Increased Production Capacity of Semi-Automatic Lens Pressing

Machine with Arduino Control Pneumatic Drive in the Type-045

Head Lamp Assembly Process

Eko Saputra, Yusuf Herlambang and Abdul Alfauzi

Politeknik Negeri Semarang, Semarang, Jawa Tengah, Indonesia

Keywords: Penekan Lensa, Head Lamp, Pneumatik, Arduino.

Abstract: Pressing the lens of the Head Lamp 045 or HL-045 product manually using both hands of the operator may

cause uneven compression. The manual process also often causes bottlenecks (time delays), also has an impact

on "Not Good" products and the HL-045 product production planning target is not achieved in the Industry.

The purpose of this research is to increase the productivity of the manufacture of HL-045 with the innovation

of a semi-automatic lens pressing machine to press the upper jig. The research method used is RCA (root

cause analyze) with the following stages: problem identification, problem determination, problem

understanding, corrective action, and system monitoring. Lens pressing machine testing was carried out using

3 pressure parameters, namely 0.3, 0.4 and 0.5 MPa with 30 trials each to obtain data on the lens pressing

process time. The test results show that the best test is at a pressure of 0.5 MPa with a lens pressing process

time of about 3.63 seconds. The conclusion of this study is that the semi-automatic lens pressing machine that

was made was able to increase production capacity by about 8.72% (initial 493 pcs/day to 536 pcs/day) and

reduce the assembly process time of the HL-045 product by 7.98% (initial 109.33 seconds to 100.6 seconds).

1 INTRODUCTION

PT. Indonesia Stanley Electric (ISE) is a

manufacturing company that produces lamps for the

application of two-wheeled and four-wheeled

motorized vehicles. The lamp parts produced include

Housing, Reflector, Extension, Lens, and Inner Lens.

The high demand from customers both in terms of

quantity and quality, then PT. Indonesia Stanley

Electric must implement good production management

standards so that production targets can be achieved.

Based on the method, the assembly process of a

product is divided into two, namely manual assembly

and automatic assembly. Manual assembly is an

assembly whose operation process is done

conventionally without special tools. Automated

assembly is an assembly that is done with automated

systems such as automation and requires more

specialized tools. (Ilyandi, 2015).

The implementation of the automation assembly

system in the line-lamp-assy has not been carried out

thoroughly. For example, the process of pressing the

lens on the line-lamp-assy of the HL type 045 product

is still done manually, see Figure 1. This makes it

difficult for the operator during the manual lens

pressing process and the pressure applied to the lens

pressing process is uneven. This also resulted in "Not

good" product quality and frequent bottlenecks or

time delays that were not in accordance with the

predetermined time standard so that the HL-045

production target was not achieved.

In addition, the HL-045 production plan has a

production target in 1 working day of 540 parts/day.

Meanwhile, the actual production of HL-045 was 493

parts/day or 97.22% of the predetermined target.

Based on these data, it can be concluded that the

production planning of HL-045 has a problem,

namely a decrease in effectiveness and productivity.

In order to solve these problems, solutions and

innovations based on automation systems are needed,

namely through the design of a semi-automatic lens

pressing machine with a pneumatic drive based on

Arduino control. Arduino IDE is sophisticated

software and can be programmed using the C

programming language (Barret, 2011).

This research describes a semi-automatic lens

pressing machine system with pneumatic drive based

on Arduino control (Croser et al., 2002; Darto et al.,

Saputra, E., Herlambang, Y. and Alfauzi, A.

Increased Production Capacity of Semi-Automatic Lens Pressing Machine with Arduino Control Pneumatic Drive in the Type-045 Head Lamp Assembly Process.

DOI: 10.5220/0011875400003575

In Proceedings of the 5th International Conference on Applied Science and Technology on Engineering Science (iCAST-ES 2022), pages 719-725

ISBN: 978-989-758-619-4; ISSN: 2975-8246

719

2015; Dindorf et al., 2017; Gupta et al., 2013; Junaidi

et al., 2018). This study also displays innovations

based on automation systems to increase the

effectiveness and productivity of HL-045 at PT.

Indonesia Stanley Electric. The machine is then

pressure tested to get the press time data.

Figure 1: Manual Lens Pressing Process.

The purpose of this research is to design and

manufacture a semi-automatic lens pressing machine

with a pneumatic drive based on Arduino control to

increase production capacity in the HL-045 assembly

process at PT. Indonesia Stanley Electric and to

determine the performance of the lens pressing machine

by comparing the differences in production results in

the HL-045 assembly process before and after the

design of the semi-automatic lens pressing machine.

2 MATERIAL AND METHOD

2.1 Method

Root Cause Analysis (RCA) is a method for finding a

problem or non-conformity in order to get to the root

cause of the problem. This method is used in order to

fix or eliminate the cause of the problem and prevent

the problem from recurring (Vorley, 2008).

Identification of root causes can be found by the

process of making fishbone diagrams. Fishbone

diagrams are a technique used for more complex

RCAs. This type of diagram identifies all the

processes and potential factors that can contribute to

the problem. Fishbone diagram technique is used to

describe the research process and to analyze the

factors that influence the problem in the lens pressing

process of the HL-045 line-lamp-assy product at PT.

Indonesia Stanley Electric covers man, method,

material, machine, money and environment.

Figure 2: Flow chart of design product.

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720

Corrective action that serves to realize the design

concept that has been made into several alternative

designs. Then one of the best designs is chosen from

several alternative designs that have been made. The

selected design is then analyzed with mathematical

calculations on the material or components that will

be used in the manufacture of the lens pressing

machine. This design also adopted the process of

design product by (Cross, et al. 2000). Figure 2 is a

design flow diagram in the manufacture of a semi-

automatic lens pressing machine.

2.2 Design

The first step in designing a semi-automatic lens

pressing machine by using design software of

Solidworks (Dassault systems, 2015) is to activate

the vacuum ejector by turning the switch on first to

attach the HL-045 lens product to the upper jig. A

vacuum ejector is a device used to convert blowing

power into suction by creating a vacuum, so that this

allows the system to attract a desired workpiece

(Syahril, 2018). After the vacuum ejector is active,

the next step is to press the push button on the

microcontroller box. When the push button is pressed,

the reed switch sensor mounted on the upper

pneumatic cylinder will detect the initial piston

stroke, so that the piston will push the upper jig down

until the piston step is detected by the reed switch

sensor mounted on the bottom of the pneumatic

cylinder.

When the piston stroke has been detected on the

lower reed switch sensor, the lower reed switch

sensor is automatically activated while the upper reed

switch sensor and vacuum injector have been

deactivated by the Arduino microcontroller

command. When the lower reed switch sensor has

detected the piston step will stop or delay for 1 second

for the process of pressing the lens on the 045

reflector head lamp which is already installed on the

lower jig. After the lens pressing process is complete,

the piston will return to its initial position and activate

the upper reed switch sensor and vacuum ejector.

The advantages of this alternative design I have

several advantages, namely: it has a simple shape,

does not require a lot of material, affordable

manufacturing costs. As for the drawbacks, the upper

jig only has 3 stays to place the lens when the lens

pressing process takes place which is considered

imperfect in the gripping process, and there is no

retainer on the right and left sides so that the

construction strength of the lens pressing machine is

considered less strong.

Figure 3: Alternatif design 1.

The work steps of alternative design II are the same

as alternative designs I, namely the process of

suppressing the semi-automatic lens is controlled

through the Arduino microcontroller with the help of

a reed switch sensor to detect the piston stroke. The

advantage of alternative design II is that the machine

construction is stronger because of the holder on the

right and left side of the lens pressing machine, the

process is easier and the vacuum gripping area is

wider with the 4 stays on the upper jig. while the

disadvantage of alternative design II is that it requires

more material so that the manufacture becomes more

expensive.

M N

Figure 4: Alternatif desain 2.

The work steps of alternative design III are the same

as alternative designs I and II, namely the process of

suppressing the semi-automatic lens is controlled

through the Arduino microcontroller with the help of

a reed switch sensor to detect the piston stroke. The

advantage of alternative design III is that the vacuum

gripping area is wider with 4 stays on the upper jig so

Increased Production Capacity of Semi-Automatic Lens Pressing Machine with Arduino Control Pneumatic Drive in the Type-045 Head

Lamp Assembly Process

721

that it can grip the lens maximally and the machine

manufacture is much cheaper because it uses ivony

pipe material for the lens sealing machine frame.

While the disadvantage of alternative design III is that

the construction strength is less strong than

alternative design II, but it is still safe to use on semi-

automatic lens pressing machines and the process is

more difficult than alternative design II.

M N

Figure 5: Alternatif desain 2.

2.3 Testing

The test was carried out using 3 pressure variations to

determine the best pressure so that the lock on the 045

head lamp product could lock optimally and the semi-

automatic lens suppressor cycle time test was carried

out by observing the HL-045 assembly process.

This process is carried out by calculating the cycle

time of the lens pressing process and the production

capacity of the HL-045, then comparing before and

after the semi-automatic lens pressing machine so that

the success rate of the solution that has been

implemented can be seen. After that, control of the

tool needs to be done to determine the success rate of

whether the solutions that have been implemented can

solve the problem and do not cause new problems.

3 RESULT AND DISCUSSION

3.1 Mesin Penekan Lensa Semi

Automatic

Based on the results of the analysis of the design and

work processes carried out, a semi-automatic lens

pressing machine with a pneumatic drive based on

Arduino control is produced in the HL-045 assembly

process which has dimensions of 550 mm x 580 mm

x 1285 mm, see Figure 6. All of the machine element

selection follows the text book of (Khurmi et al.,

2005). This machine uses Pneumatic Solenoid valve

2/2 way: Airtac 1/8". DC 12V (Max Pressure 1.0

Mpa) and Solenoid valve 5/2 way: Airtac 1/8” Single

Coil DC 12V (Max Pressure 1.2

Mpa). Pneumatic Cylinder: SMC 32 x 160 (Max

Pressure 1.0 Mpa. Regulator / Pressure valve: SMC

ARP 20 (Set Pressure 0.008 to 0.6 Mpa). Vacuum

Ejector: Pamy CV 05 – HS 1/4" (Max Vacuum

87Kpa). Suction Cup: UT-SN-F20-TPU50-

1/8AG/M5IG-FIL Microcontroller: Arduino Nano

Atmega 168 (Work Voltage 5 volts).

Figure 6: The prototype of of Semi-Automatic Lens Pressing Machine.

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722

3.2 Pressure Testing

The semi-automatic lens pressing machine was tested

with pressures of 0.3, 0.4, and 0.5 Mpa. The first test

data obtained is shown in Figure 7. Based on the data

obtained from the test results of 3 pressure variations

where one pressure variation was carried out 30 times

the lens suppression process experiment, then

different time results were obtained based on the

compressor pressure parameters that were working or

applied. Tests with a pressure of 0.5 Mpa, namely the

maximum safe pressure of the cylinder that is applied

to be the fastest time and there is no Noot Good (NG)

product compared to other pressures below it.

Figure 7: Alternatif desain 2.

3.3 Time Pressing after Impovement

The process of taking lens suppression data after the

improvement is carried out using a stopwatch when

the production process of the 045 type head lamp is

in progress. Table 1 shows the data on the time of

pressing the lens after the improvement obtained.

Table 1: Lens Pressure Time Data after Improvement.

o Procces Waktu

1 Installation of Qushion 3.64

oulder Caulkin

6.10

otmel

25.86

4 Lens Press 10.05

5 Installaation of SQ nu

6.44

6 Installaation of Bulb HL 4.32

7 Installaation of Cord Cp 6.94

8 Li

htin

Chec

22.56

9 Stampin

4.28

10 Visual Chec

10.41

Total 100.60

3.4 Comparison of Process Time

Before and after Improvement

Lens compression time data after Improvement The

research test of this semi-automatic lens pressing

machine with a pneumatic drive based on Arduino

control has been carried out using 3 pressure

variations, namely 0.3 Mpa, 0.4 Mpa, and 0.5 Mpa.

Testing with a pressure of 0.5 Mpa is the best test that

produces the fastest time and there is no NG product

compared to other pressures. Based on Figure 8 and

Table 1 it can be seen that the comparison of the 045

type head lamp assembly process before the

improvement activity was carried out with the

assembly process after the improvement activity was

carried out with the semi-automatic lens pressing

machine as shown in the figure below.

Based on Figure 8, it can be done analysis of

different work processes before and after

improvement. The difference lies in the 4th working

process, namely the lens suppression process which

previously took 18.78 seconds and after modification

it became 10.05 seconds. The graph shows that the

semi-automatic lens pressing machine with an

arduino-based pneumatic drive, in the 045 head lamp

assembly process experienced a decrease in cycle

time from 109.33 seconds to 100.6 seconds or 7.98%.

3.5 Productivity Cycle Time

Calculation Before Improvement

Time Active working hours at PT. Indonesia Stanley

Electric, which is Monday - Friday with an effective

time of 8 hours a day. Meanwhile, Saturday and

Sunday are taken to fill the overtime or overtime

schedule to meet production targets that cannot be

achieved with work activities. The following is the

calculation of the actual production amount in the 045

type head lamp assembly process before the

improvement is carried out by knowing the cycle time

of the lens suppression process before the

improvement is 109.33 seconds. The following is

Table 2 comparison before and after the improvement

of the manual lens pressing process.

0.3 0.35 0.4 0.45 0.5

Time (second)

Pressure (MPa)

Increased Production Capacity of Semi-Automatic Lens Pressing Machine with Arduino Control Pneumatic Drive in the Type-045 Head

Lamp Assembly Process

723

Figure 8: Comparison before and after Improvement.

Table 2: Comparison before and after Improvement.

Shift (hours)

Production

acit

Average

roduction time

Performance

Before

Improvement

Shift 1 (8hour)

Shift 2 (7hour)

Total (15hour)

263

230

493

109.33 baseline

After

Improvement

Shift 1 (8Jam)

Shift 2 (7Jam)

Total (15Jam)

286

250

536

100.6

Cycle time - 7.98 % from actual

Produktivitas – 8,72 % from actual

Based on the data obtained from the test results of

3 pressure variations where one pressure variation

was carried out 30 times the lens suppression process

experiment, then different time results were obtained

based on the compressor pressure parameters that

were working or applied. Tests with a pressure of 0.5

Mpa, namely the maximum safe pressure of the

cylinder that is applied to be the fastest time and there

is no Not Good (NG) product compared to other

pressures below it.

The failure to achieve production results was

caused by obstacles in the assembly process of the

HL-045 product. The obstacles that occurred were in

the form of a bottleneck (time delay) in the assembly

process, resulting in a significant difference between

the actual time and the standard time set. Based on the

study time that has been carried out on the HL-045

assembly process, it is known the cause of the

obstacles that occur, namely the lens suppression

process. The average time needed to carry out the

pressing process is 12.56 seconds. This time is very

different from the standard time that has been set,

which is 3.55 seconds.

Based on the understanding of the problem, the

potential sources that cause problems are man,

material, method, money, machine and environment.

Sources caused by the man factor itself arise due to

the level of fatigue, work spirit and skills of each

operator. The difference in assembly time that has

been carried out by each operator is not too significant

but there is a large enough time difference with the

time set. Sources caused by material factors arise due

to the presence of NG material produced by the

plastic injection and evaporation division, resulting in

material shortages in the lamp assy division.

Therefore, there is a need for a double check process

in the division before the lamp assy.

The process of pressing the lens which is still

done manually results in bottlenecks (time delay) and

an increase in cycle time so that it has an impact on

not achieving the target production planning of the

045 head lamp. The manufacture of a semi-automatic

lens pressing machine with pneumatic drive is the

action taken to solve the existing problems. so that it

can increase the cycle time and productivity of the

HL-045. Environmental conditions can affect the

morale of each operator, besides that the quality of

product hygiene is also influenced by the existing

production environment. Therefore, each operator is

required to use special shoes in order to maintain the

cleanliness of the existing production environment.

Some of the proposed alternative designs are assessed

Pasang

Qushion

Houlder

Caulking

Hotmelt Lens

Press

Pasang

SQ nut

Pasang

Bulb HL

Pasang

Cord Cp

Lighting

Check

Stamping Visual

Check

Times (s)

Sebelum Improvement

Sesudah Improvement

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724

based on the quality of the results, manufacturing

costs, construction, ergonomics and workmanship.

Based on the assessment that has been carried out, it

is found that the three alternative designs have the

highest rating, and the three alternative designs were

chosen to be the design used. Calculation of material

strength is carried out to determine material

specifications that are safe to use on lens pressing

machine components including: calculating axial

forces on the lower jig, upper jig, pneumatic base,

base table and calculating buckling that occurs in stay

1, 2, 3 and 4 lower jigs. Calculations of pneumatic

cylinders, vacuum ejectors and bolt nuts are also

carried out to determine the specifications of the three

components used in semi-automatic lens pressing

machines.

System monitoring is carried out to ensure that the

improvements made have been running with the

desired goals. System monitoring that has been

carried out is to analyze and process test data for

semi-automatic lens pressing machines using 3

pressure variations, namely 0.3, 0.4 and 0.5 Mpa.

Data processing was carried out using bivariate

analysis with the one way ANOVA method. The

results of data processing show that the best lens

pressing machine is tested at a pressure of 0.5 MPa

with the fastest average processing time of 3.63

seconds. The final result of monitoring the system

shows that the process time of pressing the 045 type

head lamp lens after the semi-automatic lens pressing

machine has decreased by 7.98% from 109.33

seconds to 100.6 seconds. This also affects the

increase in productivity from 493 pcs/day to 536

pcs/day with an increase of 43 pcs or 8.72%.

4 CONCLUSIONS

Innovations and improvements made at PT. Indonesia

Stanley Electric to provide problem solving solutions

in the HL-045 assembly process, namely the design

of a semi-automatic lens suppressor machine with an

Arduino control pneumatic drive which is proven to

be able to increase production capacity by 8.72%

(initial 493 pcs/day to 536 pcs/day) and a decrease in

cycle time of 7.98 % or 8.73 seconds (initial 109.33

seconds to 100.6 seconds). The semi-automatic lens

pressing machine was tested using 3 pressure

variations, namely 0.3, 0.4 and 0.5 Mpa. The test

results show that the most optimal test results are at a

pressure of 0.5 MPa with the fastest average lens

pressing process time of 3.63 seconds.

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