LAPORAN TUGAS AKHIR IMPROVEMENT ALAT CYLINDER CLEANER DI PT KAYABA INDONESIA

WINDU PRABOWO, Ir. F. Eko Wismo Winarto, M.Sc., Ph.D.

2018 | Tugas Akhir | D3 TEKNIK MESIN SV

PT. Kayaba Indonesia adalah perusahaan yang bergerak di bidang industri otomotif, khususnya dalam pembuatan shock abshorber. Terdapat banyak komponen penyusun shock abshorber, salah satunya adalah cylinder. Pembuatan cylinder melalui beberapa proses antara lain hot forming, head forming, machining (facing, chamfering, drilling dan tapping), cylinder cleaning, punching, drilling, buffing, dan check orifice. Dari proses-proses tersebut ditemukan beberapa masalah pada proses cylinder cleaning yaitu chemical yang digunakan pada alat cylinder cleaner untuk proses pembersihan sangat berbahaya terhadap operator. Selain itu frekuensi pengurasan cukup sering dengan harga chemical yang mahal sehingga mengakibatkan kenaikan cost produksi. Alat cylinder cleaner berfungsi untuk membersihkan sisa oli dan chip hasil dari proses sebelumnya yaitu proses machining sehingga mengurangi kegagalan pada proses punching. Improvement yang dilakukan yaitu penggantian jenis chemical, dari chemical MDA (Melondialdehyde) menjadi Motto 2010 (Mottochem Super Degreation) dan penambahan sistem sirkulasi dengan filter. Sasaran dari improvement ini yaitu dapat menambah safety operator tanpa mengurangi kemampuan pembersihan dan dapat mengurangi cost produksi pada proses cylinder cleaning. Metode yang dilakukan untuk mencapai sasaran improvement tersebut melalaui tiga tahap trial, yaitu trial 50 spesimen, trial dengan penambahan proses punching, trial memasukan dalam proses produksi selama tujuh hari. Dari hasil trial terbukti bahwa konsep improvement yang diterapkan dapat digunakan untuk proses produksi pada line cylinder machining. Hasil trial juga membuktikan bahwa alat cylinder cleaner setelah dilakukan improvement dapat menurunkan cost produksi sebesar Rp 817.227,00 setiap satu hari.

PT. Kayaba Indonesia is a company engaged in automotive, especially in the shock abshorber manufacture. There are many components of the shock abshorber, one of them is cylinder. The cylinder manufacture is through some process likes hot forming, head forming, machining (facing, chamfering, drilling and tapping), cylinder cleaning, punching, drilling, buffing, and check orifice. The problems are the cylinder cleaner tool for cleaning process that is very dangerous for operator. The draining frequency is often with expensive chemical prices resulting in increased production costs. The cylinder cleaner tool clean up the remaining oil and chip result from the process of cylinder machining. Thereby should reduce the failure of the punching process. The improvement applied is change the chemical type, from MDA (Melondialdehyde) to be Motto 2010 (Mottochem Super Degreation), and addition of circulation system through filter. The target improvement is able to improve safety operator without reducing the cleaning capability and can reduce the production cost of processed cylinder cleaning. Metode undertaken achive improvement goals, through three stages of trial. There are trial 50 specimens, trial with punching process, and trial usage on production process in seven days. The results of the trial proved that theimprovement applied concept can be used for production process on the line cylinder machining. the trial result also proved that the cylinder cleaning tool can reduce production cost of Rp 817.227,00 every one day after the improvement.

Kata Kunci : Cylinder, cylinder cleaning tool, trial.