Lampiran 4.1 Contoh Format Check Sheet Die Design
Standard
Eva
C1 C2
1 Check kesesuaian Base Line, Bansen, CL & CM terhadap Process sheet - See Drawing
dan pastikan sudah tercantum di Data 3D dan 2D.
Cantumkan Dimensi antara CL dg CM pada Drawing kalau ada offset
2 Banzen dan perubahannya setelah rotasi
No Need
Sesuaikan Process sheet.
-
-
-3 Dimensi CL terhadap Banzen
Actual :
Process sheet :
(
…
)
4 Front Mark / Loading Unloading ( refers to Proccess Sheet )
See Drawing
Sesuaikan Process sheet.
-
-
-5 R / L Panel Mark ( refer to cad data )
See Drawing
Sesuaikan dengan actual data.
-
-
-6 Arah Press ( refers to Proccess Sheet )
See Drawing
Sesuaikan Process sheet.
-
-
-7 Gambar bentangan & Seal Standard ( bila perlu )
See Drawing
Sesuaikan standard
-
-
-8 Tanda rotasi ; Center rotasi dan banzen rotasi (bilamana ada)
See Drawing
Sesuaikan Process sheet.
-
-
-9 Lokasi Vacum Cup (line H,I & A Karawang) Refer to Customer spec's
See Drawing
Sesuaikan Process sheet.
-
-
-10 Lokasi Atari ( area atari dibuat tanda khusus / di arsir) lihat Hinpyo
See Drawing
Sesuaikan Hinpyo dan Atarizuke
standard.
11 Section penting - area tertinggi ,terendah & detail kanrimen ( Draw )
See Drawing
Buatkan section area yang
diperlukan.
12 Check CAD data & Part Drawing terakhir
Data :
Level ECI Part Drawing =
(
…
) (
…
)
13 Material spec ( check process sheet & Part Drawing )
Diagram :
Part drawing :
(
…
)
(
…
) Process sheet :
(
…
)
14 Kijun Panel ( Outer / Inner side )
Diagram :
(
…
)
Part Drawing :
(
…
)
NB : coret y g tidak pe
15 Draw - P/F ( Mark , Dimensi , notasi ) pada semua view.
See Drawing
Sesuaikan standard
-
-
-16 Hitung & tulis Power Draw
Actual :
Draw Power Calculation :
(
…
) ( Max power Mesin )
17 Tentukan jumlah cushion
Actual :
Sesuaikan dengan equalizing :
(
…
) Refferensi : ( …..……….. …. )
Standard : ( …..……….. …. )
CHECK
VALUE
NO
ITEM POINT CHECK ===> " DIAGRAM "
-Actual
--
-
--
--
--
--
--
--
--
--
-kijun Outer
kijun Inner
APPROVED
CHECKED
PREPARED
Sect.Head
Leader
Designer
REVISI
10
NOMOR DOKUMEN
CHS - ATX300 - 2101
TANGGAL
22 Juli 2008
TANGGAL KELUAR
?
" CHECK SHEET "
DRAW
PROCCESS
NOMOR DIE
?
PROSES
?
NOMOR KANBAN
PT.TOYOTA MOTOR MFG INDONESIA PWPET
DIV - PDD DEPT. DIE
DESIGN SECTION
?
No.Dist STATUS
DIV.
DEPT.
SECT.
(…...)
CL
CM
Base Line
(.
..…
)
(…....)
CL
BANSEN
16 Februari 2009
P T. TOYOTA M OTOR M FG INDONESIA
DJDF DIVISION, P DD DEP A RTM ENT
DIE DESIGN SECTION
68
Lampiran 4.2 Visual SMS dan Global Design Standard
Stamping Manufacturing Standard ( SMS )
Lampiran 4.3 New Flow Die Design
HOUR % HOUR % 1 2 3 4 5 6.5 5% 6.5 5% 6 78 60% 84.5 65% 7 3.9 3% 88.4 68% 8 2.6 2% 91 70% 9 10 6.5 5% 97.5 75% 11 12 6.5 5% 104 80% 13 14 6.5 5% 110.5 85% 15 16 19.5 15% 130 100% 17 18NO FLOW WORKING HOUR ACCUMULATION NOTE
PROJECT LEADER TECHNICAL MATERIAL
CHECK NG
EDIT SURFACE & PROFILE SOLID CONSTRUCTION
MAKING
DRAW PROCESS FOLLOW ING PROCESS CUSHION RING ASSEMBLY LOWER DIE ASSEMBLY LOWER PUNCH ASSEMBLY UPPER DIE ASSEMBLY UPPER PUNCH ASSEMBLY UPPER/LOWER PAD ASSEMBLY INSERT STEEL/PUNCH/CAM ASSEMBLY UPPER DIE ASSEMBLY LOW ER DIE ASSEMBLY ACCESSORIES ACCESSORIES CONVERT DATA ( VRML / IVZ FILE) DRAFT DESIGN KENTOKAI REPAIR PROBLEM KENTOKAI
AND FINISHING DESIGN
2D MAKING CONVERT DATA PRODUCT DESIGN FINISH a a b c d e f e b c d 10% 10% 10% 10% 10% 10% 10% 10% 15% 15% 10% TOTAL ASSY BALANCE CHECK HOIST BALANCE CHECK MACHINING CHECK HOIST BALANCE CHECK MACHINING CHECK MACHINING CHECK MACHINING CHECK OK NG NG OK OK NG MACHINING CHECK NG OK MACHINING CHECK OK NG HOIST BALANCE CHECK MACHINING CHECK MACHINING CHECK OK NG MACHINING CHECK OK NG NG OK NG OK TOTAL INTERFERENCE CHECK OK
Project leader memberikan technical material yang akan digunakan untuk proses pendesaian dies.
Technical material yang diperlukan antara lain : Process sheet, Part Drawing, Cad Data dan informasi lainnya.
Pengechekan technical material oleh die design.
Diagram dan die face untuk start data design yang diperoleh dari seksi Die Face Pembuatan surface dan profile design dari data cad dan die face yang diterima. Pembuatan 3D solid construction.
Urutan pembuatan konstruksi proses draw : a. Cushion Ring Assy
b. Lower Punch Assy c. Lower Die Assy d. Upper Punch Assy e. Upper Die Assy f. Accesories
Urutan pembuatan konstruksi proses following : a. Upper / Lower Pad Assy
b. Insert Steel / Punch / Cam Assy c. Upper Die Assy d. Lower Die Assy e. Accesories
Konversi data untuk Fox Viewer (VRML / IVZ File) Fox Viewer adalah viewer software yang digunakan untuk melihat tampilan konstruksi 3D solid yang dibuat oleh design.
Kentok ai / Pengecekan konstruksi design
bersama seksi-seksi terkait dengan menggunakan Fox Viewer.
Pembuatan 2D drawing. Konversi data untuk next process : CFIO file untuk proses slice, BN dan NC die/insert di Cad Cam, Konversi dilakukan melalui STEP Converter, yang merubah data STEP menjadi CFIO.
Aktifitas yang dilakukan di TOGO adalah pembuatan machining dan tap attribute. VRML dan IVZ file di buat di original software untuk final pengechekan di fox viewer
Out put product Proses Die Design Selesai DIAGRAM & DIE FACE
STEP→CFIO
IGES
FINAL VRML/IVZ
CHECK
CHECK Check approval leader hasil repair kentokai OK
NG
MACHINING & TAP ATTRIBUTE REPAIR KONSTRUKSI DI TOGO NG REPAIR KONSTRUKSI DI ORIGINAL DATA NG CONVERT DATA CHECK NG REPAIR OK OK
IGES file untuk pembuatan insert dan original part di Manufacturing Instruction, di buat di original software.
Pada saat pembuatan konstruksi, dilakukan pengechekan untuk kemampuan proses machining dan pengechekan hoist balance
Check data konstruksi di TOGO, jika NG maka proses repair dilakukan di TOGO dan original original software data.
Check 2D drawing Check total assy balance dan total interference
70
Lam
p
iran 4.4 Contoh S
tandard DSP
NO.
A. STOPPER
1
Front Guide Stopper
C-FG-(H)
2
Angled Side Stopper
D-KSG-AR2/AL2-(H-L)
3
Rear Gauge Stopper
D-RG-E1-(H-h)
4
Rear Stopper
D-RG-D2-(H)
5
Stopper Beughel
D-MRG-A1-(H1xH2xL)
D-CPS-B2
D-CPS-C2
7
Disappearing Gauge (Swivel Type)
SHS-(L)
8
Detail Stopper Disappearing Gauge
SHS1-(L)
9
Detail Base Disappearing Gauge
SHS2
10 Detail Links Disappearing Gauge
SHS3
11
Detail Links Bent Dis appearing GaugeSHS4
12
Detail Knuckle Joint Dis appearing GaugeSHS5
13
Detail Support Cylinder Disappearing GaugeSHS6
14 Detail Hinge Pin Disappearing Gauge
SHS7, SHS8
15 Special Front Stopper
S - SFG - (H)
B. BLOCK
D-DYS-A-(D)
D-DYS-B-(D)
D-DYS-D-(D)
D-DYS-C
2
End Block
EB-A-(d)
D-D19B-A-40
D-D19B-A-65
D-D19B-C1-(A)
C. ACCESSORIES
1
Rachi
ADR-L
2
Rachi Arm
APR; APR - (L)
3
Detail Rachi
ADR1; ADR2; ADR5
TAHK-B-2-Set
TAHK-D-2-Set
6
Assy Lifter
STD-HLS-(L1-L2)
7
Lifter Housing
8
Cylinder Guide
9
Plate Holder
10
Coupling
11
Pin Stopper
12
Skid Bracket Housing
SBH - (L)
13
Shutter
(Illustration of welding Area)
14
Kicker standard
STD-A-KD-(L)
15
Kicker Base
STD-A-KD1
16
Housing
STD-A-KD2
17
Guide Pin Balancer
STD-A-KD6-(L)
18
Base Plate
STD-A-KD4-(L)
19
Pin & Coupling
STD-A-KD3,5,7
20
Air Cylinder Diagram
(For Lifter / Bellcrank)
21
Air Cylinder Diagram
(For Moving Stopper)
22
Air Cylinder Diagram
(For Kickers Pusher)
23
Tube Clamper
(Air Cylinder Component)
24
Air Speed Control Clamper
(Air Cylinder Component)
D. ELECTRICAL EQUIPMENT
1
Pengait Kabel
D-KLH-A
2
Bracket Limit Switch
D-SBS-D-(LxH)
3
Terminal Box
D-TBX-D3-12-(A)-(H/V)
E. COMPONENT
1
Spring Guide Retainer/ Pin Spring
SGC-(D-L)
Pin Urethane
S 14 / S 22
SU 14 / SU 22
3
Spool Retainer
D-HB-A/B -(D1-L)
4
Stroke End Pipe
SEP-(D-H)
5
Casted Screw
D-IN-A2-(d)
6
Hook
D-CH-D2-(D)
7
Side Pin
D-SPS-B1-(D-L)
8
Pad Hanger
PH-(A/B-L1-L2)
Dandori guide pin
D-IKP-A1
D-IKP-B/C
06-11-2004
05-11-2004
1
1
1
03-08-2004
1
0
0
0
0
0
0
0
0
1
0
DATE
REV.
1
1
1
1
1
1
1
1
07-09-2004
1
1
1
1
1
1
06-07-2004
03-08-2004
0
ITEM NAME
PAGE
A-1
A-2
ORDER CODE
A-6B
Stopper Pad
A-5
A-6A
A-8
A-7H
A-7E
A-7F
A-7G
B-1C
B-1D
B-3C
3
End Pad
Distance Block
B-2
B-1A
B-1B
B-3A
4
C-1A
C-1B
C-3F
C-3C
C-2B
C-2A
C-1C
9
E-3
E-4
C-11
E-8
E-9
2
E-6
E-7
E-5
1
16-08-2004
08-09-2004
08-09-2004
03-08-2004
03-08-2004
1
1
1
1
1
14-09-2004
0
16-08-2004
18-08-2004
18-08-2004
1
1
16-07-2004
1
A-7A
1
1
1
1
1
1
1
A-3
A-4
08-09-2004
A-7D
12-07-2004
27-08-2004
16-08-2004
11-08-2004
19-08-2004
13-08-2004
16-08-2004
18-06-2004
08-09-2004
08-09-2004
01-07-2004
11-08-2004
11-08-2004
16-08-2004
16-08-2004
16-08-2004
16-08-2004
16-08-2004
18-08-2004
12-07-2004
18-06-2004
30-06-2004
18-06-2004
11-06-2004
1
1
01-09-2004
1
1
1
1
01-07-2004
02-07-2004
02-07-2004
07-10-2004
07-10-2004
07-10-2004
07-10-2004
06-07-2004
02-09-2004
0
05-11-2004
29-09-2004
29-09-2004
05-11-2004
07-10-2004
1
1
6
C-3D
C-6A
C-3E
C-3A
C-5
C-3B
1
A-7B
E-1
D-2
D-1
C-6D
D-3
A-7C
C-4
C-6E
B-3B
E-2B
E-2A
Air Header Bracket Set
C-9
C-10
C-6F
C-7
C-8
C-6B
C-6C
0
04-02-2005
27-09-2004
10-09-2004
24-09-2004
08-09-2004
0
0
0
07-09-2004
E-10
0
0
0
Revisi : 1
Date
: March 10,2009
No. Doc : MAN-DB00-1251
Prepared
Div.Head Dep.Head Sect.Head
Leader
Staff
Checked
72
Lam
p
iran 4.6
V
isual Pengecekan Desain dengan
Fox V
Lampiran 4.7 Contoh Format Die Design Scheduling
DESIGN
BY
1 IA 04
Individual 58311-801L
1.60 Draw 1/3
INV
Firman
2 IA 05
Tandem
58311-801L
1.60 Trim 2/3
PRO-E
Tri W.
INV
Nanang
3 IA 06
Tandem
58311-801L
1.60 Trim Flange 3/3
TOGO
Gunadi
PRO-E
Iman
4 IA 07
Individual 58111-800/801L
2.00 Draw 1/3
PRO-E
Ari
5 IA 08
Individual 58111-800/801L
2.00 Trim 2/3
TOGO
Roni
6 IA 09
Individual 58111-800/801L
2.00 Trim Flange 3/3
TOGO
Jamil
7 IA 10
Individual 58211-800/801L
1.60 Draw 1/3
INV
Rois
8 IA 11
Individual 58211-800/801L
1.60 Trim 2/3
PRO-E
Joko
9 IA 12
Tandem
58211-800/801L
1.60 Trim Flange 3/3
CATIA
Dany
TOGO
Gunadi
10 IA 13
Individual 58311-800L
1.60 Draw 1/3
CATIA
Mamat
11 IA 14
Tandem
58311-800L
1.60 Trim pierce 2/3
INV
Nanang
PRO-E
Tri W.
12 IA 15
Individual 58311-800L
1.60 Cam Flange 3/3
TOGO
Roni
DESIGN
BY
1 IA 04
Individual 58311-801L
1.60 Draw 1/3
INV
Firman
2 IA 05
Tandem
58311-801L
1.60 Trim 2/3
PRO-E
Tri W.
PRO-E
Iman
3 IA 06
Tandem
58311-801L
1.60 Trim Flange 3/3
TOGO
Gunadi
TOGO
Jamil
4 IA 07
Individual 58111-800/801L
2.00 Draw 1/3
PRO-E
Ari
5 IA 08
Individual 58111-800/801L
2.00 Trim 2/3
TOGO
Roni
6 IA 09
Individual 58111-800/801L
2.00 Trim Flange 3/3
TOGO
Jamil
7 IA 10
Individual 58211-800/801L
1.60 Draw 1/3
INV
Rois
8 IA 11
Individual 58211-800/801L
1.60 Trim 2/3
PRO-E
Joko
9 IA 12
Tandem
58211-800/801L
1.60 Trim Flange 3/3
CATIA
Dany
CATIA
Mamat
10 IA 13
Individual 58311-800L
1.60 Draw 1/3
CATIA
Mamat
11 IA 14
Tandem
58311-800L
1.60 Trim pierce 2/3
INV
Nanang
INV
Firman
12 IA 15
Individual 58311-800L
1.60 Cam Flange 3/3
TOGO
Roni
DESIGNER
NO KBN NO.
DESIGN
TYPE
PART NO.
C.PNT
PROCESS
DESIGNER
PROCESS
NO KBN NO.
DESIGN
PART NO.
C.PNT
TYPE
NG
NG
NG
NG
OK
OK
OK
OK
74
76
Lampiran 4.10 Contoh Format Time Chart Design dan C/S Teknikal Data
Time Chart Design
Check Sheet Teknikal Data
NO. DOKUMEN
CHS-DB00-1211
TANGGAL 09 Februari 2009
SH
LEADER
DESIGN
REVISI
0
NO
TECHNICAL MATERIAL
CHECK
TGL TERIMA
1 Part Drawing
-2 MPP ( Process Sheet )
-3 Machine Spec
-4 Die Spec
-5 Limit Standar Part ( Hinpyo )
-6 Cad Data
-7 Diagram
-8 Feed Back Data
~> RDR
~> Try Sheet
~> Manufacturing Problem
-9 …
-10 …
NOMOR KANBAN
TANGGAL
NOMOR DIE
PROSES
KETERANGAN
" DIE DESIGN LIST DOCUMENT "
PT.TOYOTA MOTOR MFG INDONESIA
DJDF DIVISION - PDD DEPARTMENT
DIE DESIGN SECTION
No.Dist STATUS DIV. DEPT. SECT.
