Improvement After Improvement

Aug’14

[Data NG Un-Balance Last 5 Month]

Nov ‘14

Sep’14Oct’

14

Month

Dec‘14

Qty

[Pcs

]

Rat

io [%

]

50

150

100

300

350

250200

400

450

500

0.18

0.03

0.09

0.06

0.21

0.150.12

0.24

0.27

0.30

[490] [484] [495]

0.16 %

Decrease 36%

Decrease 13%

[318] [276]

0.14 %

Target 0.07%

Can’t achieved the target ratio 0.07 %

0.25 % 0.24 % 0.25 %

Nov ‘14

Sep’14

Oct’14

Aug’14

Month

[ Cost Spoilage Rotor Line Magnetic Clutch ]

Dec‘14

Qty

[Pcs

]

Mill

ions

12

3624

7284

6048

96108120

48

8

2416

56

4032

647280

[1097] [1090] [1022]0 0


Decrease 40%

Need improvement to reduce NG Un-Balance until 0.07%

[X10]

[758] [735]

Target Rp.50 MRp.80 M Rp.72 M Rp.75 M

Rp.45 M Rp.44 M


Decrease 34%Decrease 10%

Aug’14

[Data NG Scrap Last 5 Month]

Nov ‘14

Sep’14Oct’

14

Month

Dec‘14

Qty

[Pcs

]

Rat

io [%

]

12

36

24

72

84

6048

96

108

120

0.36

0.06

0.18

0.12

0.40

0.300.24

0.48

0.54

0.60

[1097] [1090] [1022]

0.42 %

Decrease 22%

[758] [735]

0.41 %Target 0.39%

0 0

[X10]

0.54%0.55%0.54%

NG Scrap Can’t achieved the target policy by QA [Target < 0.39 % ]






1/14

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 at Magnetic Clutch.2. I hope accepted as permanent employee to be able continue reduce NG Scrap until zero with skill up man power and increase awareness of defect cost due to NG Scrap.

IMPRESSION & EXPECTATION

11/14





1/14

17

FUTURE ACTIVITYA. Background

Facing

BrokenSlant of

CuttingAppearance

Un-Balance

Item NG Scrap

[Pareto NG Scrap Rotor on December’14]

Taper

Qty

[Pcs

]

Acc

umul

aton

Rat

io

[%]

50

150100

300350

250200

400450500

60

10

3020

70

5040

8090100

[276] [185] [125] [84] [65]

39.5 %

64.4 %

82.3 %94.0 %

100%

0 0

No Item NG Scrap Total Ratio

1 Un-Balance 276 0.14 %

2 Slant of Cutting 210 0.11 %

3 Appearance 192 0.10%

4 Facing Broken 84 0.04 %

5 Taper 65 0.03%

Total 698 0.41 %

Can’t Achieved

The Target

Oct’14

Sep’14Aug’14

[Data NG Scrap Last 5 Month]

Nov ‘14

MonthDec‘

14

Qty

[Pcs

]

Rat

io [%

]

12

3624

72

84

6048

96108

120

0.36

0.06

0.180.12

0.40

0.300.24

0.480.540.60

[1097] [1090] [1022]

0.42 %

Decrease 22%

[758] [735]

0.41 %Target 0.39%

0 0

0.54%0.55%0.54%

[Image of NG-Unbalance]

[Investigation by Flow Process]

Repair Process

<15 gr.cm15-2

0 gr

.cmPainting at

PT.Surtec Kariya

1 W

Front

Face

PulleyHeat

ingCuttin

g

Surface

Balancin

g

CaulkingFinal

CheckRear

Face

Finish Good

12/14


Need Improvement to Reduce NG Un-Balance 50%

Side View of RotorScale 1: 2

Back View of RotorScale 1: 2

A

B

A

B

A

B

2.40 mm

1.20 mm

Width of rear surface rotor rib area not same

No Standard on drawing

Can’t Achieved

The Target [0.07%]

18

13/14

Jan’15 Feb’15

C.1. Schedule Improvement

Additional flow process to re-check rotor 1W before machining process at TACI

Run out OD , ID Bearing , U-Position

Study about process of rotor 1W

Analysis by drawing

B.1. Analysis of NG Un-Balance & Activity ImprovementB.1.1. Material [ Rotor 1W ]

Drawing Rotor 1W [sample : LC 40 ] Analysis [ Root Cause ] Countermeasure Schedule

Why 1 : Slant of cutting from supplierWhy 2 : Run Out outside diameter, u-position and ID bearing not check after slotting process [Hot Forging] at PT.SSI

1. Check run out material in line before rotor machining process, collect data and compare with drawing [ before slotting process].

[Note]

No ModelJanuary’15

I II III IV

1 LC 40

2 EFC 130

3 2 CT

4 2 XP

PlanActual

Side View of Rotor

Outside DiameterU-Position

ID B

earin

g

U-Position

Outside Diameter

Make jig check part

1W

Scale 1: 2

After slotting PT.MTM check run out slotting only

B.1.2. Rotor 1W Process AnalysisMachining Process

at PT.MTMSlotting Process [forging]

at PT.SSICheck run out slotting

only at PT.MTM

U-Position

ID B

earin

g

U-Position

Outside Diameter

Slotting

After slotting, PT.MTM check run out slotting

only

After Machining process, PT.MTM check run out Outside

dia, ID bearing & U-position

Slotting Process [Hot Forging]

Effect : Deformation of dimension rotor [Run out Outside diameter, ID bearing & U-Position over than 0.15mm ]

Trial : 14 holes Depth : 4.5 mm Width : 3 mm Reduce weight : 12 gram.cm

19

14/14

Feb’15 Mar’15

C.2. Schedule Improvement

Next Activity to Endurance Test , Noise Test and Twisting Test Rotor Trial Repair Balancing

Balancing repair with 10 holes and more than 10 holes

Study about process repair balancing

Compare the data

B.2. Analysis of NG Un-Balance & Activity ImprovementB.2.1 Study of Trial Repair Balancing

No ModelFebruary’15

I II III IV

1 LC 40

PlanActual

Twisting and

Endurance

Can Repair

Can’t Repair OK

Standard : 1-15 gr.cm [OK] 15-20 gr.cm [repair] >20 gr.cm [can’t repair]

Standard : 10 holes Depth : 4 mm Width : 3 mm Reduce weight : 5-6 gram.cm

Balancing 20-27 gr.cm can repair with 14 hole.

Data Balancing LC 40 on Feb’15 Analysis [ Root Cause ] Countermeasure Schedule

Why 1 : Balancing 20-30 gr.cm can’t repairWhy 2 : Standard Repair 10 hole can reduce 5-6 gr.cm only

1. Trial Repair Balancing adding more than 10 holes

[Note]

THANKS FOR YOUR ATTENTION

ATTACHMENT

PRODUCT & PROCESS KNOWLEDGE

Function of magnetic clutchMagnetic clutch pulley attached to the compressor. Magnetic clutch spinning and engine speed channel to the compressor, thermostat operation based on the operation and the High / Low pressure switch.

How the Magnetic Clutch? In the car ac compressor pulleys are rotating constantly following the spin machine, in the next part of the pulleys are coils of wire email,if this wire coils in electrical current flow through a magnetic field will form the center piece that will draw the attraction of the center piece will connect the round ac compressor pulley with the compressor.

HUB STATOR ROTOR

Product & Process Knowledge mutual concerned 1/3

2. [Data Gathering & Trial Method of Repair Balancing]

Based on data trial method of repair balancing, for model 2XP, 2CT, 2WF and 2MD GASOLINE NG Based on data trial method of repair balancing, for model 2XP, 2CT, 2WF and 2MD GASOLINE NG repair balancing if follow repair method of marking balancing m/c. repair balancing if follow repair method of marking balancing m/c.

2/3

24

FUTURE ACTIVITY

3/3

QUALITY1.Reduce NG Un-Balance until 50%2.Reduce NG Setting Machining & Finishing Rotor

COST1.Reduce Defect Cost Magnetic Clutch with Reduce NG Scrap2.Reduce Monthly Expense with reduce NG in Process

DELIVERY1.Make Buffer Stock Plan Magnetic Clutch Set

MORAL1.Way Gaya Activity for Skill Up Man Power2.Education for New Man Power about Awareness Quality Up

Documents

FINAL PPT END OF OJT