PERANCANGAN SIMULASI MESIN POKAYOKE SYSTEM PADA PROSES INSTALL SPLIT-HALF BEARING CRANKSHAFT ENGINE NR DENGAN KENDALI PLC OMRON CP1E-30-DR-A

DENI PRASTIKO, Andhi Akhmad Ismail, ST.,M.Eng.

2017 | Tugas Akhir | D3 TEKNIK MESIN SV

Split-half bearing crankshaft merupakan salah satu komponen yang dipasang pada engine yang berfungsi untuk mengurangi gesekan, panas dan aus antara cylinder block dengan crankshaft, menahan beban putaran crankshaft, menahan radial load, thrust load dan menjaga toleransi kekencangan. Terdapat suatu masalah yang ditemukan setelah proses perakitan (assembly) engine mobil xenia, avanza dan cayla tersebut. Kasusnya adalah split-half bearing crankshaft jatuh saat handling team member selesai proses install split-half bearing crankshaft menggunakan jig install. Split-half bearing crankshaft ini ditemukan sehari setelah proses assembly engine tersebut, saat melalui proses motoring bench sehari setelahnya ditemukan engine noise melebihi standart, maka mengindikasikan engine tersebut NG (Noot Good). Dengan banyaknya masalah-masalah kesalahan yang bisa ditimbulkan, penulis sudah membuat safety system stoper namun belum sepenuhnya otomatis sehingga diperlukan pembaruan kedepannya pada sistem kerjanya. Oleh karena itu dibutuhkan sistem otomatis pokayoke/anti salah/safety system untuk menjamin bahwa split-half bearing crankshaft benar-benar terpasang sesuai standar. Prinsip yang dibutuhkan adalah adanya sistem kerja yang dapat menjamin terpasangnya split-half crankshaft bearing yang berjumlah lima pcs di area main bearing. Pneumatic adalah sebuah sistem penggerak yang menggunakan tekanan udara sebagai tenaga penggeraknya. Dengan kebutuhan penjaminan pemasangan yang tinggi maka digunakan konsep pneumatic system untuk improvemenet sistem yang ada. Penambahan proximity sensor untuk mendeteksi terpasangnya split-half bearing crankshaft pada main bearing cylinder block. Konsep rangkaian training kit pokayoke system ini menjaminkan pemasangan split-half bearing crankshaft lima pcs setiap kali proses kerja berlangsung serta terdapat safety system untuk team member/operator. PT. Astra Daihatsu Motor mempunyai quality standart tinggi untuk produk yang dihasilkan, dapat disimpulkan improvement system kerja ini diharapkan dapat meningkatkan quality standart perusahaan.

Split-half crankshaft bearing is one of the mounted components on the engine, its function are friction, heat and wear reducing (between the cylinders block to the crankshaft, rotation of the weight bearing crankshaft, withstand radial load, push the load and keep the tolerance firmness). There is a problem that was discovered after engine the assembly process of xenia, avanza and cayla car. The case the split half crankshaft bearing fall during members of the handling team so completed the installation split-half crankshaft bearing. The split-half crankshaft bearing was found one day after the engine assembly process, when it goes through the motoring bench process a day later discovered over motor engine noise standard. I indicates no good engine. With many problems of errors that can be generated,the author has made safety system but now its not fully automated. The works of the system should be improved. Therefore it is necessary an otomation (system of false/security automated) indicating that the fraction of split-half crankshaft bearing actually is properly installed. The principle of operation needed that there is a guarantee system a five split half crankshaft bearings properly installed to the cylinder block main bearing. Pneumatic is a system that apply air pressure as its force. With the requirement of high insurance guarantee then used concept of pneumatic system to repair the existing system. The addition proximity sensor detect the properly installed split-half crankshaft bearing on the main bearing cylinder block. The concept of this series of training kits pokayoke system guarantees the properly installation of split-half bearing crankshaft. There is five pcs every the work process takes place and there is a safety system for team member/operator. PT. Astra Daihatsu Motor has a high quality standart for every single product, therefor it can be concluded that the company improvement is expected to increase the company quality standard.

Kata Kunci : Split-Half Bearing Crankshaft, Pneumatic, Proximity Sensors, Cylinder Block, Pokayoke System