67
Lampiran 4.1 Contoh Format Check Sheet Die Design
PT.TOYOTA MOTOR MFG INDONESIA PWPET P T. TOYOTA M OTOR M FG INDONESIA DIV - PDD DEPT. P DD DEP A RTMDIE DJDF DIVISION, ENT
DIE DESIGN SECTION DESIGN SECTION
NOMOR DOKUMEN TANGGAL REVISI
CHS - ATX300 - 2101 Juli 2008 1622 Februari 2009 10
NOMOR KANBAN NOMOR DIE PROSES TANGGAL KELUAR
? ? ? ?
NO
No.Dist DIV.
" CHECK SHEET " DRAW PROCCESS
DEPT.
APPROVED
CHECKED
PREPARED
Sect.Head
Leader
Designer
VALUE
ITEM POINT CHECK ===> " DIAGRAM "
CHECK
Standard
Actual CL
1 Check kesesuaian Base Line, Bansen, CL & CM terhadap Process sheet -
See Drawing
STATUS
SECT.
Eva C1 C2
CM
(…......)
dan pastikan sudah tercantum di Data 3D dan 2D.
Base Line
-
-
-
-
-
-
-
-
-
(...…)
Cantumkan Dimensi antara CL dg CM pada Drawing kalau ada offset 2 Banzen dan perubahannya setelah rotasi
No Need
3 Dimensi CL terhadap Banzen
Sesuaikan Process sheet.
Actual : (
…
Process sheet : )
BANSEN
(…....)
CL
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 ( 13 Material spec ( check process sheet & Part Drawing )
Data : …
)(
Diagram :
Level ECI Part Drawing = … Part drawing :
( (
…
…
)
) Process sheet : (
14 Kijun Panel ( Outer / Inner side )
…
)
Diagram : (
…
kijun Outer
) kijun Inner
Part Drawing : ( … ) 15 Draw - P/F ( Mark , Dimensi , notasi ) pada semua view.
See Drawing
16 Hitung & tulis Power Draw
Actual : (
17 Tentukan jumlah cushion
… Actual :
(
…
)
NB : coret y g tidak pe
Sesuaikan standard Draw Power Calculation : ) ( Max power Mesin ) Sesuaikan dengan equalizing : ) Refferensi : ( …..……….. …. ) Standard : ( …..……….. …. )
68
Lampiran 4.2 Visual SMS dan Global Design Standard Stamping Manufacturing Standard ( SMS )
Global Design Standard
69
Lampiran 4.3 New Flow Die Design NO
WORKING HOUR ACCUMULATION
FLOW
1
HOUR
%
HOUR
Project leader memberikan technical material yang akan digunakan untuk proses pendesaian dies.
PROJECT LEADER
2
Technical material yang diperlukan antara lain : Process sheet, Part Drawing, Cad Data dan informasi lainnya.
TECHNICAL MATERIAL
3
NG
Pengechekan technical material oleh die design.
DIAGRAM & DIE FACE
Diagram dan die face untuk start data design yang diperoleh dari seksi Die Face
CHECK
4
5
EDIT SURFACE & PROFILE
6
SOLID CONSTRUCTION MAKING
DRAW PROCESS
6.5
Pembuatan surface dan profile design dari data cad dan die face yang diterima.
10% UPPER/LOWER PAD ASSEMBLY
a
MACHINING CHECK
HOIST BALANCE CHECK
OK
10%
b
ASSEMBLY
c
10%
INSERT STEEL/PUNCH/CAM ASSEMBLY NG
10%
78
60%
84.5
65%
OK LOWER DIE ASSEMBLY
MACHINING CHECK
HOIST BALANCE CHECK MACHINING CHECK 10%
MACHINING CHECK
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 Pada saat pembuatan konstruksi, dilakukan pengechekan untuk kemampuan proses machining dan pengechekan hoist balance
NG OK
OK
c
UPPER PUNCH ASSEMBLY
MACHINING CHECK
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
MACHINING CHECK
OK
b LOWER PUNCH
NG
5%
NG
HOIST BALANCE CHECK
d
6.5
Pembuatan 3D solid construction.
NG
NG
5%
FOLLOW ING PROCESS
10% CUSHION RING ASSEMBLY
a
NOTE
%
e 10% OK UPPER DIE ASSEMBLY
15%
UPPER DIE ASSEMBLY
MACHINING CHECK OK 15%
d MACHINING CHECK
NG MACHINING CHECK
OK
OK
10%
f
7
LOW ER DIE ASSEMBLY
NG
10%
e ACCESSORIES
ACCESSORIES
TOTAL ASSY BALANCE CHECK
TOTAL INTERFERENCE CHECK
NG
3.9
3%
88.4
68%
2.6
2%
91
70%
Check total assy balance dan total interference
OK 8
CONVERT DATA ( VRML / IVZ FILE) DRAFT
9
DESIGN KENTOKAI
Kentok ai / Pengecekan konstruksi design bersama seksi-seksi terkait dengan menggunakan Fox Viewer.
REPAIR PROBLEM KENTOKAI AND FINISHING DESIGN
10
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.
6.5
5%
97.5
75%
Repair problem kentokai
NG
11
Check approval leader hasil repair kentokai
CHECK OK CONVERT DATA
12
FINAL VRML/IVZ
15
6.5
5%
104
80%
VRML dan IVZ file di buat di original software untuk final pengechekan di fox viewer
MACHINING & TAP ATTRIBUTE
13
14
STEP→CFIO
REPAIR KONSTRUKSI DI ORIGINAL DATA CONVERT DATA
NG
NG CHECK
REPAIR KONSTRUKSI DI TOGO 6.5
OK
5%
110.5
85%
Pembuatan 2D drawing.
2D MAKING 19.5
17
Check data konstruksi di TOGO, jika NG maka proses repair dilakukan di TOGO dan original original software data. IGES file untuk pembuatan insert dan original part di Manufacturing Instruction, di buat di original software.
IGES
16
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.
CHECK
NG REPAIR
15%
130
100% Check 2D drawing
OK 18
PRODUCT DESIGN FINISH
Out put product Proses Die Design Selesai
70
ITEM NAME
NO.
Revisi : 1 Date : March 10,2009 No. Doc : MAN-DB00-1251
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
A. STOPPER Front Guide Stopper Angled Side Stopper Rear Gauge Stopper Rear Stopper Stopper Beughel Stopper Pad Disappearing Gauge (Swivel Type) Detail Stopper Disappearing Gauge Detail Base Disappearing Gauge Detail Links Disappearing Gauge Detail Links Bent Dis appearing Gauge Detail Knuckle Joint Dis appearing Gauge Detail Support Cylinder Disappearing Gauge
Detail Hinge Pin Disappearing Gauge Special Front Stopper
ORDER CODE
PAGE
REV.
DATE
C-FG-(H) D-KSG-AR2/AL2-(H-L) D-RG-E1-(H-h) D-RG-D2-(H) D-MRG-A1-(H1xH2xL) D-CPS-B2 D-CPS-C2 SHS-(L) SHS1-(L) SHS2 SHS3 SHS4 SHS5 SHS6 SHS7, SHS8 S - SFG - (H)
A-1 A-2 A-3 A-4 A-5 A-6A A-6B A-7A A-7B A-7C A-7D A-7E A-7F A-7G A-7H A-8
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
18-06-2004 30-06-2004 18-06-2004 11-06-2004 01-07-2004 11-08-2004 11-08-2004 16-08-2004 16-08-2004 16-08-2004 16-08-2004 16-08-2004 16-08-2004 16-08-2004 16-08-2004 18-06-2004
D-DYS-A-(D) D-DYS-B-(D) D-DYS-D-(D) D-DYS-C EB-A-(d) D-D19B-A-40 D-D19B-A-65 D-D19B-C1-(A)
B-1A B-1B B-1C B-1D B-2 B-3A B-3B B-3C
1 1 1 1 1 1 1 1
08-09-2004 08-09-2004 08-09-2004 08-09-2004 08-09-2004 03-08-2004 03-08-2004 03-08-2004
ADR-L APR; APR - (L) ADR1; ADR2; ADR5 TAHK-B-2-Set TAHK-D-2-Set STD-HLS-(L1-L2)
C-1A C-1B C-1C C-2A C-2B C-3A C-3B C-3C C-3D C-3E C-3F C-4 C-5 C-6A C-6B C-6C C-6D C-6E C-6F C-7 C-8 C-9 C-10 C-11
1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0
18-08-2004 18-08-2004 18-08-2004 12-07-2004 12-07-2004 01-09-2004 27-08-2004 16-08-2004 11-08-2004 19-08-2004 13-08-2004 16-07-2004 14-09-2004 06-11-2004 05-11-2004 05-11-2004 29-09-2004 29-09-2004 05-11-2004 07-10-2004 07-10-2004 07-10-2004 07-10-2004 07-10-2004
D-1 D-2 D-3
1 1 0
01-07-2004 02-09-2004 04-02-2005
E-1 E-2A E-2B E-3 E-4 E-5 E-6 E-7 E-8 E-9 E-10
1 1 1 1 1 0 0 0 0 0 0
06-07-2004 02-07-2004 02-07-2004 06-07-2004 03-08-2004 07-09-2004 07-09-2004 08-09-2004 10-09-2004 24-09-2004 27-09-2004
Lampiran 4.4 Contoh Standard DSP
B. BLOCK 1
Distance Block
2
End Block
3
End Pad
1 2 3
C. ACCESSORIES Rachi Rachi Arm Detail Rachi
4
Air Header Bracket Set
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Assy Lifter Lifter Housing Cylinder Guide Plate Holder Coupling Pin Stopper Skid Bracket Housing Shutter Kicker standard Kicker Base Housing Guide Pin Balancer Base Plate Pin & Coupling Air Cylinder Diagram Air Cylinder Diagram Air Cylinder Diagram Tube Clamper Air Speed Control Clamper
1 2 3 1
Approved
Checked
Div.Head Dep.Head Sect.Head
Leader
Prepared
Staff
2 3 4 5 6 7 8 9
D. ELECTRICAL EQUIPMENT Pengait Kabel Bracket Limit Switch Terminal Box E. COMPONENT Spring Guide Retainer/ Pin Spring Pin Urethane Spool Retainer Stroke End Pipe Casted Screw Hook Side Pin Pad Hanger Dandori guide pin
SBH - (L) (Illustration of welding Area) STD-A-KD-(L) STD-A-KD1 STD-A-KD2 STD-A-KD6-(L) STD-A-KD4-(L) STD-A-KD3,5,7 (For Lifter / Bellcrank) (For Moving Stopper) (For Kickers Pusher) (Air Cylinder Component) (Air Cylinder Component) D-KLH-A D-SBS-D-(LxH) D-TBX-D3-12-(A)-(H/V) SGC-(D-L) S 14 / S 22 SU 14 / SU 22 D-HB-A/B -(D1-L) SEP-(D-H) D-IN-A2-(d) D-CH-D2-(D) D-SPS-B1-(D-L) PH-(A/B-L1-L2) D-IKP-A1 D-IKP-B/C
71
Lampiran 4.5 Visual Library Standard Konstruksi dan Komponen
Lampiran 4.6 Visual Pengecekan Desain dengan Fox Viewer
72
73
Lampiran 4.7 Contoh Format Die Design Scheduling
NO KBN NO.
DESIGN TYPE
PART NO.
C.PNT
PROCESS
1 IA 04 2 IA 05
Individual 58311-801L Tandem 58311-801L
3 IA 06
Tandem
58311-801L
1.60 Trim Flange 3/3
4 5 6 7 8 9
Individual Individual Individual Individual Individual Tandem
58111-800/801L 58111-800/801L 58111-800/801L 58211-800/801L 58211-800/801L 58211-800/801L
2.00 2.00 2.00 1.60 1.60 1.60
IA 07 IA 08 IA 09 IA 10 IA 11 IA 12
1.60 Draw 1/3 1.60 Trim 2/3
Draw 1/3 Trim 2/3 Trim Flange 3/3 Draw 1/3 Trim 2/3 Trim Flange 3/3
10 IA 13 11 IA 14
Individual 58311-800L Tandem 58311-800L
1.60 Draw 1/3 1.60 Trim pierce 2/3
12 IA 15
Individual 58311-800L
1.60 Cam Flange 3/3
NO KBN NO.
DESIGN TYPE
PART NO.
C.PNT
PROCESS
1 IA 04 2 IA 05
Individual 58311-801L Tandem 58311-801L
3 IA 06
Tandem
58311-801L
1.60 Trim Flange 3/3
4 5 6 7 8 9
Individual Individual Individual Individual Individual Tandem
58111-800/801L 58111-800/801L 58111-800/801L 58211-800/801L 58211-800/801L 58211-800/801L
2.00 2.00 2.00 1.60 1.60 1.60
IA 07 IA 08 IA 09 IA 10 IA 11 IA 12
1.60 Draw 1/3 1.60 Trim 2/3
Draw 1/3 Trim 2/3 Trim Flange 3/3 Draw 1/3 Trim 2/3 Trim Flange 3/3
10 IA 13 11 IA 14
Individual 58311-800L Tandem 58311-800L
1.60 Draw 1/3 1.60 Trim pierce 2/3
12 IA 15
Individual 58311-800L
1.60 Cam Flange 3/3
DESIGN DESIGNER BY
INV PRO-E INV TOGO PRO-E PRO-E TOGO TOGO INV PRO-E CATIA TOGO CATIA INV PRO-E TOGO
Firman Tri W. Nanang Gunadi Iman Ari Roni Jamil Rois Joko Dany Gunadi Mamat Nanang Tri W. Roni
NG NG
NG
NG
DESIGN DESIGNER BY
INV PRO-E PRO-E TOGO TOGO PRO-E TOGO TOGO INV PRO-E CATIA CATIA CATIA INV INV TOGO
Firman Tri W. Iman Gunadi Jamil Ari Roni Jamil Rois Joko Dany Mamat Mamat Nanang Firman Roni
OK OK
OK
OK
74
Lampiran 4.8 Visual Soft Data Katalog Desain
75
Lampiran 4.9 Visual Soft Data Perhitungan Desain
76
Lampiran 4.10 Contoh Format Time Chart Design dan C/S Teknikal Data Time Chart Design PT.TOYOTA MOTOR MFG INDONESIA
T/P GROUP D/F GROUP D/D GROUP
DJDF DIVISION - PDD DEPARTMENT
NO. DOK
CHS-DB 00-1215
DIE DESIGN SECTION
TA NGGA L
09 Februari 2009
TIME CHART DESIGN WORK TABLE
REVISI
Part Number Part Name T/P Charge D/F Charge Die Design Charge 1 Process Plan Form Making (Technical Project) 2 Process Sheet Making 3 Process Sheet Inquiry 4 Process Sheet Explanation to Die Design 5 DIE DESIGN START 6 Die Face Data Provision for Design Start 7 Die Face Data Provision for Correction 8 Design Check ( Kentokai ) 9 Die Design x D/F Finally Confirmation Association 10 Tanker Cylinder Piping 11 Electric and Air Piping 12 Rigidity Check 13 A-Rank Data Provision 14 Scrap Simulation 15 Die Face Confirmation 16 CL Check 17 Loading Unloading Simulation 18 Dynamic Interference Check 19 DIE DESIGN FINISH
0
Home Line Die Class Process Leader Designer ( X - 10 ) ( X- 7 ) ( X- 5 ) ( X- 2 ) X ( X+ 3 ) ( Z - 14 ) ( Z - 10 ) (Z-9) (Z-8) (Z-8) (Z-7) (Z-6) (Z-5) (Z-4) (Z-4) (Z-4) (Z-3) Z
1/4
2/4
3/4
4/4
Check Sheet Teknikal Data No.Dist STATUS
PT.TOYOTA MOTOR MFG INDONESIA
NO. DOKUMEN
CHS-DB00-1211
NOMOR KANBAN
DJDF DIVISION - PDD DEPARTMENT
TANGGAL
09 Februari 2009
NOMOR DIE
DIE DESIGN SECTION
REVISI
0
TECHNICAL MATERIAL
SH
PROSES TANGGAL
" DIE DESIGN LIST DOCUMENT " NO
DIV.
CHECK
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 …
-
TGL TERIMA
KETERANGAN
DEPT.
SECT.
LEADER
DESIGN
77
Lampiran 4.11 Kumpulan Faktor Eksternal dan Internal di Seksi Die Design
