By
Aktian Widyarizki 1-1109-050
A thesis submitted to the Faculty of
ENGINEERING AND INFORMATION TECHNOLOGY
in partial fulfillment of the requirements for the
BACHELOR’S DEGREE in
MECHATRONICS ENGINEERING
SWISS GERMAN UNIVERSITY EduTown BSD City
Tangerang 15339 Indonesia
January 2014
Revision after the thesis defense on 20th of January 2014
Aktian Widyarizki
STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Aktian Widyarizki
_____________________________________________
Student Date
Approved by:
Dr. Ir. Tutuko Prajogo, MSMfgE
_____________________________________________
Thesis Advisor Date
Dr. Ir. Gembong Baskoro, M.Sc
_____________________________________________
Dean Date
Aktian Widyarizki
ABSTRACT
DESIGNING AND CONSTRUCTING A PACKAGING SYSTEM PROTOTYPE FOR REXONA DEOLOTION SACHET WITH Z-FOLDING
CONCEPT CASE STUDY PT. UNILEVER INDONESIA
By
Aktian Widyarizki
Dr. Ir. Tutuko Prajogo, MSMfgE, Thesis Advisor SWISS GERMAN UNIVERISTY
In an industry field, applying a principle of ‘minimize waste and maximize productivity’ is very essential in order to reach production affectivity. Some methodologies are done in conducting this thesis project, but the author focus on two aspects: Analyzing the current production in PT. Unilever Indonesia, and Designing
& Constructing Machine Development using Z-Folding System.
From the theory of Automation, to get a high productivity in manufacturing field, it is better to use integrated automatic with machine, than manual work with labor.
Because labor has unpredictable emotions, basic characteristics of human being that can be bore and feel discourage. That is why, the purpose of doing this thesis project is to design a Prototype of Z-Folding machine that could be used as the best suitned way to increase production rate for Rexona Deolotion Sachet Production and to eliminate human error during the packaging process. Author is successfully reached the purpose of this thesis project, conceptually. However, for a better result author could give some improvement on the electrical and mechanical designs that could be implemented by the industry when crystallization of this thesis project.
Keywords: Production Affectivity, Automation, Prototype of Z-Folding Machine.
Aktian Widyarizki
© Copyright 2014 by Aktian Widyarizki
All rights reserved
Aktian Widyarizki
DEDICATION
I want to dedicate this thesis project to all my family, especially my loving Mother, Father and my Brothers for instilling the importance of hard work and higher education. And also to MNP for opening my eyes to the real world, because of her patience and understanding. I cherish the memories we had. Thank you for giving me emotional encouragement throughout this thesis project.
Aktian Widyarizki
ACKNOWLEDGEMENTS
First of all, I would like to express my deep gratitude to Allah SWT for everything that has happened in my life. The loss, the challenge, and the upcoming success.
Secondly, I want to take this opportunity to show my thankfulness and love to my lifemate Elvira Marsha, Cornellius Calvin, Muhammad Ikhsan, Christle Gunawan, Valentine Kinanti. I am overwhelmed with gratitude for their encouragement and love.
Then, I personally want to dedicate this thesis project for PT. Unilever Indonesia, especially to Mr. Joko Widyarista, Mrs. Diny Fadlilia, and my project supervisor Mr.
Andree Gema Mustafa. Thank you so much for your patience and time, I have learned and gained many new knowledge and priceless experiences since I have met them.
They also supported me to the success of this thesis project, the information and knowledge given is highly appreciated.
Not to forget, my thesis advisor Mr. Tutuko Prajogo, all my lecturers in Mechatronics Engineering department, and the entire staff of SGU, I also would like to express my recognition for them. Their presence in my life has made me closer to chase my dreams and passions, and of course to a successful life ahead.
To those who direct or indirectly contributed in this research, your support means a lot to me.
Thank you very much.
Aktian Widyarizki
TABLE OF CONTENTS
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENT ... 6
TABLE OF CONTENTS ... 7
LIST OF FIGURES ... 12
LIST OF TABLES ... 14
CHAPTER 1 - INTRODUCTION ... 15
1.1 Background ... 15
1.2 Thesis Purpose ... 16
1.3 Thesis Work of Scope and Limitation ... 16
1.4 Short Methodology ... 18
1.5 Thesis’s Overview ... 18
CHAPTER 2 – LITERATURE REVIEW ... 20
2.1 Introduction ... 20
2.2 Manufacturing Industries and Products ... 20
2.2.1 Manufacturing Products ... 21
2.3 Manufacturing System in General ... 23
2.3.1 Input and Output of Manufacturing ... 24
2.3.2 Basic Categories of Manufacturing System ... 26
2.4 Automated Production Line ... 29
2.4.1 Reasons of Automating ... 29
2.4.2 Reasons of Prototyping ... 30
2.5 Manual Assembly ... 30
2.5.1 Palletizing Process ... 31
2.5.2 Manual Method of Work Transport ... 32
2.5.3 Mechanized Work Transport ... 33
2.6 Packaging Machine ... 33
2.7 Classification and Types of Sensors ... 34
2.8 Controller ... 35
2.9 Electric Motor ... 36
Aktian Widyarizki
CHAPTER 3 – METHODOLOGY ... 38
3.1 Introduction ... 38
3.2 Interview and Survey at PT. Unilever Indonesia ... 38
3.3 Analysing the Current Production Line ... 38
3.3.1 Current Production Process of Rexona Deolotion Sachets ... 39
3.3.1.1 Raw Material ... 39
3.3.1.2 Mixing Process ... 40
3.3.1.3 Filling Process ... 42
3.3.1.4 Wrapping Process ... 46
3.3.1.5 Packaging Process ... 47
3.3.2 Labor Expenditure ... 48
3.4 Design the Machine Development ... 48
3.4.1 Requirements from PT. Unilever Indonesia. ... 48
3.4.1.1 Sachet Characteristic ... 52
3.4.1.2 Dimension and Palletization ... 53
3.4.2 Machine Characteristics ... 53
3.4.2.1 General Description ... 53
3.5 Mechanical Design and System ... 55
3.5.1 Main Body ... 55
3.5.1.1 Frame Support ... 56
3.5.1.2 Wheel ... 57
3.5.1.3 Frame Support ... 57
3.5.1.4 Dock Conveyor ... 58
3.5.2 Driving System ... 58
3.5.2.1 Chain ... 58
3.5.2.2 Sprocket ... 59
3.5.2.3 Belt Conveyor ... 61
3.5.2.4 Roller Feeding ... 61
3.5.2.5 Chute Out Feed ... 62
3.5.3 Tension Part ... 63
3.5.3.1 Tensioner ... 63
3.5.3.2 Drive Roller ... 63
3.6 Electrical and Control Design and System ... 64
3.6.1 Power Supply ... 64
3.6.2 Photo Electric Sensor ... 64
Aktian Widyarizki
3.5.3.1 Detecting Method ... 65
3.6.3 Selecting Relay ... 66
3.6.4 MCB ... 67
3.6.5 Fuse ... 67
3.6.6 Selecting Reversible Motor AC ... 68
3.6.6.1 AC Motor Speed Controller ... 71
3.6.7 Selection of Controller ... 73
3.6.7.1 Mitsubishi Controller ... 74
3.6.7.2 PLC Controller Works ... 78
3.6.7.3 Ladder Program ... 79
3.6.7.4 I/O List ... 80
3.6.7.5 PLC Configuration ... 81
3.6.8 Overall AC Line Z-Folding Concept ... 81
3.7 Designing Production and Process ... 82
3.7.1 Line Balancing ... 85
CHAPTER 4 – RESULT AND DISCUSSION ... 86
4.1 Mechanical System ... 86
4.1.1 Frame and Extending Part ... 86
4.1.1.1 Wheel for Mobile Drive ... 87
4.1.1.2 Frame Conveyor ... 87
4.1.1.3 Dock Conveyor ... 88
4.2 Driving System ... 88
4.2.1 Belt Conveyor ... 88
4.3 Tension Part ... 89
4.3.1 Drive Roller ... 89
4.3.2 Extending Motor ... 89
4.4 Control System ... 91
4.4.1 Photo Sensor ... 92
4.4.2 Controller ... 93
4.5 Electrical System ... 93
4.5.1 Relay ... 94
4.5.2 Control Panel ... 94
4.5.3 Electrical Connection in Z-Folding Machine... 95
4.6 Result of designing Production Rate ... 99
4.7 Labor vs. Automation ... 101
Aktian Widyarizki
4.7.1 Manual Production ... 101
4.7.2 Planning on Production Speed Modification ... 101
4.7.3 Manual vs. Automatic in speed 110 sachet/minute ... 102
4.7.3.1 Prediction on Manual Production ... 102
4.7.3.2 Prediction on Automatic Production ... 102
4.7.4 Production Planning with Automation Production ... 103
CHAPTER 5 – CONCLUSION AND RECOMMENDATION ... 104
GLOSSARY ... 106
REFERENCES ... 107
APPENDICES ... 108
Appendix A – Technical Drawing ... 108
A. 1 Frame Body ... 108
A. 2 Plat Support ... 109
A. 3 Frame Conveyor ... 110
A. 4 Belt ... 111
A. 5 Dock Conveyor ... 112
A. 6 Shaft Roller Motor ... 113
A. 7 Roller Outer ... 114
A. 8 Shaft Roller Bearing ... 115
A. 9 Shaft Roller Motor ... 116
A. 10 Bearing - 1 ... 117
A. 11 Roller Feeding - Assembly ... 118
A. 12 Roller Feeding - Nylon ... 119
A. 13 Shaft Dock Roller Feeding ... 120
A. 14 Shaft Roller Feeding ... 121
A. 15 Dock Bearing Roller Feeding ... 122
A. 16 House Bearing ... 123
A. 17 Dock Bearing ... 124
A. 18 Gear Nylon ... 125
A. 19 Sprocket - 1 ... 126
A. 20 Chain ... 127
A. 21 Screw – M5 ... 128
A. 22 Screw – M6 ... 129
A. 23 Support Roll - Front ... 130
A. 24 Assembly Z-Folding ... 131
A. 25 AC Motor ... 132
A. 26 Dock AC Motor ... 133
Aktian Widyarizki
B. 2 Photo Sensor Autonics BEN5m-MFR ... 136
B. 3 Reversible DKM AC Motor 9SRDGC-40G ... 138
B. 4 PLC Mitsubishi FS1x – 14MR ... 139
Appendix C – Electrical Wiring... 140
C. 1 AC Line ... 140
C. 2 Input/Output PLC Address ... 141
C. 3 Motor Connection ... 142
Appendix D – Flow Chart ... 143
Appendix E - Program ... 144
Appendix F – Production Process and Production Rate ... 147
F. 1 Production Process 1 Rexona Deolotion ... 147
F. 2 Production Process 2 Rexona Deolotion ... 148
F. 2 Production Rate Current Condition Rexona Deolotion ... 149
F. 2 Production Rate Planning Rexona Deolotion ... 150
Appendix G - Palletization ... 151
G. 1 Old Fibrete Dimension ... 151
G. 2 New Fibrete Dimension ... 151
G. 3 Old Configuration ... 152
G. 4 New Configuration ... 153
Appendix H – Contract and Support from PT. Unilever Indonesia ... 154
H. 1 Contract ... 154
H. 2 Contact Report 1 ... 155
H. 3 Contact Report 2 ... 156
H. 4 Non- Discloser Agreement ... 157
Appendix I – Bill of Material ... 158
CURRICULUM VITAE ... 160
Aktian Widyarizki
LIST OF FIGURES
1.1 Methodology Block Diagram ... 18
1.2 Relationship between Product Variety and Product Quantity ... 21
1.3 Input and Output Analysis of Manufacturing ... 25
1.4 Unwinder and Compensation ... 44
1.5 Filling Process at RexonaDeolotion Production ... 45
1.6 Flat pouches of RexonaDeolotion ... 46
1.7 Wrapping Process at RexonaDeolotion Production ... 47
1.8 Assumption of Demand Forecasting for RexonaDeolotion in Monthly demand .. 50
1.8 Assumption of Utilization for RexonaDeolotion in Monthly ... 51
2.0 Existing Fibrete with Manual Assembly ... 52
2.1 Proposed Fibrete with Automatic Assembly ... 53
2.2 Z-Folding Pattern for RexonaDeolotion Sachet... 54
2.3 Main Body Frame (from the side)... 56
2.4 Frame Support Conveyor ... 57
2.5 Wheel under the Main Body Frame ... 57
2.6 Frame Conveyor ... 58
2.7 Dock Conveyor ... 58
2.8 Chain Conveyor ... 59
2.9 Sprocket ... 60
3.0 Belt Conveyor with Drive Roller ... 61
3.1 Roller Feeding on the Main Body Frame... 62
3.2 Shaft Drive Roller ... 63
3.3 Components of Photoelectric Control ... 65
3.4 MCB Incoming and Outgoing ... 67
3.5 AC Motor Wiring Connection ... 71
3.6 DSK Speed Controller Connection ... 72
3.7 Speed Controller Wiring with Motor Conveyor 2 ... 73
3.8 Relations between Sensor, Processor, and Actuator activities in PLC ... 75
3.9 Mitsubishi PLC FX1S Main Units ... 76
Aktian Widyarizki
4.1 OR Symbol ... 79
4.2 PLC Configuration ... 81
4.3 AC Line Design Prototype Z-Folding Machine ... 82
4.4 Production Process in Rexona Deolotion Line ... 85
4.5 Front side of Main Body Frame ... 86
4.6 Backside of Main Body Frame ... 87
4.7 Belt Conveyor with Rexona Deolotion Sachets ... 88
4.8 Experiment Method ... 89
4.9 Weight Measurement of Conveyor 1 ... 90
5.0 Weight Measurement of Conveyor 2 ... 91
5.1 Sachet Position during Photo Sensor ... 93
5.2 Control Panel Box (Front side) ... 94
5.3 Electrical Connections inside Control Panel Box ... 95
5.4 Sachet Folding with Normal Speed ... 96
5.5 Sachet Folding Reduce 20% of Normal Speed ... 96
5.6 Sachet Folding Reduce 40% of Normal Speed ... 97
5.7 Sachet Folding Reduce 60% of Normal Speed ... 98
5.8 Result of 5 Times Experiment of Running Time ... 98
5.9 Current Production Line... 100
6.0 Planning Production Line ... 100
Aktian Widyarizki
LIST OF TABLES
1.1 Key Characteristics of Sensor ... 35
1.2 Raw Materials for RexonaDeolotion ... 40
1.3 Data of Assumption for Demand Forecasting of Rexona in Monthly ... 49
1.4 Data of Utilization of Rexona Deolotion ... 51
1.5 Comparison of the Existing Fibrete and the Proposed Fibrete ... 52
1.6 Comparison of AC and DC Motors ... 69
1.7 Comparison of PLC and Microcontroller ... 74
1.8 Mitsubishi PLC – FX1S Series ... 77
1.9 Input and Output List ... 80
2.0 Production Efficiency Factor ... 84
2.1 Sensor Checking Position ... 92
