BAB 6 KESIMPULAN DAN SARAN
6.1. Kesimpulan Berdasarkan hasil evaluasi dari rancangan tata letak fasilitas baru plant 1 plant
3
PT.
Komatsu
yang akan dibangun di
Remanufacturing
Asia
didapatkan
bahwa tidak ada masalah dengan aliran material (flow) dan
kegiatan
fasilitas
(activity)
baru
keleluasaan departemen
plant
area yang
3
pada
rancangan
tersebut.
(space) mengalami
tata
Namun,
terdapat
letak
dari
beberapa
ketidakcukupan
area
sisi subdalam
peletakan mesin maupun ketidakleluasaan area kerja bagi operator.
Sub-departemen
–
sub-departemen
tersebut
adalah: a. Departemen washing 1. Prewash 2. Deep tank 3. Robowash water 4. Robowash chemical b. Departemen machining 1. Crankshaft grinding 1 2. Crankshaft grinding 2 3. Lathe machine for axle tube
Rancangan dinyatakan terhadap
tata
layak
letak
dengan
fasilitas melakukan
sub-departemen
–
baru
ini
dapat
perluasan
area
sub-departemen
yang
disebutkan di atas. Perluasan area ini akan berdampak terhadap
ukuran
beberapa
sekitar
sub-departemen
sub-departemen yang
yang
mengalami
ada
di
perluasan
tersebut. Hal ini dikarenakan perusahaan sudah tidak
130
dapat
memberikan
perluasan
area
secara
keseluruhan,
sehingga yang dapat dilakukan adalah mengurangi luas area sub-departemen yang masih berlebih. Sub-departemen
yang
mengalami
dampak
akibat
perluasan area sub-departemen di atas adalah : a. WIP crankshaft and camshaft b. Line boring machine c. Magnaflux d. WIP axle tube e. Metal spray room
6.2. Saran Saran yang dapat diberikan sebagai bahan masukan bagi perusahaan antara lain : a. Sistem penanganan material untuk memindahkan engine dari overhead crane yang berkapasitas 5 ton dan 10 ton hendaknya dipertimbangkan dengan sebaik-baiknya, karena crane
apabila ini
pemindahan
terhambat,
maka
engine akan
antar
overhead
menghambat
aliran
produksi secara keseluruhan. b. Pergantian tata letak fasilitas di sub-departemen assembly
yang
semula
berupa
workstation
terpusat
menjadi lintasan lini seperti yang dicita-citakan perusahaan hendaknya dilaksanakan setelah masalahmasalah yang dapat menghambat kelancaran berjalannya lintasan lini dapat teratasi. Berdasarkan pengamatan penulis,
masalah-masalah
yang
dapat
menghambat
kelancaran berjalannya lintasan lini tersebut antara lain : 1. Keterlambatan spare part Masalah
ini
dapat
diatasi
dengan
memperbaiki
sistem inventory dan production planning control.
131
2. Pekerja yang kurang terampil dalam merakit engine sehingga menyebabkan terjadinya redo (bongkar dan pasang kembali) Masalah
ini
dapat
diatasi
dengan
memberikan
training atau pelatihan kepada pekerja mengenai proses perakitan engine. 3. Kurang
lengkapnya
alat
yang
digunakan
dalam
proses perakitan Masalah ini dapat diatasi dengan melengkapi alatalat
yang
pekerjaannya
digunakan tidak
ketidaktersediaan alat.
132
oleh
pekerja
terhambat
sehingga karena
DAFTAR PUSTAKA Apple, J.M, 1990, Tata Letak Pabrik dan Pemindahan Bahan, Institut Teknologi Bandung, Bandung. Assauri,S., 1977, Manajemen Produksi, Lembaga Penerbit Fakultas Ekonomi, Universitas Indonesia, Jakarta. Daryanto, Y, 2003, Perencanaan Tata Letak Fasilitas Produksi Berdasarkan Group Technology dengan Metode Non Linear and Assignment Allocation Algorithm (Studi Kasus di PT. Swasti Pandawa Armada, Magelang), Program Studi Teknik Industri, Fakultas Teknologi Industri, Universitas Atma Jaya Yogyakarta, Yogyakarta. Dasi,
P.M.K.D, 2008, Usulan Perancangan Ulang Tata Letak Fasilitas (Studi Kasus di CV. Pandanus Internusa, Yogyakarta), Skripsi, Program Studi Teknik Industri, Fakultas Teknologi Industri, Universitas Atma Jaya Yogyakarta, Yogyakarta.
Kurniawan, A.A., 2007, Perancangan Ulang Tata Letak Fasilitas Produksi (Studi Kasus di PT Prestige Furniture, Yogyakarta), Program Studi Teknik Industri, Fakultas Teknologi Industri, Universitas Atma Jaya Yogyakarta, Yogyakarta. Lee,
Q., Arild Amundsen, William Nelson, Herbert Tuttle., 1996, facilities and Workplace Design, Engineering and Management Press Institute of Industrial Engineers Norcross Georgia, USA.
Meyers, Fred E dan Stephens, Matthew P., 2005, Manufacturing Facilities Design and Material Handling, 3rd Ed, Prentice Hall, Inc., New Jersey. Muther, Richard., 1970, Plant Layout and Design, Handbook of Modern Manufacturing Management, Mc Graw Hill.
133
Satria, 2007, Plant Layout / Facilities Layout, Http://www.bysatria.wordpress.com/2007/03/11/plant -layout-facilities-layout/-20k-, diakses 25 April 2009. Tompkins, James A., White, John A., Bozer, Yavus A., dan Tanchocho, J.M.A., 2003, Facilities Planning, 3th Ed, John Wiley & Sons, Inc., United States of America. Wignjosoebroto, S., 2003, Tata Letak Pabrik dan Pemindahan Bahan, Edisi Ketiga, PT. Guna Widya, Jakarta. Yuniarti, A.T., 2009, Usulan Perancangan Tata Letak Baru Akibat Perluasan Pabrik (Studi Kasus di PT. Mega Andalan Kalasan, Yogyakarta), Skripsi, Program Studi Teknik Industri, Fakultas Teknologi Industri, Universitas Atma Jaya Yogyakarta, Yogyakarta.
134
LAMPIRAN 1 No.
Departemen
1 2 3
Disassy Line Customer Inspection Valve Seat
4
Oil & After Cooler
5 6 7
8
9
Nama sub-departemen Disassy Line Customer Inspection Disassy Roller Roller Measurement Valve seat remove Deep Tank Robowash Water Oil & After Cooler Disassy
Jumlah sub-Ukuran sub-departemen (m2) departemen p l L 7 4 4,5 18 1 4 4,5 18 1 4,5 1 4,5 2 1 2 2 3,2 1 3,2 1 3,95 1 3,95 1 1,5 1,5 2,25 1 3,5 2,5 8,75 1 2 2 4 1 5 3 15
1 Robowash Pulley & Drives 1 Pulley & Drives Disassy All pump & Compressor, Filter Head Group, All Corrosion pump & Resistor Compressor, Filter Head Group, Corrosion Resistor Disassy 1 FIP 1 WIP Turbo & Mechanism Room 1 WIP 1 Disassy FIP, T/C, Mech. Valve
Washing
Primer Painting
10 Machining
2,5 5,55 5,55 4,44 4,3
6
42
3 3 3 3 3 6 6
6 9 8,76 9 9 36 33
6
42
1 1 1 1 1 1 1 1
2 3 2,92 3 3 6 5,5
Engine Washing Prewash Deep Tank 5500Ltr Robowash Water Robowash Chemical Anti Rust Area Sandering Area WIP After Washing Prepare Painting Preparation Painting Block Block & Others Primer Painting Room Block Cleaning & Washing (Robowash Block) Block Surface Grinding Lathe machine for Axle Tube Metal spray room
1 2 2 2 2 2 1 1 1 1 1 1 2 1 1
34,05 3 5 3 3 3 8 5 6 5 12 8 8 8,025 5,9
Preparation & Measurement Block
1
Block Cutting Protrution Line Boring Machine
1 1
WIP Machining Block, Diff. house Magnaflux Wip Axle Tube Conrod Machine
7
6
Equipment p
l
L
Nama
Tools p
l
L
Nama
2,075 70,6538 9 3 15 3 9 3 9 3 3 9 5 40 7,08 35,4 5 30 7,08 35,4 5,2 62,4 6 48 6 48 Surface Grinding Machine 48,15 Lathe Machine Big 6 6 35,4 Metal Spray Lathe Machine 02 5,5 33
11 Assembly Station
5,47
21,88
5,47
60,17
1 1 1 1
7,4 2,5 2,5
5,47 5,5 5,5
40,478 13,75 13,75
5
4,5
22,5
Conrod Alignment Tool Crankshaft Grinding
1 2
WIP Crankshaft & Cam Shaft polish Fabrication Room
1 1
5 7,5 7,5 7
4,5 4,5 4,5 4,5
6
13,9
WIP Fabrication
2
Receive Out House Send Out House Office Machining, fabrication, & Lab.
1 1 1
Milling & Lathe Machine
1
1 Short Block 1 1 Short Block 2 1 Short Block 3 1 Short Block 4 1 Short Block 5 1 Short Block 6 1 Short Block 7 1 Short Block 8 1 Preparation Area 1 Liner & O ring Assembly 1 Liner wash 1 Crankshaft cleaning & measure 1 Piston & conrod preparation 1 Oil pump & strainer preparation 3 Parts prepare & tools area 1 Marking Area 1 WIP shortblock 1 WIP after painting 1 WIP Subassy 5 General Assy station 1 RFU ShortBlock 1 Preparation Line 14 Station 11 RFU Oil Pan F/W housing & Flywheel Gear Case & Cover 1 Oil Pump & Piston Cooling Nozzle Assembling 1 Oil Cooler & Cam follower Assembling 1 Cylinder Head Exhaust Manifold Assembling 1 Cross Head & Pulley Group Damper Assembling 1 Rocker Arm Push Rod Starting Motor Assembling 1 Water Pump Corrosion resistor Assembling 1 Intake Manifold & Heater After Cooling Assembling 1 Turbocharger Assembling Filter Head Oil, Air Compressor, and Fuel Filter Head Assembling 1 1 Muffler, Air Cleaning Housing, Heat Shield, Fan 1 Alt. drive, Alternator Assembling
l
L
Nama
p
l
L
p 4
l 3,25
L 13
Allowance Luas-(Engine atau Mesin) Total 3,74506 9,25494
Valve Grinding Deep Tank 3000 Spray Wash machine Apollo SWE800 After cooler tester Oil Cooler Cleaner
0,4
1
0,4
1,2
2
2,4
0,4
2
1,2 1,8 1,7
1,3 0,65 0,5
1,56 1,17 0,85
2
2,1
4,2
1,56
2,64
Turbo Balancer Cylinder Head tester 1 Cylinder Head Tester 2 Hyd Press Stand Hyd Press Stand Thermostat Tester Deep Tank 3000 Spray Wash machine Apollo SWE800 Deep Tank 3000 Spray Wash machine Apollo SWE800
1,4 1,55 1,55 1,25 1,25 0,51
0,75 1,25 1,25 0,6 0,6 0,26
1,05 1,9375 1,9375 0,75 0,75 0,1326
2,5 2,5 2,5 2 2 0,8
2,5 2,1 2,1 1,1 1,1 0,8
6,25 5,25 5,25 2,2 2,2 0,64
1,05 1,9375 1,9375 0,75 0,75 0,1326
5,2 3,3125 3,3125 1,45 1,45 0,5074
1,3
1,3
1,69
2,15
215
462,25
1,69
460,56
1,2
1,3
1,56
2
2,1
4,2
1,56
2,64
Abrasive Blasting
2,75
1
2,75
2,75
1,9
5,225
2,75
2,475
FIP testbench FIP tester
3,15 3,15
1,8 1,3
5,67 4,095
4,25 4,25
3,5 3
14,875 12,75
5,67 4,095
9,205 8,655
Deeptank 5500 Spray Wash Machine Apollo Spray Wash Machine Apollo
3,05 2,45 2,45
2,32 2,62 2,62
7,076 6,419 6,419
4 3,9 3,3 3,3
3,25 3,2 3,5 3,5
13 12,48 11,55 11,55
3,74506 7,076 6,419 6,419
9,25494 5,404 5,131 5,131
6,83 8 1 2,9
1,4 2,2 0,65 1,15
SWE800 Spray Machine
1,2
1,3
1,56
Hyd Press Stand 25T
1,1
1,3
1,43
2 7,75 9 2,65 4,6 1,3 2,6
2,1 2,25 3,5 1,5 2,85 1,65 2,1
4,2 17,4375 31,5 3,975 13,11 2,145 5,46
1,56 9,562 17,6 0,65 3,335 1,43 0,405
2,64 7,8755 13,9 3,325 9,775 0,715 5,055 12,315 10,555
9,562 17,6 0,65 3,335 Hytorc Wrench
4 11
4,61 4,5 3,6 3,2 4,5
Electricity p
1,5 3,75 2,25 12,4875 2 11,1 6,1 27,084 2,9 12,47
7
Deep Tank Robowash Water Prewash Sandering Area Sand Blasting room WIP FIP Room FIP Assembly Room FIP Test Room
Mesin Nama
Line Boring Machine Line Boring Machine
Conrod Machine
22,5 33,75 Crankshaft Grinding Machine 1 33,75 Crankshaft Grinding Machine 2 31,5 Polish Machine Drill Machine 83,4
4,473 3,473
1,35
7,428 9,514 2,65 0,9
10,1
19,7
4 4 4 4 4 4 4 4 4 4 1,5 4 4 4 4 6 12 20 15,69 4 11,98 59,5 4 11 4 4 13 7 5 5 6 5 5 10 5
3,83 3,83 3,83 3,83 3,83 3,83 3,83 3,83 2,2 2,2 1,5 2,2 2,2 3,74 3,74 6 6 6 6 6 7,6 3,5 4 6 6 6 6 6 6 6 6 6 6 6 6
6,25 5,25
2,5 2,5
15,625 13,125
3,31002 2,57002
1,6
6,08
4,6
2,5
11,5
6,08
1,1
5,42
SWE800 Spray Machine
1,2
1,3
1,56
3 2
2,75 2,1
8,25 4,2
1,485 1,56
6,765 2,64
9,2 11,2 4,3 2,6 2,1 2,5
3,9 3,9 2,3 2,6 2,1 2,25
35,88 43,68 9,89 6,76 4,41 5,625
16,67586 21,35893 1,4575 0,81 0,175 0,54
19,2041 22,3211 8,4325 5,95 4,235 5,085
3,5 3,25 4,15 5 3,9 4,1 5,4 4 4 4 4 4 4 4 4
3,5 2,85 3,55 2,9 2,6 2,8 3,2 3,25 3,25 3,25 3,25 3,25 3,25 3,25 3,25
12,25 9,2625 14,7325 14,5 10,14 11,48 17,28 13 13 13 13 13 13 13 13
3,0625 1,65 4,655 4,02 2,25 2,585 5,55 3,74506 3,74506 3,74506 3,74506 3,74506 3,74506 3,74506 3,74506
9,1875 7,6125 10,0775 10,48 7,89 8,895 11,73 9,25494 9,25494 9,25494 9,25494 9,25494 9,25494 9,25494 9,25494
3,65
3,15
11,4975
2,9
8,5975
1,485
2,245 16,6759 2,245 21,3589 0,55 1,4575 0,9 0,81 0,5 0,9 1,1
0,35 0,6 1,3
0,175 0,54 1,43
CMM Portable Roughness Tester 1,75 1,1 1,9 1,2 1 1,1 1,5
Wiring Harness Sensor Assembling
1
4
6
12 Dyno Test
Dyno Test Preparation Dyno Test Engine Completed
1 5 1
15,425 6 14,4
5 7 5
24 0 77,125 42 72
13 Finishing
Masking & Preparation Before Painting Assembly Painting Room Wrapping Area RFU Assembly
1 1 1 1
6 8 4 18,2
7 7 7 5
42 56 28 91
14 Warehouse
Warehouse ALB Preparation Warehouse
1 1
26 34
15,31 398,06 15,28 610,198
1,8 2,4
1,8 0,6
3,24 1,44
3,0625 1,65 4,655 4,02 2,25 2,585 5,55
Hytorc Hytorc Hytorc Hytorc Hytorc Hytorc Hytorc
8,8 8,8 8,8 14,96 14,96 36 72 120 94,14 24 91,048 208,25 16 66 24 24 78 42 30 30 36 30 30 60 30
0,405
3,8
ARC Welding 1 ARC Welding 2 Hyd Press Stand 25T
1,75 1,5 2,45 3,35 2,25 2,35 3,7
0,45
Magnaflux detector
3,97 18,3017 12 54 4,6 16,56 4,6 14,72 8 36 Milling Machine 1 Milling Machine 2 Milling Machine 3 189 Lathe Machine 1 Lathe Machine 3 Lathe Machine 4 0 Lathe Machine 5 15,32 15,32 15,32 15,32 15,32 15,32 15,32 15,32 8,8
0,9
0,74 3,31002 0,74 2,57002
Hyd Press Stand 25T
1,1
1,3
Drive Drive Drive Drive Drive Drive Drive
0,9 0,9 0,9 0,9 0,9 0,9 0,9
0,45 0,45 0,45 0,45 0,45 0,45 0,45
0,405 0,405 0,405 0,405 0,405 0,405 0,405
1,43
Starting Motor testbench
1,22
1,1
1,342
3
2,85
8,55
1,342
7,208
Alternator Testbench1 Alternator testbench2
1,15 1,35
0,85 1,06
0,9775 1,431
2,85 3
2,5 2,75
7,125 8,25
0,9775 1,431
6,1475 6,819
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Disassy line Customer inspection Valve seat Oil & After cooler Pulley & drives All pump and compressor FIP Washing Primer painting Machining Assembly station Dyno test Finishing Warehouse
LAMPIRAN 2 LAYOUT KESELURUHAN YANG TELAH MENGALAMI PERUBAHAN LUAS AREA GARDEN 20 sq. m.
MECHANIC REST STAGE 20 sq. m.
TOILET 21 sq. m.
MECHANIC REST STAGE 33 sq. m.
GARDEN 12 sq. m.
TOILET 18 sq. m.
MECHANIC REST STAGE 42 sq. m.
PAINT COLLECTOR
GARDEN 14 sq. m.
GARDEN 21 sq. m.
GARDEN 14 sq. m.
MECHANIC REST STAGE 33 sq. m.
TOILET 14 sq. m.
COOLING DYNO 44 sq. m.
GARDEN 11 sq. m.
GARDEN 12 sq. m.
OIL TRAP
GARDEN 28 sq. m.
18 sq. m.
42 sq. m. Wrapping Area 28 sq. m.
398 sq. m.
56 sq. m.
WAREHOUSE ALB PREPARATION
DYNO TEST
DYNO TEST
DYNO TEST
DYNO TEST
DYNO TEST
42 sq. m.
42 sq. m.
42 sq. m.
42 sq. m.
42 sq. m.
91 sq. m.
Engine Completed ALLOWANCE ENGINE sq. m.
RFU ASSY
ALLOWANCE ENGINE 72
ALLOWANCE ENGINE
ALLOWANCE ENGINE
ALLOWANCE ENGINE
½ T, 5.5m
FILTER HEAD OIL TURBOCHARGER AIR COMPRESSOR ASSEMBLING FUEL FILTER HEAD ASSEMBLING 30 sq. m. 30 sq. m.
Altern ator ALLOWANCE testbe nch 1
MUFFLER AIR CLEANER HOUSING HEAT SHIELD FAN 60 sq. m.
ALT. DRIVE WIRING HARNESS ALTERNATOR SENSOR ASSEMBLING
Alterna ASSEMBLING tor ALLOWANCE testben ch 2 sq. m. 30
24 sq. m. Tool & Equipment Spare Part Main 80 Storage sq. m.
Piston & ConRod Preparation 9 sq. m.
C/ Shaft Cleaning Measure 9 sq. m.
13DUST sq. m. COLLECTOR
17DUST sq. m. COLLECTOR
Roller Conv.
Ball Conv.
General Assy Station
General Assy Station
General Assy Station
General Assy Station
24 sq. m.
24 sq. m.
24 sq. m.
24 sq. m.
KOPERASI 40 sq. m.
Consumable Good Counter
4.0m.
Preparation Painting Block 35 sq. m.
TOILET
OIL TRAP
GARDEN
M AL O LO S WA T A NC T E
WIP AFTER WASHING
ROBOWASH Sand Blasting DEEP Sandering AreaALLOWAN SPRAY WATER ROOM WASH 9 sq. m. 9 sq. m. CE TANK WATER SWE80 9 sq. m. 6 sq. m. 0
35 sq. m. ALL PUMP & COMPRESSOR FILTER HEAD GROUP CORROSION RESISTOR 1 sq. m. 11 sq. m. DIS ASSY
T E S T E R
27 sq. m.
MINI LAT HE
SPRAY WASH
DISASSY 5 sq. m.
Disassy Line
18 sq. m.
ROLLER 2 sq. m.
Disassy Line
12 sq. m.
18 sq. m. PULLEY & DRIVES ALLO HYD ROBOWASH WANC 4 sq. m. DIS ASSY PRESS 12 sq. m.
STAND E 25T
Disassy Line
18 sq. m.
OIL & AFTER COOLER 3 sq. m. DIS ASSY
Disassy Line 18 sq. m.
After Cooler Tester Oil Cooler
3 Cleaner sq. m.
Block & Others Primer Painting ROOM 62 sq. m.
GARDEN
PAINT COLLECTOR
Disassy Line
18 sq. m.
Consumable Goods Main Storage
18 sq. m.
Preparation Line 16 sq. m.
Preparation Line 16 sq. m.
15 sq. m.
Customer Inspection
HYT ORC DRIV E
56 sq. m.
TRA CEA BILI TY TOO LS
Disassy ALLOWANCE ENGINE Line
40 sq. m. Document Storage
18 sq. m.
Preparation Line 16 sq. m. 1.7m.
1 sq. m.
Disassy Line 18 sq. m.
Preparation Line 16 sq. m.
VALVE GRINDIN ALLOWAN G CE
WATER ROBOWASH ALLOWAN SWE80 0 CE WATER 4 sq. m.
WIP
PRE WASH 9 sq. m.
COIL HEATER
HYD ALLO PRES WAN S CE STAN D 25T
ENGINE WASHING
Block Cleaning & Washing (Robowash Block) 48 sq. m. SPRAY ALLOWAN WASH CE WATER SWE80 0
MECHANIC REST STAGE
R
SWE800
SPRING TESTER
2T, 5.5 m
36 sq. m.
VALVE SEAT CUTTER
2T, 5.5m
33 sq. m.
DEEP TANK 9 sq. m.
2T, 5.5 m
WIP FIP ROOM
VALVE SEAT ROLLER REMOVE MEASUREMENT 3 sq. m. 2 sq. m. 4 sq. m.
Prepare Painting 30 sq. m.
TOILET
GARDEN 12 sq. m.
21 sq. m.
120.0m. 128.0m.
Sandering Area 40 sq. m.
MECHANIC REST STAGE 37 sq. m.
ROBOWASH ROBOWASH SPRAY SPRAY WASH WASH WATER ANTI RUST CHEMICAL WATER WATER SWE1612 SWE1612 12 sq. m. 12 sq. m. 9AREA sq. m.
GARDEN 11 sq. m.
TOILET 21 sq. m.
DEEP DEEP TANK 5500 LT TANK
12 sq. m.
GARDEN 16 sq. m.
ENGINE PRE WASH 13 sq. m.
OIL TRAP
HIGH PRESSUR E WATER BLASTER
ROBOWASH SPRAY ROBOWASH SPRAY WASH WASH WATER ANTI RUST CHEMICAL WATER WATER SWE1612 SWE1612 12 sq. m. 12 sq. m. 9AREA sq. m.
MECHANIC REST STAGE 30 sq. m.
DEEP TANK DEEP 5500 LT
12TANK sq. m. GARDEN 21 sq. m.
GA Storage 64 sq. m.
OHC 2 T
Block Surface Grinding 2 48 sq. m. SURFACE GRINDING MACHINE
BIG LATHE MACHINE
GARDEN
FIP Assembly ROOM
2.0m.
Block Surface Grinding 1 48 sq. m. SURFACE GRINDING MACHINE
40 sq. m.
CYLIND ER Tur HEAD bo TESTE Bal 3 sq. m. ALLOWANCE ALLOWANCE R 1DIS ASSY anc DEEP er MECH. VALVEWIP TURBO & TANKFIP, T/C, CYLIND ER MECHANISM ROBOWASH HEAD T ALLOWAN SPRAY ROOM ALLOWANCE WATER HTESTE CE m. WASH E R2 2WATER sq. 42 sq. m.
Abrasive Blasting Allowance
Preparation & Measurement HYT ALLO ORBlock HYD WANC C PRESS ALLOWANCE E WR 33 sq. m. STAND 25T EN CH
22 sq. m.
2T, 5.5 m
54 sq. m.
2T, 5.5m
2T, 5.5 m
LATHE ALLOWANCE MACHINE 2
GARDEN
ALLOWANCE ENGINE
OHC 10 T
LINE BORING MACHINE
Block Cutting Protrution
42
SIN K sq.FILm. TER CAT
2.0m.
O2,ACC GAS ROOM
Lathe Machine For Axle Tube
Metal Spray Room 30 sq. m.
Station 14 16 sq. m.
ALLOWANCE ENGINE
OHC 2 T
LINE BORING MACHINE
40 sq. m.
MET AL SPR AY
HYD PRESS STAND 25T
Station 13 16 sq. m.
Station ALLOWANCE ENGINE CONVEYOR 12 16 sq. m.
2T, 5.5 m
2X FIPSOL TEST VE ROOM NT
OD ALLOWANCE MACHI
83 sq. m.
DRI LL ALLOWANCE MA CHI NE
40 sq. m. Station 11 16 sq. m.
ALLOWANCE ENGINE
General Assy Station
5.5 m, 1/2 T
23 sq. m. NE
Line Boring Machine 2 60 sq. m.
Block, Diff House
Fabrication Room
2
Station 10 16 sq. m.
ALLOWANCE ENGINE
2.5m.
CONROD CONR MACHINE
23 sq. m.
FIP Allowance Tester
CONROD ALLIGNMENT TOOL
FIP Allowance Testbench
WIP Crankshaft & Cam Shaft Polsh
1.8m.
CrankShaft Grinding CRANKSHAFT GRINDING 1 1 41 sq. m.
VERTICAL BORING
A R C W ALLOWAN EL CE DI N G 1
Station 9 16 sq. m.
ALLOWANCE ENGINE
WIP SUB ASSY 94 sq. m.
SPRAY WASH WATER ALLOWAN SWE80 0 CE
2T, 5.5 m
OHC 5 T
WIP AFTER PAINTING 120 sq. m.
HYD
CrankShaft Grinding CRANKSHAFT GRINDING 2 2 50 sq. m.
WIP Machining
ARC
ALLOWANCE ENGINE
24 sq. m.
2T, 5.5 m
WEL ALLOWANCE DING
Station 8 m. 16 sq.
ALLOWANCE ENGINE
HYD
14 sq. m.
POLISH MACHINE
M. FLUX
2 T, 5.5 m
WIP AXLE TUBE
MAGNAFLUX
2.2m.
WIP Fab 18 sq. m.
112 sq. m. Station 7 m. 16 sq.
Station 6 m. 16 sq.
ALLOWANCE ENGINE
PRESS ALLOWAN STAND CE
Send Out House 15 Fab sq. m.
WIP Short Block 72 sq. m.
MARKING AREA 36 sq. m.
Station 5 m. 16 sq.
ALLOWANCE ENGINE
PRESS ALLOWAN STAND CE
Receive Out House 17 Fab sq. m.
Station ALLOWANCE ENGINE 4 m. 16 sq.
6.1m.
2 T, 5.5 m
2T, 5.5 m
Up
ALLOWANCE ENGINE
1/2 T, 5.5 m
3.0m.
3.0m.
Short Block 1 Install Bushing & ALLOWANCE ENGINE Plug 15 sq. m. Block Liner & Oring Preparation Liner Assembly Area Wash. 9 sq. m. 9 sq. m. 2 sq. m. Short Block 2 Install Liner ALLOWANCE ENGINE 15 sq. m.
Station 3 m. 16 sq.
Station 2 m. 16 sq.
ALLOWANCE ENGINE
5 m, ½ T
Short Block 3 C/ENGINE Shaft ALLOWANCE 15 sq. m.
2T, 5.5 m
Short Block 4 Piston & ALLOWANCE ENGINE ConRod 15 sq. m.
OFFICE Station ALLOWANCE 16ENGINE sq. 1 m.
OHC 10T
OHC 5T
2 T, 5.5 m
LATHE ALLOWANCE MACHINE 5
36 sq. m. OFFICE ROUGHNES S TESTER MACHINING/FAB. & Lab (office Lt 2 Lab Lt 1)
Preparation Line 208 sq. m.
5 m, ½ T
Short Block 6 Short Block 5 Short Block 7 Fly/W Housing, Gear Case Short Block 8 ALLOWANCE ENGINE ALLOWANCE ENGINE ALLOWANCE ENGINE ALLOWANCE ENGINE Oil Pump & Timing Gear FIP Drive, Cam Shaft Front Cover Strainer Assy & Measure Oil Pan 15 sq. m. 15 sq. m. 15 sq. m. 15 sq. m.
MILLING & LATHE LATHE ALLOWANCE MACHINE MACHINE 4
MILLING ALLOWANCE MACHINE 3
CMM PORTAB LE
RFU Short Block 91 sq. m.
½ T, 5 m
54 sq. m.
Roller Conv.
2.4m.
Parts Prepare & Tools Area 15 sq. m.
½ T, 5 m
Parts Prepare & Tools Area 15 sq. m.
15 sq. m.
½ T, 5 m
Parts Prepare & Tools Area 15 sq. m.
½ T, 5 m
MACHINE 3
2 T, 5.5 m
Oil Pump & Strainer Preparation
LATHE 189 sq. m. ALLOWANCE
12 sq. m.
LATHE ALLOWANCE MACHINE 1
12 sq. m.
MILLIN G ALLOWANCE MACHI NE 2
WIP Fab
2.5m.
30 sq. m. MILLING ALLOWANCE MACHIN E1
ENGINE PRE WASH 13 sq. m.
OIL TRAP
GARDEN 8 sq. m.
TOILET 11 sq. m.
GARDEN 8 sq. m.
66.0m.
78 sq. m.
40 sq. m.
ALLOWANCE ENGINE
60.0m.
24 sq. m.
ARM INTAKE MANIFOLD WATER PUMP PUSH ROD HEATER CORROSION RESISTOR ST. MOTOR AFTER COOLER ASSEMBLING ASSEMBLING ASSEMBLING 30 sq. m. 30 sq. m. 36 sq. m.
½ T, 5.5 m
24 sq. m.
Startin g ALLOWANCE motor testbe ROCKER nch
CROSS HEAD PULLEY GROUP DAMPER ASSEMBLING 42 sq. m.
CYLINDER HEAD & EXHAUST MANIFOLD ASSEMBLING
MAINTENANCE ROOM
DYNO TEST PREPARATION ALLOWANCE ENGINE
ALLOWANCE ENGINE
77 sq. m.
½ T, 5.5 m
OIL PUMP & OIL COOLER & PISTON CAM FOLLOWER COOLING NOZZLE ASSEMBLING ASSEMBLING
½ T, 5.5 m
66 sq. m.
½ T, 5.5 m
RFU OIL PAN F/W HOUSING & FLYWHEEL GEAR CASE & COVER
91 sq. m.
40 sq. m.
Compressor Room 40 sq. m.
6.0m.
WAREHOUSE
Compressor Tanks
42 sq. m.
OHC 10 T
OHC 5 T
WAREHOUSE
Masking & Preparation Before Painting
ASSY’ PAINTING ROOM
3.2m.
519 sq. m.
3.3m.
Receiving Parts
