TUGAS AKHIR
ANALISA BIAYA MATERIAL DIES END PLATE RADIATOR UNIVERSAL DI PT. SELAMAT SEMPURNA Tbk.
Diajukan Sebagai Salah Satu Persyaratan Guna Memperoleh Gelar Sarjana ( Strata 1 ) Pada Jurusan Teknik Industri
ROBERTO ROSSI 0160311-049
JURUSAN TEKNIK INDUSTRI FAKULTAS TEKNOLOGI INDUSTRI UNIVERSITAS MERCU BUANA JAKARTA 2008
DAFTAR ISI
Lembar Pernyataan ......................................................................
i
Lembar Persetujuaan ...................................................................
ii
Lembar Pengesahan .....................................................................
iii
Abstrak
...
iv
Abstrak versi Inggris
.
v
KataPengantar
........................................................................ .
vi
Daftar isi ....................................................................................
ix
Daftar Gambar ............................................................................
xii
Daftar Tabel .................................................................................
xvi
Daftar Lampiran ..........................................................................
xix
BAB I
PENDAHULUAN 1.1 Latar Belakang ....................................................
1
1.2 Perumusan Masalah.............................................
2
1.3 Pembatasan Masalah ...........................................
3
1.4 Tujuan dan Manfaat Penelitian ..........................
4
1.5 Metodelogi Penelitian ........................................
5
ix
1.6 Sistematika Penulisan .........................................
BAB II
5
LANDASAN TEORI 2.1 Pengertian Proses Produksi .................................
7
2.2. Teori Produktivitas ..............................................
10
2.2.3 Perancangan dan pengembangan Produk..........
13
BAB III METODOLOGI PENELITIAN 3. 1 Tahanan Penelitian ...........................................
17
3.2 Kerangka Berpikir .............................................
19
3.3 Metode Pengumpulan Data ..............................
20
3.4 Metode Analisis Data ........................................
20
BAB IV PENGUMPULAN DAN PENGOLAHAN DATA 4.1 Produk Radiator ...................................................
21
4.2 Produk Manufacture Engineering .......................
26
4.2.1 Produk Dies / Press Tool ..........................
26
4.2.2 Proses Produksi End Plate Radiator .........
38
4.2.3 Produk Dies Draw-1 End Plate Radiator ..
46
x
4.2.4 Data Material Cost Pembuatan Dies Draw-1 End Plate Radiator ...........................................
BAB V
54
HASIL DAN ANALISA 5.1
Perhitungan Biaya Material Pembuatan Dies Independent Draw-1 End Plate Radiator ........
5.2
60
Perhitungan Biaya Material Pembuatan Dies Universal Draw-1 End Plate Radiator
5.3 Kapasitas produksi ............................................. 5.3.1 Kapasitas Produksi Dies Independent Bulan
. 74 85 85
5.3.2 Kapasitas Produksi Dies Universal Per Bulan.. 87 BAB VI
KESIMPULAN DAN SARAN 6.1 Kesimpulan .......................................................
92
6.2 Saran
saran .....................................................
93
DAFTAR PUSTAKA ................................................................
94
LAMPIRAN ...............................................................................
95
xi
DAFTAR GAMBAR
Gambar
2.1
Proses Pengembangan Produk ....................
14
Gambar
3.1
Bagan Kerangka Berpikir Penelitian ..........
19
Gambar
4.1
Produk Radiator ..........................................
22
4.2
Produk Radiator ...........................................
22
4.3
Produk End Plate Plate Radiator ................
23
4.4
Produk Side Plate Radiator .........................
23
4.5
Produk Fin Radiator ...................................
24
4.6
Produk Water Tube Radiator.......................
24
4.7
Produk Tank Radiator .................................
25
4.8
Bending........................................................
28
4.9
Flangging .....................................................
28
4.10
Emboshing ...................................................
28
4.11
Deep Drawing .............................................
29
4.12
Colar Drawing ...........................................
29
4.13
Blanking ....................................................
30
4.14
Pierching .....................................................
30
4.15
Notching .....................................................
31
4.16
Triming .......................................................
31
xii
4.17
Dies Draw-1 End Plate ...............................
32
4.18
Dies Notching End Plate .............................
32
4.19
Dies Draw-2 End Plate ................................
32
4.20
Dies Pierching End Plate ............................
33
4.21
Dies untuk Side Plate .................................
34
4.22
Hasil Dies Pierching dan Notching ............
34
4.23
Hasil Dies Bending dan Emboshing ...........
35
4.24
Dies Drawing Tank ....................................
35
4.25
Hasil Dies Drawing ...................................
36
4.26
Dies Triming Tank .....................................
36
4.27
Hasil Dies Triming ......................................
36
4.28
Dies Pierching Tank ...................................
37
4.29
Hasil Dies Pierching ...................................
37
4.30
Produk Draw-1 End Plate Radiator ............
38
4.31
Proses Draw-1 End Plate Radiator .............
39
4.32
Produk Notching End Plate Radiator .........
40
4.33
Proses Notching End Plate Radiator ..........
41
4.34
Produk Draw-2 End Plate Radiator ............
42
4.35
Proses Draw-2 End Plate Radiator ............
43
4.36
Produk Pierching End Plate Radiator ........
44
xiii
4.37
Proses Pierching End Plate Radiator ..........
45
4.38
Produk Draw-1 End Plate Radiator ............
46
4.39
Design Dies Draw-1 End Plate Radiator ....
47
4.40
Top Plate ....................................................
47
4.41
Punch Holder ..............................................
48
4.42
Punch Draw .................................................
48
4.43
Stripper Punch ............................................
49
4.44
Die Block .....................................................
49
4.45
Stripper Die ................................................
50
4.46
Die Holder .................................................
50
4.47
Bottom Plate ...............................................
51
4.48
Support ........................................................
51
4.49
Bottom Base ..............................................
51
4.50
Spring ..........................................................
52
4.51
Dowel Pin ....................................................
52
4.52
Screw Plug ...................................................
52
4.53
Stripper Bolt ................................................
53
4.54
Guide Post ...................................................
53
4.55
Baut Inbus....................................................
53
xiv
Gambar
5.1
Dies Independent Draw-1 End plate Radiator
. 60
5.2
Dies Universal Draw-1 End plate Radiator ..
74
5.3
Dies Universal Bawah ,Insert DieTertutup
..75
5.4
Dies Universal Bawah Insert Die Terbuka
...75
5.5
Dies Universal Atas Insert Die Tertutup ......
76
5.6
Dies Universal Bawah Insert Die Terbuka
. 76
5.7
Punch Draw untuk Dies Universal Draw-1 End Plate Radiator .......................................
5.8
Stripper Draw untuk Dies Universal Draw-1 End Plate
5.9
78
Radiator ....................................
78
Die Block untuk Dies Universal Draw-1 End Plate
Radiator ....................................
xv
79
DAFTAR TABEL
Tabel
4.1 Biaya Material Cost Dies Draw-1 End Plate Radiator Range 1 ..........................................
Tabel
4.2 Biaya Material Cost Dies Draw-1 End Plate Radiator Range 2 ..........................................
Tabel
56
4.3 Biaya Material Cost Dies Draw-1 End Plate Radiator Range 3 ..........................................
Tabel
55
57
4.4 Biaya Material Cost Dies Draw-1 End Plate Radiator Range 4 ..........................................
58
Tabel
5.1 Data pesanan End Plate Radiator .................
59
Tabel
5.2 Material Cost Dies Independent Draw-1 End Plate Radiator ADR 1 ...........................
Tabel
5.3 Material Cost Dies Independent Draw-1 End Plate Radiator ADR 2 ...........................
Tabel
63
5.5 Material Cost Dies Independent Draw-1 End Plate Radiator ADR 4 ...........................
Tabel
62
5.4 Material Cost Dies Independent Draw-1 End Plate Radiator ADR 3 ...........................
Tabel
61
5.6 Material Cost Dies Independent Draw-1
xvi
64
End Plate Radiator ADR 5 ........................... Tabel
5.7 Material Cost Dies Independent Draw-1 End Plate Radiator ADR 6 ...........................
Tabel
73
5.15 Material Cost Badan Dies Universal Draw-1 End Plate Radiator .........................
Tabel
72
5.14 Material Cost Dies Independent Draw-1 End Plate Radiator ADR 13 .........................
Tabel
71
5.13 Material Cost Dies Independent Draw-1 End Plate Radiator ADR 12 .........................
Tabel
70
5.12 Material Cost Dies Independent Draw-1 End Plate Radiator ADR 11 .........................
Tabel
69
5.11 Material Cost Dies Independent Draw-1 End Plate Radiator ADR 10 .........................
Tabel
68
5.10 Material Cost Dies Independent Draw-1 End Plate Radiator ADR 9 ...........................
Tabel
67
5.9 Material Cost Dies Independent Draw-1 End Plate Radiator ADR 8 ...........................
Tabel
66
5.8 Material Cost Dies Independent Draw-1 End Plate Radiator ADR 7 ...........................
Tabel
65
5.16 Material Cost Insert Punch Universal
xvii
77
Draw-1 End Plate Radiator ........................ Tabel
5.17 Material Cost Insert Stripper Die Universal Draw-1 End Plate Radiator .........
Tabel
86
5.20 Kapasitas Produksi Dies Universal per bulan .......................................................
Tabel
83
5.19 Kapasitas Produksi Dies Independent per bulan .......................................................
Tabel
81
5.18 Material Cost Insert Die Block Universal Draw-1 End Plate Radiator .........
Tabel
80
88
5.18 Perandingan Kapasitas Dies Independent dan Universal End Plate Radiator ................
xviii
90
DAFTAR LAMPIRAN
Lampiran
1
Gambar Design Dies Draw-1 End Plate Radiator .. .....................................
Lampiran
2
Tabel Material Cost Dies Draw-1 End Plate Radiator Range 1 .........................
Lampiran
3
4
5
6
7
8
100
Gambar Proses pemasangan Dies Independent pada mesin, saat penggantian tipe produk....
Lampiran
99
Gambar Design Dies Universal Draw-1 End Plate Radiator ......................................
Lampiran
98
Tabel Material Cost Dies Draw-1 End Plate Radiator Range 4 ........................
Lampiran
97
Tabel Material Cost Dies Draw-1 End Plate Radiator Range 3 ........................
Lampiran
96
Tabel Material Cost Dies Draw-1 End Plate Radiator Range 2 .........................
Lampiran
95
101
Gambar Proses pemasangan Insert Dies Universal pada mesin, saat penggantian tipe produk ...........................................................
xix
102
