Design of pokayoke system on the process of mounting actuator bracket based on programmable logic controller in automotive manufacturing industry

Politeknik Manufaktur Astra, Teknik Produksi dan Proses Manufaktur, Jl. Gaya Motor Raya No. 8, Sunter II, Jakarta, Indonesia

^* Corresponding author: syahril.ardi@polman.astra.ac.id.

Abstract

This research was conducted in automotive manufacturing industry company in Indonesia. There is one Key Performance Index that needs to be fixed, that is the process mounting actuator bracket. The type of trouble that can occur on the actuator bracket is on the quality of the mounted bracket. The bracket mounting process is carried out using three bolts on each side which must be mounted with a predetermined torque value of 5.4 Nm. Manually process can cause bolt on one side or more. Based on data from the Quality Assurance network, the process diagnostic table or tightening has shown less optimal installation process of actuator bracket on actuator brake in Jundate Trimming. The absence of line stop detection on a jig can cause a torque process error on one or more bolts. We modify the mechanical design of the pokayoke system. While the jig design is not modified there is only the addition of clamp systems that serves to determine the position of the work piece, proximity sensor as a detector work piece, and push button as a button to distinguish the work piece between ABS work piece and VSC on jig. This pokayoke system is based on Programmable Logic Controller control. This pokayoke system design prevents the occurrence of damaged bolts on screw threads when mounting an imperfect actuator bracket.