DESIGN AND DEVELOPMENT

CONTROL SYSTEM FOR AUTOMATIC LOADER OUTPUT

OF SNAP GAUGE ON MACHINING C LINE 6 AT PT. FNI
Rahardian Faizal Zuhdi
Politeknik Manufaktur Astra
(Polytechnic of Astra Manufacturing)
Engineering Production & Manufacturing Processes Study Program
Mechatronics Concentration
Jl. Gaya Motor Raya No. 8, Sunter II, Jakarta 14330, Jakarta
E-mail: Rahardian.faizal.z@gmail.com
Abstract - PT. Federal Nittan Industries (PT. FNI) is a company engaged in manufacturing of engine valve
automotive components. In the manufacturing, engine valve are experiencing machining process in the machining
area. One of the machines at the machining area is snap gauge. Snap gauge is used for valve engine dimensional
inspection process which includes examination of the head, seat, keeper groove, stem, and carbon. In snap gauge
there is a section called loader output. Current conditions, the low height of output loader required operators to
bend over during engine valve withdrawal. This resulted in an operators morality, especially the operators
enthusiasm and fatigue level in work. With this problem, then a mechanism created to increase the height of the
loader output in which the mechanism was capable to run automatically. Thus the height of the previous loader
was 40cm, after the development of the device, it is now increased to 65cm and the operators do not have to bend
over like previously. By changing the posture of operators at work, it increases the level of ergonomic which
affects on the level of operator safety.
Keywords: control system, PLC, Loader Output, Snap Gauge
I.
1.1

Introduction
Background
PT. Federal Nittan Industries (PT. FNI) is a
company engaged in the manufacturing of engine
valve automotive components. Products of PT.
Federal Nittan Industries are shown in Figure I-1.
PT. Federal Nittan Industries is a joint venture
company between Nittan Valve Co., Ltd. Japan and
PT. Astra Otoparts, which was established since July
1, 1995. PT. Federal Nittan Industries occupied a
new factory located at Jalan Halmahera-9 Block DD,
MM 2100 Industrial Estate, Cikarang Barat, Bekasi
17520 in 2009. The process of engine valves
manufacturing generally consists of forgings,
stellite, heat treatment and machining.
Some customers of PT. Federal Nittan
Industries are, Daihatsu, Honda, Yamaha, Suzuki,
and Hino. Increased sales of motor vehicles resulted
in increased demand for engine valve production
from customers. Referring to this, PT. Federal Nittan
Industries doing improvement on some machines.
One improvement is the engine which manufacture
snap gauge. Snap gauge is used for valve engine
dimensional inspection process which includes
examination of head, seat, keeper groove, and
carbon. Improvement would be done was on the
loaderoutput which was too short and created
difficulties for operators. In addition, too low
position of loader also affected the operators safety
and ergonomic levels in terms of spine health that
have long-term consequences. Turning to the
morality consequences, it reduced operator working
enthusiasm because in the process of valve engine
withdrawal operators must bend over or even squat.

Currently, PT. Federal Nittan Industries

conducted cost reduction program, in order to reduce
the expenses for the purchase of spare parts. So in
developing the device, it mostly utilized spare parts
were used or damaged spare parts so it use waste
parts which were no longer used that impact on
decreasing the expenses of spare parts purchasing.
The improvement included the increase of
penumatic cylinder as the up and down mechanism
of loaderoutput, so the loader height increased and
could facilitate operators in withdrawing snap gauge
valve. Up and down process of pneumatic cylinder
is automatic when loaderoutput is full. Of altitude
measurement data, snap gauge loaderoutput at all
line, the data obtained was that the snap gauge at line
6 had the lowest height of loaderoutput that tthe
author would do improvement at snap gauge line 6.
1.2
Research Questions
Based on the existing background, reseacrh
problems are formulated and discussed as follows:
1. How to create a mechanism to increase the
height of loader output?
2. How to create control system for loader output
so it can run automatically and safe?
3. How to create a device that is able to achieve
one or all of QCDSMPE (Safety, Quality, Cost,
Delivery,
Morality,
Productivity
and
Environment)?
4. How to create a device that is able to provide
low cost but high benefits for the company?
1.3

Limitation of Research
The final project was limited by several
things, namely:

1.

2.
3.
4.
5.

6.

Discussed the PLC program on automatic

loader output and did not discuss the program
on the main machine.
Discussed the cost of making the automatic
loader output.
Discussed device cabling of input and output
and PLCs.
Did not discuss mechanical calculations in the
manufacture of automatic loader output.
Did not discuss the calculation of electric, wind
pressure in the manufacture of automatic
loader output.
Did not discuss in detail the main engine i.e
snap gauge.

1.4
Objectives
The objectives of this final project were:
1. To improve operatorsproductivity of
machining C Line 6.
2. To improve ergonomics and safety in
withdrawing the part process engine valve after
the process of snap gauge.
3. To facilitate snap gauge operators works in
withdrawing the part process engine valve after
the process of snap gauge.
1.5 Benefits
The benefits of conducting this final project,
namely:
1. Increased the productivity due to the
withdrawal and putting back the part process of
valve engine becomes more efficient.
2. Increased safety and ergonomics for operators
when withdrawing and putting back part
process engine valve.
3. Reduced spare parts waste and spare parts
purchasing costs because in making of the
device was utilized used spare parts.
II.
Theoretical basis
2.1
Ergonomics
The definition of ergonomics in
Wignjosoebroto Sritomos book is: ergonomics
(English) actually comes from the Greek words of
Ergo which means work and Nomos which means
legal. Thus ergonomics is intended as a scientific
discipline that studies the human being in relation to
work. Ergonomics discipline in particular learns the
limitations of human ability to interact with
technology and products they make. This discipline
comes from the fact that human beings have
capability limits of both short term and long term
when dealing with environmental circumstances of
their system works in the form of hardware
(machinery, equipment, etc.) and software (working
methods, systems and procedures, etc.). Thus it is
clear that ergonomics is multi-disciplinary science,
because it learns knowledge from biological
(medicine, biology), psychological (psychology)
and society (sociology) sciences.

2.2

Snap Gauge
Snap gauge is a gauge or a measuring
device that is often used in the manufacturing
industry, especially the PT. Federal Nittan
Industries. Gauge is used for measuring the outside
dimensions of an object. This gauge framework is U
shaped and has the jaw with a measuring surface.
Snap gauge there is a fitting type (GO) and not
fitting type (NO GO). Figure II-1 shows a snap
gauge measuring instrument.

Figure II-1 Snap gauge

2.3

Loader
Loader is an entry or exit lane for the
engine valve to be processed in a machine or have
gone through a process to eventually be forwarded
to the next process. In figure II-2 loader output is
used in industry, especially at PT. Federal Nittan
Industries.

Figure II-2 Loader Output

2.4

Control System
The control system can be viewed as a
system in which an input or some specific inputs are
used to control the output at a specific value. A
control system can control various aspects such as
controlling a variable to obtain the desired value,
controls the sequence of events / processes and
control whether an event occurred or not. Basically
the control system used to control the sequence of
events. A control system consisting of input, the
control element / control and output. The basic
working principle of a control system can be called
a causal relationship between the input and output
components. The presence of an input signal makes
the system processes the signal so as provide the
system output. Simply, the basic working principle
of the control system shown in Figure II-3:

Input

Control
System

Output

Figure II-3 The working principle of the control

system

III.
3.1

Data Collection and Design

Snap Gauge
Snap gauge is a manufacturing machine
that is used to check sizes or dimensions of engine
valve. In this process the engine valve is measured
using a camera that is recording and matching it with
the data that has been previously setup. Figure III-5
shows display of panel screen while the machine is
performing measurements on part process.
At snap gauge, part process of the previous
process will go through loaderinput and come out
through loaderoutput. At the snap gauge line 6, the
condition of loaderoutput was too low so it was
difficult in withdrawing and putting back processes
on the tray. Figure III-1 shows a snap gauge machine
image at machiningline 6.

40cm

Figure III-2 Problems on loader output

From the measurements performed, the
average height of loader output in snap gauge was
40cm. Due to the low height of loader, it had caused
operators increasing levels of fatigue and lack of
enthusiasm so that affected the productivity of
operators during the work. PT. Federal Nittan
Industries assigned one operator for three machines,
so that the low position of loader made the operator
bend over when withdrawing the part process, this
lead to operators decreased morality in their
enthusiasm and level of fatigue. This bending
conditions also affected the level of operators
safety, in this case the spinal health due to they bend
over too frequent durig the work. Figure III-3 shows
the posture of an operator when withdrawing part
process.

Figure III-1 Snap gauge machine

Figure III-6 shows snap gauge engine parts,
the author did an improvement on the unloading or
outlet chute parts.
3.2

Problems occured
In the previous figure it has been described
that inprovement was done in the unloading or outlet
chute. On the current condition, the height of loader
on each line particular line 6 on the snap gauge was
too low. Before doing this improvement, the author
first conducted interviews with several operators in
the area of machining line 6, three people in three
shifts. Of the three operators who were interviewed,
they claimed that the low height of loader had caused
the decreasing performance of operators within one
working shift. Figure III-2 shows the loader and the
height of loader which was too low in average of
each line.

Figure III-3 Operator's posture

3.3

Specifications required
In the development of automatic loader
output the mechanical development, control systems
and PLC program must be tailored to the needs of
the field or work area. The specs are as follows:
1.

2.

In the development of automatic loader output,

additional height must be considered with the
current loader height which was 40cm from the
floor, so the minimum additional height is
25cm so that the operators do not have to bend
over in the withdrawing of engine valve.
This device must be flexible or can be used on
another machine if necessary.

3.

This device requires a control system which

has fixed or permanent settings, so that
operators can not change the setting so that the
device is able to work optimally without any
changes to the settings.
4. In developing this device, it should utilize
existing components and minimize the
purchase of components to fit the company's
program namely Cost Reduction Program.
5. The PLC used is a kind of compact PLC, where
the PLC used is OMRON CPM2A
6. In the event of damaged device, it should be
easy in troubleshooting or problem analysis.
7. This device should be run automatically by
simply pressing one button, and the device can
work continuously.
8. For the control system, the control panel used
is not too big so it does not need to add the
construction of the main engine.
9. Automatic loader output must be equipped
with an emergency stop button to avoid
possible accidents.
10. Automatic loader output must be equipped
with a manual operator switch used as an
instruction from the operator that the engine
valve has been drawn all and operators already
in a safe position.
3.4
3.4.1

Design
Design Making

5
2

electrical, pneumatic, and control are used as

supportings so that the device is able to work in
accordance with the desired working system that is
able to work optimally. The components required in
the development of automatic loader output and
their functions are shown in Table III-1.
Table III-1 Components required
Item
Number
Air Cylinder

Rotary Air Cylinder

Solenoid Valve

Speed Control

Relay 24VDC

Reed Switch

Lampu Indicator

MCB 2 Phase

Proximity Sensor

Push Button Operator

PLC

Selector Switch

Emergency Stop

IV.
4.1

Development and Testing

PLC Cabling
To activate the PLC Omron CPM2A using
a voltage type of 2 Phase with voltage of 220 VAC.
Both phases were connected to L1 and L2 / N ports
in order to enable the PLC Omron CPM2A. As for
the common input and output, they were given
positive voltage (24 V). Figure IV-1 shows the PLC
cabling.

Figure III-4 Design of automatic loader output

Description of figure III-11 is as follows:
1.
2.
3.
4.
5.

Loader with positions on the right and left.

Solenoid Valve.
Adjuster with knob to adjust the loader width.
Two pneumatic cylinder on the right and left in
accordance with the position of loader.
Guide is used to align the motion of the
cylinder stroke while ascend so it does not spin
or sway, using the former pneumatic cylinder
that has been damaged.

Components Design
To develop the device according to the
working system required in the field, it takes some
supporting components in the development of
automatic loader output. These components either

Figure IV-1 PLC cabling

3.4.2

4.2

Input Device Cabling

Table IV.1 is the input data used in Omron
PLC CPM2A to perform work functions of
automatic loader output. In the table below input

device used amounted to 10 devices which are

connected to 12 PLC addresses from 000 to 011.
Table 0-1 Data Input of PLC Omron CPM2A
N
Addres
Description
o
s
000
Selector Switch Manual
1
2

001

Selector Switch Auto

002

Selector Switch Man. Left

003

Selector Switch Man. Right

004

Emergency Stop

005

Operator Button

006

Sensor F.W 1

007

Sensor F.W 2

008

RS1 High

10

009

RS1 Low

11

010

RS2 Low

12

011

RS2 High

4.5
4.5.1

The Device Testing

PLC Input Testing
The way of PLC Input testing was done in
two ways, namely by connecting the PLC to the PC
and can see the indicator LED on the physical
display of PLC.
Testing was done by pressing the push
button, activated the selector switch, activated the
proximity switches, and activated the reed switches
on the cylinder. OK parameter when conducting the
test was if the activated input device would turn on
the indicator light located in the PLC according to
the address given to each device. PLC input device
test results are shown in Table IV-3.
Table IV-3 input device testing

4.3
Output Device Cabling
Table IV.2 shows the data outputs used in PLC
Omron CPM2A to perform work functions of
otomatic loader output.
Table 0-2Data Output of PLC Omron CPM2A
Address Description Solenoid
Cylinder
Relay 1
Solenoid Cylinder
1000
Valve 1
Kiri
Relay
2
Solenoid
Cylinder
1001
Valve 2
Kanan
Relay 3
Solenoid Cylinder
1002
Valve 3
Gate
4.4

Development of Pneumatic Systems

4.5.2

Output Device Testing

PLC output testing was done by connecting
PLC to the personal computer (PC) by monitoring
mode and see it directly through the existing LED
status on PLC and to see the change / movement of
the actuator used. PLC output test results are shown
in Table IV-4.
Table IV-4 Output device testing

Figure IV-2 Pneumatic Systems

In the figure IV-2, automatic loader output
consists of 3 pieces of pneumatic cylinder. Where
two of them are as right and left loader lifting, and
one of tem as a gate or output direct changer of part
process. This system used 2 single solenoid valves
5/2 and single solenoid valves 1 3/2.

4.5.3

Device Working System Testing

The device working system testing was
performed to know whether the machine working
system has worked well, and according to the
program that has been determined. The test results
are shown in Table IV-5.

Table IV-5 The device working system testing

V.
5.1

Conclusions and Suggestions

Conclusions
The development of automatic loader
output generates some conclusions that can answer
the research questions formulated and described in
Chapter I.
1.
2.

3.

4.

4.6
Evaluation after Device Development
4.6.1
Loader Height
After the development of automatic loader output,
the height of loader output increased, from the
previous height of 40cm and added with 25cm, the
height of the current strokecylinder is 65cm. Change
in height can be seen in Figure IV-3.

After the development of this device, the

height increased from 40 cm to 65 cm.
The development of this automatic loader
output used PLC Omron CPM2A with the
making of program which can be repeated
automatically, and there are also programs for
operator safety at work.
The development of this device affects the
safety, namely the addition of operator button
as the instruction that condition is safe. For
ergonomic, the device changes the posture of
operators at work.
The development of this device mostly used
spare parts and waste materials from both spare
part maintenance and from fabrication waste
material.

5.2

Suggestions
The development of the automatic loader
output is not yet ideal in its height increased, with
the ideal height should be 80cm or 40cm of
additional height, but because of the limited
pneumatic cylinders spare part it only can be added
for 25cm. Expectations after the development of this
device is the improvement made to add the height of
automatic loader output to be ideal and to facilitate
operators in the work.
REFERENCES
W. Bolton, Sistem Instrumentasi dan Sistem
Kontrol,Jakarta : Erlangga

Figure IV-3 The height differences before and after

device development
4.6.2

In Ergonomic and Safety

Figure IV-4 shows the results of the device
development that affects the position and work of
operator.

Robert Boylestad and Louis Nashelsky.1994,

Electronic Device And Circuit Theory Fifth
Ed.New Delhi.Eight Printing Prentice-Hall
of India Private Ltd.
Budi Susilo.2013,Rancang Bangun Simulator
Pneumatik Sebagai Alat Pemindah
Barang.Semarang
Wirawan Sumbodo.2008,Tekni Produksi Mesin
Industri.Direktorat PembinaanSekolah.
Menengah KejuruanKlaten.
Parr MSc., CEng., MIEE, MInstMC., Andrew,
2003, Hidrolika dan Pneumatika Pedoman
bagi Teknisi dan Insinyur Edisi
kedua.Jakarta: Erlangga.
Croser Peter, Ebel Frank.2002,Pneumatics Basic
Level.Festo Didactic

Figure IV-4 Differences in the posture of operator

Lehto Mark, Buck James.2008.Intoduction to

Human Factors and Ergonomics for

Engineering.United States
Mital, Kilbom, Kumar.2000.Ergonomics Guideline
and Problem Solving.London
Nurmianto, Eko. 1996. Ergonomi: Konsep Dasar
dan Aplikasinya.Surabaya.