PRACTICUM REPORT

PSIT 1
MODULE 4
PROCESS PLANNING

Group
Name
Class
Assistant
Scoring Criteria
Report Format
Content
Analyze
TOTAL

: IP-7
: Imam Mukhri
Wildan Adiwena
: IP
: P 96

Practicum Date : 27 April 2015

Practicum Day : Monday
Submitted Date : 4 May 2015
Yogyakarta, 27 April 2015
Assistant

:
:
:
:

(Muhammad Ihsan NST)

PSIT LABORATORY
INDUSTRIAL ENGINEERING
FACULTY OF INDUSTRIAL TECHNOLOGY
UNIVERSITAS ISLAM INDONESIA
2015

CHAPTER IV
PROCESS PLANNING

1.1 Practicum Goal

1. Understand the process of making a product
2. Understand the process of assembling a product
3. Able to design Bill Of Material of a product
4. Able to design Operation Process Chart (OPC) of a product
5. Able to design Assembly Chart (AC) of a product
6. Understand and comprehend of using machinery in doing Production process.
1.2 Practicum Task
1. Make a structure product and Bill OF Material from car prototype (Tamiya) based
on information types and sum of component of the whole constituent.
2. Make an Assembly Chart based on from result first task above.
3. Make an Operation Process Chart for components that have been determined.

1.3 Output
1.3.1

Structure of Product

Figure 1. Component of Product

To make a product we should know what the component of a product
first, from know that then we can assembly the component to build a
product. That product above is structure of Sport Car (Tamiya), and the
components are?
1. Upper Body
2. Lower Body
3. Wheels
4. Dynamo
5. Bumper
6. Dynamo Cover
7. Gear Pack
8. Roller Pack
9. Hook
10. Battery Cover
11. Gear Cover
12. Front Gear Cover
In this case, we would assembly all of parts above to be a Sport Car
(Tamiya) with Bill Of Material (BOM) design, Assembly Chart (AC)

design and Operation Process Chart (OPC) design. Then the process of
assembly this product will be explained in sub chapter below.
1.3.2

Bill Of Material

Figure 2. Bill Of Material of Sport Car

Table 1. Bill Of Material of Sport Car Table

No.

Components

Quantity

Make or Buy

000

Sport Car

Make

6171

Body Assembly

Make

4122

Lower Body Assembly

Make

3043

Connecting Rod

Buy

3053

Gear

Buy

3063

Lower Body

Buy

3073

Dynamo

Buy

3083

Front Gear Cover Assembly

Make

1014

Metal Front Battery

Buy

3093

Dynamo Cover Assembly

Make

2014

Metal Rear Battery

Buy

1.3.3

2034

Dynamo Cover

Buy

3103

Wheels

Buy

3113

Battery Cover

Buy

4132

Upper Body

Buy

4142

Hook

Buy

6181

Bumper Assembly

Make

5152

Bumper

Buy

5162

Roller

Buy

Assembly Chart

Figure 3. Assembly Chart of Sport Car

1.3.4

Operation Process Chart

Figure 4. OPC of Battery Cover

Figure 5. OPC of Bumper

Figure 6. OPC of Gear

Figure 7. OPC of Upper Body

1.4 Analysis

1.4.1

Bill Of Material
1. To make a Sport Car (Tamiya) we begin with assembly components
first we assembly the body, body sport car are divide into 3
components: lower body, upper body, and hook.
2. First we assembly lower body. Lower body have components also, we
begin with put connecting rod on front and back lower body, then set
the gear on both connecting rod, after that put the dynamo on back side
of lower body.
3. Then, in lower body there are parts to be assembled again. Front gear
is consist of battery metal and front gear cover, after that rear gear is
consist of battery metal also and rear gear cover, both of them should
put in front and rear lower body.
4. After that, assembly no. 2 and no.3 with four wheels and battery cover.
5. After lower body is finish, put upper body on lower body and lock it
with hook.
6. Next step is assembly bumper; we should put four rollers on left side
and right side on front bumper and back bumper.
7. Last step is assembly that bumper on front side and back side. Finally
Sport Car (Tamiya) is ready to use.

1.4.2

Assembly Chart
First, we assembly battery metal (1014) and front gear cover
(1024) become Sub12 Assembly (S12A1), then we assembly front
connecting rod (3043) and front gear (3053) become Sub12 Assembly 2
(S12A2), after that assembly back connecting rod (3043) and back gear
(3053) become Sub12 Assembly 3 (S12A3), and then assembly Sub12
Assembly 3 (S12A3) with lower body (3063) become Sub11 Assembly 1
(S11A1).
Second, place Sub12 Assembly 2 (S12A2) on Sub11 Assembly 1
(S11A1) become Sub10 Assembly 1 (S10A1), next place Sub12 Assembly
1 (S12A1) on Sub10 Assembly 1 (S10A1) become Sub9 Assembly 1
(S9A1).
Third, place dynamo (3073) on Sub9 Assembly 1 then become
Sub8 Assembly 1 (S8A1). Next is combine battery metal (2014) with
dynamo cover (2034) become Sub12 Assembly 4 (S12A4), then assembly

it with Sub8 Assembly 1 (S8A1) and become Sub7 Assembly 1 (S7A1).

After that place first wheel (3013) on left front side of Sub7 Assembly 1
(S7A1) become Sub6 Assembly 1 (S6A1), then place second wheel (3013)
on right front side of Sub6 Assembly 1 (S6A1) become Sub5 Assembly 1
(S5A1), after that place third wheel (3013) on left back side of Sub5
Assembly 1 (S5A1) become Sub4 Assembly 1 (S4A1), next place last
wheel (3013) on right back side of Sub4 Assembly 1 (S4A1) become Sub3
Assembly 1 (S3A1).
Fourth, assembly battery cover (3113) on Sub3 Assembly 1 (S3A1)
become Sub2 Assembly 1 (S2A1), then place upper body (4132) on Sub2
Assembly 1 (S2A1) and get parts of Sub1 Assembly 1 (S1A1). Next lock
upper body and lower body with hook (4142) and become Assembly 1
(A1).
Fifth, assembly roller (5162) on front bumper (5152) become Sub2
Assembly 2 (S2A2), then place roller (5162) again on front bumper (5152)
become Sub1 Assembly 2 (S1A2). After that place next roller (5162) on
back bumper (5152) become Sub2 Assembly 3 (S2A3), then place last
roller (5162) on back bumper (5152) and get part Sub1 Assembly 3
(S1A3).
Last step is combine Assembly 1 (A1) with Sub1 Assembly 2
(S1A2) become Assembly 2, then assembly again Assembly 2 (A2) with
Sub1 Assembly 3 (S1A3) and become Assembly 3 (A3). After that we do
inspection of this parts if any section less or another something wrong, and
FINALLY after we assembly some part, the sport car (Tamiya) has
become final product.
1.4.3

Operation Process Chart

1. In Figure 4. OPC battery Cover, is containing about process how to
make battery cover. To make battery cover, first we should heat the
plastic with heating machine for 10 minutes to make the plastic
become soft, and next put it into forming for 2 minutes machine to
make form of battery cover, then put this form in quenching machine
for 1 minute to freeze that form, after that make the hole as needed

with borring machine for 3 minutes, then put it into cutting machine
during 10 minutes to make fix form and do inspection analyze if there
is something less, and battery cover become final part.
2. Bumper, as shown in Figure 5 is made by metal, to make this bumper
we begin with cut this metal with cutting machine for 2 minutes to
make shape that bumper, then make hole for roller and lower body of
sport car with borring machine during 5 minutes, next grind this
bumper in grinding machine to make the shape more fine, and also do
inspection to analyze if there is something less, finally bumper is ready
to use.
3. Base material of Gear of sport car (Tamiya) is made from plastic, first
step to make this part is cut this plastic to make shape of gear with
cutting machine during 15 minutes, then do inspection if there is
something less for 5 minutes, and then make hole to this gear for
connecting rod with borring machine for a minute, and finally gear is
ready assembly with another parts.
4. As shown in Figure 7, upper body made by plastic, first step to make it
is heat this plastic with heating machine for 10 minutes to make the
plastic more soft, then put it into molding machine for 5 minutes to
mold so become shape of upper body of sport car (Tamiya), after that
do inspection as usual for 5 minutes to analyze if there is something
less, then put that mold which contain plastic into heating machine for
5 minutes to get more good shape, then put it into quenching machine
for 1 minute to freeze and have fix shape, after that place that upper
body shape in painting machine for 15 minutes to paint so can look
more interest and wait for 20 minutes to dry that paint, and finally this
part is finish and ready to use.