faculty : industrial technology total page : 25 major

UNIVERSITAS ISLAM INDONESIA FM-UII-AA-FKU-01/R0

MANUFACTURING PROCESS TRAINING MODULE

Faculty : Industrial Technology Total Page : 25

Major / Study Program : Industrial Engineering Modules Name : Design Process

Practicum Code : Manufacturing Process Date of Validity : September 25th, 2021

Manufacturing System Laboratory 1







TABLE OF CONTENT

I. LEARNING OBJECTIVES ....................................................................................... 3

II. DESIGN AND MANUFACTURING ...................................................................... 3

2.1 CAD (Computer Aided Design) ....................................................................... 3

2.2 CAM (Computer Aided Manufacturing) ......................................................... 4

III. PRODUCT ............................................................................................................... 4

3.1 Product Material ............................................................................................... 5

a. Definition of Material ................................................................................... 5

b. Type of Material ........................................................................................... 5

c. Material Processing ...................................................................................... 5

3.2 Design of Manufacturing Process .................................................................... 6

a. Material ......................................................................................................... 6

b. Machine ........................................................................................................ 7

c. Bill of Material ........................................................................................... 10

d. Assembly Chart .......................................................................................... 14

e. Operation Process Chart (OPC) .................................................................. 15

f. Production Flow ......................................................................................... 19

g. Size and Tolerance ...................................................................................... 19

h. Process Control Plan ................................................................................... 21

REFERENCE ............................................................................................................... 25







I. LEARNING OBJECTIVES

The following are the learning objectives of the Manufacturing Process Practicum in

Module 2:

1. Practitioners know and understand the products made.

2. Practitioners know and understand the machine used.

3. Practitioners are able to design products using Solidworks software.

4. Practitioners understand the flow of the product manufacturing process.

II. DESIGN AND MANUFACTURING

In the industrial world, it is known as CAD/CAM. CAD/CAM is software that has two main

parts, namely CAD drawing design (Computer-Aided Design) and CAM (Computer-Aided

Manufacturing) drawing design (Budi, Waluyo, & Purwanto).

2.1 CAD (Computer Aided Design)

CAD is a design drawing containing product drawings that include sizes and geometric

shapes. CAD is also used in the design of various tools and equipment used in

manufacturing components.

The function of CAD itself is used through the engineering process from conceptual

design and layout, through engineering and component analysis to defining manufacturing

methods.

Figure 1 Computer-Aided Design







2.2 CAM (Computer Aided Manufacturing)

CAM is a design about the feeding process, toolpath, machine setup, and others. A product

produced by CAM will match the design drawn on the CAD process with the CAM system.

CAM refers to the use of computers that convert engineering designs to final products.

Product processes also require the necessary control and coordination for physical

processes, equipment, and materials. With CAM, computers assist managers,

engineering/manufacturing engineers, and production workers with automated production

tasks. CAM with CAD system results in a faster and more efficient manufacturing process.

Figure 2 Computer Aided Manufacturing

III. PRODUCT

Product is anything that can meet the needs as desired by the customer. The product is

designed by the company by taking into account several aspects, such as quality, design,

shape, size, material, and others to achieve the goal of the company (Lubis, 2004).

In the industrial world, a product is known, namely a manufactured product, where

the product is managed and processed using a manufacturing process, for example, chairs,

cars, motorcycles, dispensers, and other products, each of which has a different shape.

These objects will not exist if they are not transformed (created/made) from various types

of materials and assembled to become objects used in everyday life (Supriyanto, 2013).

Here are some aspects that must be considered in making a product in the

manufacturing process.







3.1 Product Material

a. Definition of Material

Materials are made and arranged by materials to become something that will be used

(William, 2009). So from this understanding, it can be concluded that product materials

are several materials used in the process of making a useful product or finished product.

Materials or materials used in the industrial sector are very much because they adjust

the products made.

b. Type of Material

In the manufacture of a product, materials can be produced on the factory floor or

purchased from other companies. As for the various forms of engineering materials that

are widely used or needed in the industrial world, based on their form, technical

materials are divided into three, there is (Kurniawan, 2020):

1. Solid is a material that has a massive shape, relatively fixed, strong bonds

Example: metal, iron, plastic, glass, wood, plastic, etc.

2. Liquid is a material whose shape follows the vessel and the bond is weak

Example: lubricants, water, gasoline, diesel, etc.

3. Gas is a material that follows the shape of the vessel but is not visible

Example: CO2, hydrogen, oxygen, etc.

c. Material Processing

The processing of materials used from the above types of materials is solid. Processing

of solid materials such as iron can be done using several machines to become a finished

product. The process of processing solid objects can be carried out on a lathe for

scraping, milling machines for face-feeding, hacksaw machines for cutting workpieces,

welding machines for joining one material with another. So that from the material that

was originally an iron cylinder it can become a finished product such as a chair frame,

table, etc.







3.2 Design of Manufacturing Process

Manufacturing process design is one of the manufacturing processes, namely designing a

product. The product is designed and designed by engineers after it is processed into the

manufacturing process. In the design of the manufacturing process, there are several things

that need to be considered, namely the product material, the machine used, the bill of

material (BOM), Assembly Chart, product size and tolerance, operation Process Chart

(OPC), and production flow. The following is a design of the manufacturing process with

an example of the product is a pencil case. The following is an example of a pencil case

product as a reference in the manufacturing process.

Figure 3 Pencil Case

From the design of the manufacturing process above, it is necessary to pay attention

to the material, machine, bill of material, assembly chart, operation process chart, and the

production flow of the pencil case.

a. Material

It can be seen in Figure 3, which is a pencil case product that has several materials or

materials used in its production process. The materials used are:







1. Iron

Iron is a type of metal that is often used in everyday life that comes from iron ore

(mines). In addition, iron is the most important metal in the industrial world, the

price of iron has a high economic value (Pakasi, 2019).

2. MDF

MDF (Medium-Density Fiberboard) is a type of processed wood that is made using

wood chips obtained. MDF wood has a smooth structure compared to other types

of wood so it is more comfortable to use and does not need to be sanded (Pratama,

2019).

3. PLA (Poly Lactic Acid)

PLA is a type of polymer plastic derived from easily biodegradable materials such

as corn flour, tapioca flour, or processed sugar cane. Although PLA is

environmentally friendly, the resulting prints are strong and very neat (Putra &

Sari, 2018).

b. Machine

From Figure 3 above, it is a product that has been assembled from several parts into a

pencil case product. So the following is the name of the part and the type of machine

used in the pencil case product.

Figure 4 Name of Pencil Case Part







The above part will be processed into a pencil case product using several

machines. The machines used in the manufacture of pencil cases are as follows:

1. Hacksaw Machine

In a hacksaw machine, a part is made, namely the base, ironside, and pencil hole.

On a base with long iron material, it has a predetermined size cutting process using

a hacksaw machine. Furthermore, the iron side and pencil hole have the same

process as the base which has long iron material and is cut according to a

predetermined size using a hacksaw machine.

Before After

2. Drilling Machine

The drilling machine is used to punch holes in a workpiece with a round structure

using a predetermined chisel. In the pencil case using a drilling machine is the pencil

hole part. The function of the drilling machine on the pencil hole part is to make

holes in the iron that has been cut using a hacksaw machine. The drill bit used is

adjusted according to a predetermined size.

Before After







3. Milling Machine

The milling machine is used for base and iron side parts. The process of the milling

machine for the base and iron side is to do the feeding to make a container for MDF

parts and pencil holes to be assembled on the welding machine.

Before After

4. Mesin 3D Print

The 3D printing machine is used for parts storage. The 3D print process itself is to

design using CAD software, then input into the slicer software to control the process

of the 3D print, after that the design is processed on a 3D print machine using PLA

material.

Before After

5. Welding Machine

Welding machines are used to join one part to another using the electrodes on the

welding machine. The combined parts are:

• Base with iron side.

• Base with pencil hole.







Before After

6. Grinding Machine

The grinding machine is used for the process of removing material by scraping after

the welding process. So that the assembly results of the base part, ironside, and

pencil hole have a smooth or even structure from the previous rough or uneven in

the welding process.

c. Bill of Material

Bill of materials (BOM) is a structural description of all materials, parts, sub-

assemblies, and quantities used or required to assemble, combine, and produce the final

product or parent assembly.

According to Scott (1994), BOM is linking product structure and material

planning system. A good product if in the process is presented in a BOM, starting from

the product it is made or assembled into the final product.

A manufacturing engineer uses the BOM as part of the design process and

determines which items should be purchased or produced. The production and

inventory control planning process uses BOM with Master Production Schedule (MPS)

(Modul 1 Perencanaan Proses, 2015).

In this practicum, the format used is BOM with a table whose columns contain

information that includes:

1. Level.

2. Part number.

3. Part name or description.







4. Quantity for each assembly.

5. Decision (quantity of parts for each one finished product).

When viewed from the product components, BOM is divided into two types:

1. Single Level Bill

Single Level Bill is a production with components made only one level, a simple

format of BOM which can be seen in Table 1 below.

table 1 Example of Single Level Bill

2. Multilevel Bill of Material

In this practicum, a Multilevel tree is used where the Single Level Bill of Material

is not enough to describe a subassembly product, so a product with a sub-assembly

process uses a Multilevel Tree and a Multilevel Tree Bill of Materials.

A multilevel tree or product structure tree is defined as an information chart

about the relationship between the final product and the components that make up

the final product. Product structure is information about the relationship between

components in an assembly, besides that, it also provides information about all

items, such as part number and quantity needed (Ansori & Rahayu, 2019). Here's

an example of a nested tree from a pencil case:







Figure 5 Example of a Multilevel Tree Pencil Case Structure

Table 2 Example of Multilevel BOM Pencil Case

Level

Part

Number

Part Name Material Quantity Make

or Buy

0 9.0.5 Pencil Case PLA, Iron, dan

MDF Wood 1 Make

1 8.1.1 Storage PLA 2 Make

1 7.1.4 Main Body Iron and MDF

Wood 1 Make

2 6.2.4 Body Base Iron and MDF

Wood 1 Make

3 5.3.2 Base Iron 1 Make

3 4.3.3 MDF MDF Wood 1 Make







Level

Part

Number

Part Name Material Quantity Make

or Buy

2 3.2.2 Center Body Iron 1 Make

3 2.3.2 Pencil Hole Iron 1 Make

3 1.3.2 Iron Side Iron 2 Make

The multilevel tree pencil case above illustrates the relationship between the

final product and its constituent parts such as assembling the parts at level 3 into a

new part at level 2. So these parts need other parts to make and so on. The following

is information that can be given in the creation of a multilevel tree.

Figure 6 Description of the Multilevel Tree Section

From this information, a product structure tree can be made. In Figure 6

above, it is explained that the pencil case manufacturing process starts from the

part at level 3, the lower left, namely storage. So the process of making the

center body is by assembling from iron side (1st process) and then making

pencil hole (2nd process) to become a finished product, namely pencil case (9th

process).







d. Assembly Chart

An assembly chart is a graphic depiction that describes the flow sequence of

components and sub-assemblies that will be assembled into a product. assembly chart

serves to show the components that make up a product and explain how to make the

assembly flow of these components. The following is the format for making an

assembly chart.

Figure 7 Assembly Chart Format

From the explanation of the assembly chart format above, the following is an

example of making an assembly chart of a pencil case product.







Figure 8 Example of Assembly Chart Pencil Case

e. Operation Process Chart (OPC)

The operation process map is a depiction of a diagram containing the steps of the

material processing process, from raw materials to components or finished products

(Siregar, 2014).

The OPC contains the information needed for further analysis in the form of

time spent, the material used, and the place or machine used to process the material. So

that in an operation process map, only operations, and inspection activities are recorded,

as well as the final steps included in storage activities. The benefits of OPC are:

1. To find out the needs of the machine

2. To estimate raw material requirements

3. One of the tools to determine factory layout

4. One of the tools to improve the current workings

On the OPC there is a symbol used in a working map. In 1947 the American

Society of Mechanical Engineers (ASME) standardized symbols consisting of five







symbols which were the result of the development of the symbol proposed by Gilbreth.

In its use in OPC, only three symbols are used, namely (Mutia & Maryana, 2015):

Table 3 OPC Symbols and Description

No Symbol Symbol Name Description

1

Operation

Operational activities occur

when the workpiece changes

properties (both physical and

mundane). Occurs in the

production process which

usually occurs on a machine or

workstation.

2

Inspection

Inspection occurs when the

workpiece undergoes an

inspection process, both in terms

of quantity and quality.

3

Storage

Storage occurs when the

workpiece is stored for a long

period.

After knowing the OPC symbol in Table 3 above, there is a format for making

OPC, the following is the format for making OPC.







Figure 9 OPC Format

From the above format, it can be represented in an example of an OPC on a product,

namely a pencil case.







Figure 10 Example of OPC Pencil Case

From the results of making the OPC, a summary table is made with the format of

activities, amount, and time (minutes). The following is a summary of the OPC (Operation

process chart) pencil case flow as shown in Table 4 below.

Table 4 Example of OPC Pencil Case Summary

Summary

Activity Quantity Time (minute)

19 99

5 25

1 0

Total 25 124







f. Production Flow

The production flow is a series of sequences in the product manufacturing process,

where the production flow will be explained in the form of the name of the part, the

material of the part, and the machine.

Table 5 Example of Pencil Case Flow

No. Part name Material Machine

1 Storage PLA 3D Print

2 Iron Side Iron Hacksaw, Milling and Welding

3 Pencil Hole Iron Hacksaw, Drilling and Welding

4 MDF Iron Jigsaw

5 Base Iron Hacksaw and Milling

g. Size and Tolerance

Tolerance is a deviation that is allowed or permitted. Each basic measure is given two

allowable deviations, namely the upper deviation and the lower deviation. Due to the

presence of deviations, a workpiece is fabricated and processed using tolerances, so that

the workpiece can be mounted and assembled. Size tolerances are divided into 3 types,

that is:

1. Internasional Tolerance (IT)

In international tolerances the magnitude is determined by ISO / R286 (ISO system

for limits and adjustments), it is to comply with functional requirements and

uniformity. ISO R286 specifies standard tolerances which are:

• IT 01-4 is for very thorough work,

• IT 5-11 is used in general machining, for interchangeable parts, which can also

be classified in very precise work, and ordinary work.

• IT 12 - 16 is used for menial work.

2. General Tolerance

The general tolerance is a measure given to a process that does not require precision

or is not part of a paired object. The general tolerance value always has the same

upper and lower deviation limits. So that the level of quality (surface hardness) and







the basic size is determined by the amount of tolerance. The following is an image

of the general tolerance table.

Table 6 General Tolerance

From Table 6 above, if it is implemented on a pencil case product, size and

tolerance can be made which consists of the part name, measured side, actual size,

product tolerance, and final size.

Table 7 Example of Pencil Case Tolerance

No. Part Measured

Side

Actual

Size

(mm)

Tolerance

(mm)

Final Size

(mm)

Final Size

(cm)

1 Storage

Length 70 ± 0,3 70,3 7,03

Width 50 ± 0,3 50,3 5,03

Height 30 ± 0,2 30,2 3,02

2 Iron

Side

Length 70 ± 0,15 70,15 7,015

Width 6,8 ± 0,1 6,9 0,69

Height 68 ± 0,15 68,15 6,815

3 Pencil

Hole

Length 142,9 ± 0,2 143,1 14,31

Width 40 ± 0,15 40,15 4,015

Height 5 ± 0,05 5,05 0,505

Diameter 10 ± 0,1 10,1 1,01

4 MDF Length 132,9 ± 0,5 133,4 13,34







No. Part Measured

Side

Actual

Size

(mm)

Tolerance

(mm)

Final Size

(mm)

Final Size

(cm)

Width 3 ± 0,1 3,1 0,31

Height 63 ± 0,3 63,4 6,34

5 Base

Length 132,9 ± 0,2 133,1 13,31

Width 70 ± 0,15 70,15 7,015

Height 10 ± 0,1 10,1 1,01

3. Special Tolerance

A special tolerance is a tolerance whose value is outside the general tolerance. The

difference from the general tolerance, that the special tolerance has a smaller value

than the general tolerance value.

h. Process Control Plan

Process Control Plan is a representation in a tabular form that states the sequence or

sequence of operations along with their parameters in the manufacture of parts of a

product. Some points that must be considered in filling out the process plan sheet table

are:

1. Process Number

Is the sequence number of the process in making a product from the beginning such

as measurement to completion such as placing goods in a warehouse.

2. Operation Description

The operation description contains the process in the operation of a product from

raw materials to finished products.

3. Work Station

Work station is an area or place in carrying out production activities in converting

raw materials into finished products that have added value.







4. Setup Number

The setup number is the number of the setup of each process.

5. Setup Tool

Setup tools are tools used in the setup process to provide convenience, comfort, and

safety for operators.

6. Tools

Tools are tools or components in the form of chisels or other tools used in the part-

making process, for example in making a hole the tools used are drill ∅7.

7. Setup Time

Setup time is the time required on a machine or work station when the machine is

turned off to end the production process until the machine is turned on again and

ready for the next production.

8. Processing Time

Processing time is the time required to process from a machine to make a product.

9. Total Time

Total time is the total time from setup, manufacturing process, to finished product.

From the results of the above discussion, the following is the application of LRP

with an example, namely the pencil case product in the table below (Modul 1

Perencanaan Proses, 2015).

PROCESS CONTROL PLAN

Number : 1 Page :

Part Number: 7.1.1 Image File :

Part Name : Storage Material : PLA

Size (cm)

Length : 7,03

Made by : PT. Siman Diameter : 5,03

Date : March 25th

, 2024 Tall : 3,02

Process

Number

Process

Description

Work

Station

Setup

Tools

Setup

Time

(s)

Process

Time (s)

Total

Time (s) Setup

Number Add-Tools

1 Printing 3D Print Bakest

sekop 300 300

2 Inspection - Measuring

tool - -








Number : 2 Page :


Part Name : Iron Side Material : Iron

Size (cm)

Length : 7,015

Made by : PT. Siman Wide : 0,69

Date : March 25th

, 2024 Tall : 6,815

Process

Number

Process

Description

Work

Station

Setup

Tools

Setup

Time

(s)

Process

Time (s)

Total

Time

(s) Setup

Number Add-Tools

1 Measure - Ruler 120 120

2 Cut the

cylinder iron

Hacksaw

Machine

Coolant

and rasp 300 300

3

Feeding the

body of iron

base

Milling

Machine Coolant 600 600


tool - -


Number : 3 Page :


Part Name : Pencil Hole Material : Iron

Size (cm)

Length : 14,31


Date : March 25th

, 2024 Tall : 0,505

Diameter : 1,01

Process

Number

Process

Description

Work

Station

Setup

Tools

Setup

Time

(s)

Process

Time (s)

Total

Time

(s) Setup

Number Add-Tools


2

Cut the iron

becomes a

square

Hacksaw

Machine

Coolant

and rasp 300 300

3 Perforated iron

hole body

Drilling



tool - -








Number : 4 Page :


Part Name : MDF Material : MDF Wood

Size (cm)

Length : 13,34


Date : March 25th

, 2024 Tall : 6,34

Process

Number

Process

Description

Work

Station

Setup

Tools

Setup

Time

(s)

Process

Time (s)

Total

Time

(s) Setup

Number Add-Tools


2 Cut the MDF

wood

Jigsaw

Machine 300 300


Tool - -


Number : 5 Page :


Part Name : Base Material : Iron

Size (cm)

Length : 13,31


Date : March 25th

, 2024 Tall : 1,01

Process

Number

Process

Description

Work

Station

Setup

Tools

Setup

Time

(s)

Process

Time (s)

Total

Time

(s) Setup

Number

Add-

Tools


2

Cut the iron

becomes a

square

Hacksaw

Machine

Coolant

and rasp 300 300

3

Feeding the

body of iron

side

Milling


4 Inspection - Ruler - -







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