REMANUFACTURED PRODUCT LIFETIME FOR LEADING HEAVY EQUIPMENT REMANUFACTURING COMPANY IN INDONESIA
By
Herryan Syahputra 2-1952-038
MASTER’S DEGREE in
MASTER OF MECHANICAL ENGINEERING ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia
January, 2021
Revision after thesis defense on 1 February 2021
Herryan Syahputra 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.
Herryan Syahputra
_______________________________________ ______
Student Date
Approved by:
Dena Hendriana, B.Sc., M.Sc., Ph.D.
_____________________________________________
Thesis Advisor Date
Dr. Ir. Gembong Baskoro, M.Sc
_____________________________________________
Thesis Co-Advisor Date
Dr. Maulahikmah Galinium, S.Kom., M.Sc
_____________________________________________
Dean Date
Herryan Syahputra ABSTRACT
IM PROVEM ENT IN REUSABLE PART QUALITY TO PROLONG REM ANUFACTURED PRODUCT LIFETIM E FOR LEADING HEAVY EQUIPM ENT REM ANUFACTURING COM PANY IN INDONESIA
By
Herryan Syahputra, ST
Dena Hendriana, B.Sc., M.Sc., Ph.D., Advisor Dr. Ir. Gembong Baskoro, M.Sc, Co-Advisor
SWISS GERMAN UNIVERSITY
Remanufacturing is a process of reusing used parts with almost the same quality as new products. The 6D114 series engine components have the problem of a low contribution margin due to high production costs cause by small reuse ratio of the used parts. The piston part has a replacement ratio of 100%. This study aims to reduce production costs by increasing reusable parts, especially piston parts. Reusable criteria parameters for pistons are obtained from the reverse engineering. Then the process of remaining life assessment is carried out by looking at the effect of the wear level on the ring groove 1 and 2 pistons, a performance test is performed, specifically the compression pressure test and blow-by pressure test. And to validate the simulation results and performance tests, a seeding test is carried out on the unit. From the results of this study, it is found that the parameters for determining the reusable part of the piston are the worn-out value of the piston ring groove, compression pressure, and blow- by pressure. From the reusable piston results, it can reduce the cost of purchasing piston parts by 98.8%.. This resulted in an increase in the contribution margin from 7.8% to 12.6%.
Keywords: Remanufacturing, Contribution Margin, Piston, Remaining Life Assessment, Reverse engineering
Herryan Syahputra
© Copyright 2021 by Herryan Syahputra
All rights reserved
Herryan Syahputra DEDICATION
Dedication is normally short and direct. Example:
I dedicate this works for my family, United Tractors. Tbk, and
Universal Tekno Reksajaya.
Herryan Syahputra ACKNOWLEDGEMENTS
During the process of this thesis, the author received a lot of help from various parties.
On this occasion the author would like to thank:
1. My Family. dr. Febrina Sylva Fridayanti and Aldebara Mecca Syahputra.
2. Mr. Dena Hendriana B.Sc, S.M., Sc.D , Mr. Dr. Ir. Gembong Baskoro, M.Sc and all Lecturers who have guided me while studying in Swiss German University.
3. Universal Tekno Reksajaya and United Tractors which has given me the opportunity to continue my master degrees.
4. My department team, Corporate Technolo gy Development.
Herryan Syahputra TABLE OF CONTENTS
Page
STATEMENT BY THE AUTHOR ... 3
ABSTRACT... 4
DEDICATION ... 6
ACKNOWLEDGEMEN TS ... 7
TABLE OF CONTENTS ... 8
LIST OF FIGURES ... 9
LIST OF TABLES ... 11
CHAPTER 1 - INTRODUCTION ... 14
1.1 Background ... 14
1.2 Research Problem ... 19
1.3 Research Objectives ... 20
1.4 Significance of Study ... 20
1.5 Research Question... 20
1.6 Hypothesis... 20
CHAPTER 2 – LITERATURE REVIEW ... 22
2.1 Remanufacturing ... 22
2.2 Remaining Life Assessment ... 24
2.3 Hydraulic Excavator ... 26
2.4 Piston... 29
2.5 Aluminium Silicon Alloy... 31
2.6 Piston Ring ... 37
2.7 Blow-by-Pressure... 41
2.8 Forces Applied in Piston ... 45
2.9 Contribution Margin ... 48
2.10 Research Reason ... 50
CHAPTER 3 – RESEARCH METHODS ... 52
3.1 Research Flow Chart ... 52
3.2 Theoritical Approach ... 53
3.3 Experimental Consideration... 53
Herryan Syahputra
3.6 Reverse Engineering ... 56
3.7 Remaining Life Assessment Simulation Process... 61
3.8 Performance Test ... 70
CHAPTER 4 – RESULTS AND DISCUSSIONS... 15
4.1 Material Analysis ... 75
4.2 Fatigue Lifetime Analysis ... 77
4.3 Compression Pressure Analysis ... 90
4.4 Blow-by-Pressure Analysis... 93
4.5 Seeding Test Analysis ... 95
4.6 Financial Analysis... 96
CHAPTER 5 – CONCLUSION AND RECCOMENDATIONS ... 99
5.1 Conclusion ... 99
5.2 Recommendations ... 100
GLOSSARY ... 101
REFERENCES ... 102
CURRICULUM VITAE ... 103
Herryan Syahputra LIST OF FIGURES
Figures Page
1. Graphic Pareto Production Component. ... 16
2. Komatsu 6D114 Series engines ... 16
3. Pareto Problem in Engine Diesel (VR.Deulgaonkar, et al. 2020) ... 17
4. Occurances of Failure Causes. ... 18
5. Piston Failures... 19
6. Flow Process remanufacturing (Ronak et all, 2017)... 23
7. Main Parts of Hydraulic Excavator... 26
8. Excavator Hydraulic System Diagram... 28
9. Piston... 30
10. The gap between the cylinder piston and the combustion chamber. ... 31
11. Types of Al-Si Alloy microstructure ... 32
12. Wear Levels of Al-Si Alloys from the function of the shear distance ... 34
13. Al-Mg phase diagram... 37
14. Al-Cu phase diagram ... 37
15. Piston ring denomination ... 37
16. Forces Acting on The Piston Ring ... 38
17. Blow-by Pressure ... 41
18. Schematic drawing of the entry of oil into the clearance ring with a piston ... 42
19. Clearance on Groove Piston... 43
20. Effect of clearance on blow-by ... 44
21. Research flow chart... 52
Herryan Syahputra
23. 6D114 Series Engine Piston Design Image ... 57
24. Worn out area on piston 6D114 Series ... 57
25. The process of measuring used piston. ... 58
26. Load position... 65
27. S-N Curve ADC14 ... 69
28. Compression Pressure Test Scheme ... 71
29. Blow-Pressure Test. ... 73
30. Stress Analysis Result on Piston with 0 mm worn ... 78
31. Stress Analysis Result on Piston with 0,3 mm worn ... 79
32. Stress Analysis Result on Piston with 0,5 mm worn. ... 80
33. Original and failed piston in the transport utility vehicle engine ... 81
34. Failure on piston surface ... 81
35. Factor of Safety Result... 82
36. Factor of safety in piston with 0 mm worn ... 83
37. Factor of safety in piston with 0,3 mm worn ... 84
38. Factor of safety in piston with 0,5 mm worn ... 85
39. Pin Hole position on piston. ... 86
40. Fatigue Lifetime Analysis on Piston with 0 mm worn ... 87
41. Fatigue Lifetime Analysis on Piston with 0,3 mm worn ... 87
42. Fatigue Lifetime Analysis on Piston with 0,5 mm worn. ... 88
43. Correlation Compression Pressure and Variable Worn on Piston ... 93
44. Comparison Contribution Margin Between Actual & STD Company ... 96
45. Pareto spare part cost ... 97
46. Reduction cost of piston spare parts ... 98
47. Contribution Margin to Result After Development. ... 98
Herryan Syahputra LIST OF TABLES
Table Page
1. Failures observed & detected in various engine component ... 17
2. Details of engine failures ... 18
3. Failure modes and recommendation on piston ... 19
4. PC300 Series excavator specifications, 6D114 Engine Series ... 29
1. Mechanical properties of the Al-Si alloy ... 33
2. Composition of ADC14, ADC12 and ADC10 ... 35
3. ADC14 Physical, Mechanical, Electrical and Thermal P roperties ... 36
4. Main Types of Compression Ring ... 39
1. Main Types of O il Scrapper Ring ... 40
2. Standard Blow-by Pressure Table PC-300 (Komatsu Ltd., 2002) ... 44
3. Literature review ... 50
4. Timeframe of research ... 53
1. Tools for research... 54
2. The measurement results of the used piston ... 58
3. Worn out variable on ring groove ... 59
4. X-Ray Fluorescence Result on piston 6D114 Series ... 59
1. Chemical composition standard of aluminium alloys ADC14 ... 60
2. Mechanical prooperties standard of aluminium alloys ADC14 ... 60
3. Hardness test result of brand new piston engine 6D114 series ... 61
4. Standard compression pressure ... 71
3. Standard blow-by pressure on the 6D114 Series engine ... 74
4. Input and Output in Transient Structural Analysis ... 77
Herryan Syahputra 3. The cost of remanufacturing parts with advanced restoring technologies and new
parts ... 90
4. Failure modes and recommendation on piston ... 91
3. Compression pressure test result... 92
4. Blow-by pressure test result ... 95
