9 research outputs found
Reduction Cost in Material Spring-type Coil for Heavy-duty Oil Filter By-pass System with Redesigning
Full text linkThe bypass system in oil filters plays a crucial role in maintaining engine cleanliness and performance by allowing oil to flow through the filter when the pressure exceeds set limits. A critical component of this system is the coil spring that controls the bypass valve. In this study, an experimental approach was applied to reduce material cost while preserving performance. We redesigned the spring from four coils of 3.5 mm diameter to three coils of 3 mm diameter, using the same standard hard steel wire SW‑C. The redesigned springs were subjected to a standard impulse test of 250,000 cycles under 7 kgf/cm² pressure and a loading test with deflections from 1 to 10 mm at pressures up to 11 kgf. Results show that the new three‑coil SW‑C spring meets all performance criteria: impulse life and load‑deflection characteristics fall within standard tolerances. A direct comparison with the original design demonstrates negligible differences in functional behavior, confirming that material usage and costs can be reduced without sacrificing reliability. These findings offer valuable guidance for the cost‑efficient production of oil filter components in automotive engineering.Sistem bypass pada filter oli berperan penting dalam menjaga kebersihan dan kinerja mesin dengan memungkinkan oli mengalir melalui filter saat tekanan terlalu tinggi. Komponen penting dari sistem ini adalah pegas koil yang mengendalikan katup bypass. Namun, biaya Material pegas koil yang tinggi menjadi tantangan bagi produsen. Penelitian ini bertujuan untuk mengurangi biaya Material pegas koil pada sistem bypass filter oli dengan mendesain ulang. Metodologi yang digunakan meliputi analisis Material alternatif, simulasi kekuatan dan daya tahan, serta pengujian kinerja dalam kondisi pengoperasian yang sebenarnya. Hasilnya menunjukkan bahwa penggunaan Material baru yang lebih murah, dikombinasikan dengan modifikasi pada desain koil, dapat menghasilkan pegas dengan kinerja yang setara dengan aslinya tetapi dengan biaya produksi yang lebih rendah. Penerapan desain baru ini diharapkan dapat menghasilkan penghematan biaya yang signifikan tanpa mengorbankan kualitas dan kinerja sistem filter oli. Temuan ini memberikan kontribusi penting bagi bidang teknik otomotif, khususnya dalam upaya meningkatkan efisiensi biaya produksi komponen mesin
Design Improvement of Mold Bracket for Quarter Trim to Reduce Ejector Mark Defects
Full text linkThis study focuses on improving the quarter trim bracket mold in the mold making division to mitigate the risk of ejector marks, which were identified through long-term analysis. The author redesigned the mold by considering the ejector layout, cooling layout, clamping force calculations, and number of pressure plates, to ensure the product is free from defects. The addition of an ejector pin in the rib area is proposed as a solution to minimize this problem. The quarter trim bracket mold is designed using two pressure plates measuring 30 x 60 mm and four measuring 30 x 80 mm, with a total pressure plate area reaching 13,200 mm². Based on calculations, this part requires a clamping force of 14.5 tons to be produced on a 30 ton capacity injection machine. This clamping force is important to keep the mold tightly closed during the production process, and is calculated based on the cavity pressure in the mold and the shot area. All mold designs are created following company standards to ensure accuracy of sizes and calculations. This research is expected to improve production quality and operational efficiency
Rancang Bangun Jig Welding Modifikasi Pneumatic Clamp Untuk Pengelasan Rear Tube Sepeda Motor Listrik
Full text linkWelding of electric motorcycle rear tube frames at PT Ganding Toolsindo still uses manual clamp welding jigs, which cause problems with long part setup times and less precise weld joints. This study aims to design a more efficient welding jig, which can increase productivity and welding quality by modifying the pneumatic clamp on the welding jig used. The research methods used include literature studies, field observations, data analysis and collection, welding jig design with pneumatic clamps, manufacturing, and testing of welding jigs. Welding with manual clamp welding jigs requires a part setup time of 40 seconds. While the part setup in welding with pneumatic clamp modified welding jigs is 19 seconds. The reduction in part setup time by using pneumatic clamp modified welding jigs is 21 seconds or 52%. These results prove that the use of pneumatic clamp modified welding jigs can increase welding efficiency and produce more precise weld joints.Pengelasan rear tube frame sepeda motor listrik di PT Ganding Toolsindo masih menggunkan jig welding manual clamp yang menimbulkan permasalahan lamanya waktu setup part dan hasil sambungan las kurang presisi. penelitian ini bertujuan untuk merancang jig welding yang lebih efisien, yang dapat meningkatkan produktivitas dan kualitas pengelasan dengan melakukan modifikasi pneumatic clamp pada jig welding yang digunakan. Metode penelitian yang digunakan antara lain studi literature, observasi lapangan, analisis dan pengumpulan data, desain jig welding dengan pneumatic clamp, pembuatan dan uji coba jig welding. Pada pengelasan dengan jig welding manual clamp, waktu yang dibutuhkan untuk setup part selama 40 detik. Sedangkan setup part pada pengelasan dengan jig welding modifikasi pneumatic clamp adalah sebesar 19 detik. Hal ini menunjukkan bahwa penggunaan jig welding modifikasi pneumatic clamp dapat menggurangi waktu proses sebesar 21 detik atau sebesar 52%
Analisis Wake Area Desain Mobil Box dengan Simulasi Aerodinamika
Full text linkThe standard box car design has a large drag and wake area which results in high fuel consumption. One way to reduce drag and wake area is to modify the box car design. Modifications were made by adding an aerokit spoiler and deflector to a standard box car which is expected to reduce drag and wake areas. The next step is to design a simulation using CFD-based CAD. The analysis was carried out with three variations of speed, namely 60 km/hour, 80 km/hour and 100 km/hour. The simulation results show that the design of the box car with the modification of the addition of aerokit spoilers and deflectors can reduce the drag and wake areas
Synergizing QCC and PDCA Approaches to Foster Kaizen Practices in Wingbox Production at Karoseri
Full text linkThis research applies the Quality Control Circle (QCC) method and the PDCA (Plan-Do-Check-Action) approach to overcome problems in hydraulic cylinder bracket mounts in a manufacturing company. At the "Plan" stage, a defect classification analysis, matrix diagram for problem classification, analysis of existing conditions, setting quality, cost, and morale targets, as well as Why-Why and 5W+1H analysis were conducted. At the "Do" stage, the cylinder bracket mounts was redesigned using UNP 5.4 material as a solution to the existing problems. At the "Check" stage, measurements of the improvement results were made to ensure the achievement of the planned targets, including the reduction of damage frequency and repair costs. The results of overcoming the problem of broken hydraulic cylinder bracket mounts showed a decrease in complaints during the 2-month period after implementation. The application of the QCC method and PDCA approach not only effectively addressed the problem, but also increased customer confidence, company sustainability, and worker morale. The next step is “Action” stage to ensure process continuity by standardizing through the creation of operation standards for the manufacture and installation of hydraulic cylinder bracket mounts. As a result, the material change from SPHC 6.0 to UNP 5.4 successfully resolved the damage problem and eliminated complaints within two months after implementation. After implementation, the company can reduce the cost expense of repair by IDR 1,413,510. This success had a positive impact on customer confidence, cost efficiency, and worker morale
Effect of SiO₂ Nanoparticle Dispersion on The Stability and Thermal Conductivity of Polyvinyl Ether-Based Nanolubricant
Full text linkHeat transfer efficiency in lubrication systems can be achieved by utilising nanolubricants by dispersing nanoparticle additives into pure lubricants to increase nanolubricant stability and thermal conductivity. This study aims to investigate the effect of silicon dioxide (SiO₂) nanoparticle dispersion in polyvinyl ether (PVE)-based lubricants on the stability and thermal conductivity characteristics of nanolubricants. SiO₂/PVE nanolubricant was prepared using a two-step method with a volume concentration of 0.007%. Stability evaluation was carried out through UV–Vis spectrophotometry testing over a period of 30 days. Thermal conductivity was measured using KD2-Pro at a temperature range of 30 ℃ to 80 ℃. The results of the study showed that SiO₂/PVE was declared stable after 144 hours with an absorbance of 80%. Thermal conductivity characteristics decreased with increasing temperature, and the nanolubricant increased compared to PVE lubricants. The maximum increase in thermal conductivity was 2.72% compared to the pure lubricant, and at a test temperature of 30 °C, SiO₂/PVE was compared to SiO₂/corn oil, SiO₂/paraffin oil, SiO₂/sunflower SiO₂/oil, and SiO₂/soybean oil; the results showed an increase in thermal conductivity of 66.69%, 80.63%, 67.70%, and 46.45%, respectively. The thermal conductivity behaviour tends to increase when SiO₂ nanoparticles are dispersed into the pure lubricant, compared to the pure PVE lubricant and previous studies. These findings indicate that SiO₂/PVE nanolubricant produces a significant increase in thermal conductivity, resulting in accelerated heat transfer, reduced friction and wear, and ultimately leading to increased energy efficiency and improved overall system performance.Heat transfer efficiency in lubrication systems can be achieved by utilising nanolubricants by dispersing nanoparticle additives into pure lubricants to increase nanolubricant stability and thermal conductivity. This study aims to investigate the effect of silicon dioxide (SiO₂) nanoparticle dispersion in polyvinyl ether (PVE)-based lubricants on the stability and thermal conductivity characteristics of nanolubricants. SiO₂/PVE nanolubricant was prepared using a two-step method with a volume concentration of 0.007%. Stability evaluation was carried out through UV–Vis spectrophotometry testing over a period of 30 days. Thermal conductivity was measured using KD2-Pro at a temperature range of 30 ℃ to 80 ℃. The results of the study showed that SiO₂/PVE was declared stable after 144 hours with an absorbance of 80%. Thermal conductivity characteristics decreased with increasing temperature, and the nanolubricant increased compared to PVE lubricants. The maximum increase in thermal conductivity was 2.72% compared to the pure lubricant, and at a test temperature of 30 °C, SiO₂/PVE was compared to SiO₂/corn oil, SiO₂/paraffin oil, SiO₂/sunflower SiO₂/oil, and SiO₂/soybean oil; the results showed an increase in thermal conductivity of 66.69%, 80.63%, 67.70%, and 46.45%, respectively. The thermal conductivity behaviour tends to increase when SiO₂ nanoparticles are dispersed into the pure lubricant, compared to the pure PVE lubricant and previous studies. These findings indicate that SiO₂/PVE nanolubricant produces a significant increase in thermal conductivity, resulting in accelerated heat transfer, reduced friction and wear, and ultimately leading to increased energy efficiency and improved overall system performance
Reduction of Cost in Material Spring-type Coil for Heavy-duty Oil Filter Bypass System with Redesign
No full textThe bypass system in oil filters plays a crucial role in maintaining engine cleanliness and performance by allowing oil to flow through the filter when the pressure exceeds set limits. A critical component of this system is the coil spring that controls the bypass valve. In this study, an experimental approach was applied to reduce material cost while preserving performance. We redesigned the spring from four coils of 3.5 mm diameter to three coils of 3 mm diameter, using the same standard hard steel wire SW‑C. The redesigned springs were subjected to a standard impulse test of 250,000 cycles under 7 kgf/cm² pressure and a loading test with deflections from 1 to 10 mm at pressures up to 11 kgf. Results show that the new three‑coil SW‑C spring meets all performance criteria: impulse life and load‑deflection characteristics fall within standard tolerances. A direct comparison with the original design demonstrates negligible differences in functional behavior, confirming that material usage and costs can be reduced without sacrificing reliability. These findings offer valuable guidance for the cost‑efficient production of oil filter components in automotive engineering
Comparative Assessment of Spot Welding and Lock Seam on Automotive Inner Tubes for QCDSM and Product Lifecycle Sustainability
Full text linkIn the automotive manufacturing industry, enhancing quality and productivity is crucial to meet customer expectations while ensuring safety, environmental sustainability, and energy efficiency. This study evaluates the collapse strength of automotive inner tubes following ISO 2941 standards, comparing lock seam design with SGCC material and resistance spot welding (RSW) applied to SECD material. The findings show that the lock seam process improves structural strength by approximately 20%, due to more uniform pressure distribution, leading to better stability. A key advantage of the lock seam is its spiral construction, which contrasts with RSW's localized spot welds, contributing to more consistent performance. Additionally, the lock seam process reduces production costs and minimizes environmental impact by using thinner, cost-effective SGCC material. It also enables faster production, enhancing delivery efficiency. The absence of welding fumes improves safety conditions and boosts operator morale, while contributing to a cleaner working environment. From a Product Lifecycle Management perspective, this study shows that the lock seam process optimizes design quality, production efficiency, and sustainability, aligning with the goals of Quality, Cost, Delivery, Safety, and Morale (QCDSM). These results support the adoption of lock seam technology for sustainable, efficient automotive manufacturing
Penerapan Single-Minute Exchange of Die (SMED) untuk Penurunan Waktu Setup dan Biaya Produksi pada Injection Molding
Full text linkWaktu setup yang lama pada proses injection molding dapat menyebabkan downtime yang signifikan, mengurangi produktivitas, dan meningkatkan biaya produksi. Penelitian ini bertujuan untuk mengurangi waktu setup mold pada mesin berkapasitas 450 ton di PT MWT dengan menerapkan metode Single Minute Exchange of Dies (SMED). Metode ini diterapkan dengan mengidentifikasi dan mengonversi aktivitas internal menjadi eksternal serta menyederhanakan langkah-langkah aktivitas internal. Hasil penelitian menunjukkan bahwa waktu setup berhasil dikurangi dari 196 menit menjadi 156 menit, menghasilkan pengurangan waktu sebesar 20,4%. Selain itu, biaya produksi harian berkurang sebesar Rp333.333 atau sekitar 20,4% dari total biaya sebelum perbaikan. Peningkatan efisiensi waktu memungkinkan perusahaan untuk meningkatkan kapasitas produksinya tanpa menambah sumber daya. Penerapan metode SMED juga berdampak positif pada kualitas produk, dengan risiko produk cacat yang lebih rendah karena proses setup yang lebih cepat dan terstandardisasi. Penelitian ini menunjukkan bahwa metode SMED merupakan langkah efektif dalam meningkatkan efisiensi dan daya saing perusahaan di industri manufaktur
