ABSTRACT
This project investigated the effectiveness and efficiency of the machine after had been upgrade from manual to semi
auto part. The experimental studies were conducted on studying the process of two machine which is SDKZ and RD
708 machine. In this project, the machine will be explained very detail how it can operate and works. Even SDKZ is
categorized in semi auto machine; there are still some parts that operate manually. It will cause the operation time of
the manual part is taking shorter than the semi auto machine. So, each process of the machine will be investigated to
make sure that the machine can reduce its operation time. By studying the process, the problem is caused by the pick
and place of cam in the machine is manually operated. Besides that, the productivity of the SDKZ product need to be
increased is one of the objectives in this project work. So, by study the concept of pick and place from RD 708
machine, the process and design of RD708 will be applied to the SDKZ machine. The process of process, assemble,
electrical and programming will be discussed in this project. From 2D CAD, it will be generated to the 3D model.
After the design has finished, it will modified so it can assemble to the SDKZ machine. Furthermore, the
manufacturing calculation was applied to the machine to make sure that the machine will be more effective and more
efficient.
1.0. INTRODUCTION
Automation machine is the utilization of different control frameworks for working hardware, for example, apparatus,
forms in industrial facilities, boilers and warmth treating broilers, exchanging on phone systems, controlling and
adjustment of boats, air ship and different applications with insignificant or diminished human intercession. Factory
automation will focus on the product lines through electronic controls, fluid power and sensor products. The
automation machine use PLC as a cpu which is connecting the input and output of the machine. Since most recent
commercial PLC is use general purpose processors, they should execute an relay ladder logic (RLL) program.
2.3. RD 708
RD 708 was a machine that assembly a sensor called potentiometer. This kind of machine was made by Japan and also
imported from that country. RD 708 is semi auto type of machine. Based on the research, there are few process that
almost same with the SDKZ machine. The process is happen during the flow of cam through the channel.
3.0. METHODOLOGY
3.1. Introduction
In this creating time, to do such an examination of the computerization machine model is very less demanding and
does not require much time in light of the fact that everything should be possible for all intents and purposes by
utilizing programming. Thus, it is essential to form a simulation model in order to study and optimize the automation
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machine model. The core focus in this study is to improve the pick and place section in the SDKZ machine used at
industrial. This chapter will focus on the entire standard operation procedure (SOP) from the start until the
achievement of this study. Methodology is the regular study of procedures and particular way or set of procedures.
The purpose of the experiment work is to investigate the cause of reason why semi auto machine does not achieve
their target monthly and produce less product than manual machine. For this project, the analysis of operational time
will be set to be the important parameter. So this process of work can show parameter or calculation that used for
design work. Overall this chapter was discussed about investigation and analysis of automation machine in actual
condition. By record both of the operational time for manual and semi auto machine, the comparison can be made so
the problem can be identified. Then, the expected of time taken and time loss for the operation for semi auto machine
after had been modified also need to be taken and considered. The part of pick and place of cam SDKZ switch is the
main part that will be discussed in this chapter. This part need go through “kaizen” process where some modification
had been constructed. In the other word, this study focused on the modification or change of design for the machine by
constructing and comparing the result on different design.
4.1.3. Productivity
Based on the calculation of the cycle time, no of workstation and efficiency of the machine, there are different
between both of manual and semi auto SDKZ machine. Cycle time of the semi auto is bigger than the manual
machine. It cause by the desired output rate by semi auto is lower than the output rate come out from the manual
machine. From the calculation of task time, the task time of manual machine is lower than the semi auto. This is
because the process of assembly in the semi auto machine consists of 22 process. While for the efficiency of the
machine, it seems that the manual machine is more efficient than the semi auto machine. It is because there are less
occur happen in the manual machine.
Cycle Time =
Minimum No
Of Workstation =
Efficiency =
4.2.3. Productivity
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From the calculated operation time loss, it shows that the total loss is 18 units per hour. This problem is caused by the
time loss of the machine that affect the productivity of the machine. Below shows the example of calculation:
Product loss = =
=
= 18 units
From what has been discussed in result process, the modification design process give out the different result. The
amount of the productivity now for the semi auto SDKZ machine is increasing more than before. The calculation of
the productivity shows the efficiency of the machine is increasing from 34% to 56%. This is because of the reducing
of the time loss in the assembling process. Thus, there is less error occurred on the machine anymore.
5.0. CONCLUSION
As a conclusion, the objective of this project was successfully achieved. This project has managed to come out
expected result of the modification of pick and place process part for the cam in the SDKZ machine. This kind of
project also has developed a new design that can reduce the production time of SDKZ switch for semi auto SDKZ
machine. The simulation and drawing using SOLIDWORK help any people in making drawing, analysis and many
more. This project also has taught many kind of thing especially in industrial manufacturing simulation.
RD708 machine was used as a benchmark and the concept of that machine was applied to the SDKZ
machine. RD708 was choose as the benchmark machine because there have part that similarly as the SDKZ machine.
From this project, both SDKZ and RD708 machine has been studied first. This is because both of the machine have
different flow process. The pick and place part from the RD708 was applied and modified at SDKZ machine. From the
project, creativity is an essential factor to modified machine. It is because to modify a machine is the hardest part in
industrial.
On top of that, the productivity of the switch seems to be increasing from before. Hopefully, by doing a
modification to a pick and place part in SDKZ machine, the total time loss can be reduced. This project also had bring
some calculations and comparison between manual and semi auto machine. Thus, from semi auto machine, it then
compared with the latest upgrade SDKZ machine. The time taken, process of the machine and productivity has been
recorded so comparison can be made. By doing some calculations, we know that the efficiency of manual and semi
auto SDKZ machine is totally different.
In term of manpower, both manual and semi auto machine are different. In manual line, the operator that was
used is 8 persons while in semi auto machine, there are 4 operators only. The advantage of using the semi auto
machine is manpower can be reduce thus the productivity can be rise. We know that when the operation is loss or
reduce, the productivity is going up. Through all this matter, all objectives were achieved and this project was succeed
followed all scope works
6.0 RECOMMENDATION
For the recommendation, this project should be developed because it can help in reducing time loss of the machine in
manufacturing process. Other engineer or researcher should develop other part in SDKZ semi auto machine for better
result in increasing the productivity of the switch. This project can give many benefits to many manufacturing factory
or industrial. Developing the style of design process will need more attention of research. If this project can be
continued further, it will give many benefits of developing the manufacturing process.
To improve the effectiveness of the output result for further research, the machine need more kaizen or
improvement. Some of the part of the machine may cause to this problem and failure. On top of that, some manual
part need to be changed also. It is because than manual part is slow than the auto part. For this cases, robotic arm also
can be used at the future to replace the semi auto SDKZ machine.
7.0 REFERENCES
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Remanufacturing. Procedia CIRP, 2014. 15: p. 443-448.
2. Yin, Y.H., et al., Automating design with intelligent human–machine integration. CIRP Annals -
Manufacturing Technology, 2015. 64(2): p. 655-677.
3. Haik, Y., ENGINEERING DESIGN PROCESS. 1st Edition ed. 2003: Bill Stenquist. 269.
4. Marulcu, I. and M. Barnett, Fifth Graders’ Learning About Simple Machines Through Engineering Design-
Based Instruction Using LEGO™ Materials. Research in Science Education, 2012. 43(5): p. 1825-1850.
5. Cai, L., et al., An approach to optimize the machining accuracy retainability of multi-axis NC machine tool
based on robust design. Precision Engineering, 2016. 43: p. 370-386.
6. Koo, K., et al., Architectural design of an RISC processor for programmable logic controllers. Journal of
Systems Architecture, 1998. 44(5): p. 311-325.