PT.

KAYABA INDONESIA DOCUMENT NUMBER : FR-1111-W-001

PCM DEPT. ISSUE DATE : 10-01-2019
N0 DATE ITEM REASON START DONE BY TECH. ADV QA PROD. PROCESS ENG & MAINT

APPROVED BY APPROVED BY APPROVED BY APPROVED BY EVALUATED BY PREPARED BY

REVISION
FACILITY REQUIREMENT & EVALUATION SHEET
Sawano Andi K Edu A Andy MD Harijawan W Zainal A

For new product STANDARD AND RULES Drawings of related products REQUIRED DIMENSIONS OF EQUIPMENT NO DETAILED SPECIFICATION CHECK
EQUIPMENT NAME CO2 WELDING
For production increase Water Pollution Control Law Process ＦＭＥＡ sheet Robot Spesification

REFERENCE
Increase of efficiency Air Pollution Prevention Act Process plan sheet 1 Robot welding use OTC Daihen Almega AX-V6 (standart type)
INSTALLATION PLACE Line Under Bracket Complete 2 Robot repeatability ± 0.2 mm
Panel Side door

PURPOSE INSTALLATION

ENVIRONMENT
Quality improvement Noise Control Law Experienced fault table Operatio 3 Robot must have a safety fence device
n
Labor shortage Vibration Registration Law Standard work combination sheet 4 Robot must be able to display the position coordinates (for setting and correction)
MANUFACTURE QTY 1 MACHINE
In-house manufacture Fire Protection Law Layout drawing 5 Simple teaching for difficult movement (Using wire type pendant conection for program teaching)
BUDGET Thousand-yen Environmental improvement High-pressure regulation Machining condition table 6 Ambient temperature 30~40ºC
RESULT (As specified in completion report) Thousand-yen Safety measures Equipment accuracy table

DOCUMENT
INSTALLATION DATE Date: September 1, 2019 Process way change Operation Manual of Parameter Front Welding Cabin
door
MANUFACTURE NO. Date: Update Operation Manual of Machine 1 Robot covered welding cabin
MACHINE NO. Used outside company Industrial Safety and Health Law Dayli Check Sheet Welding Welding 2 Automatic front door with pneumatic system for loading & unloading (use steel plate)

SAFETY
Jig Robot
INVESTMENT NO. Space saving Robot Safety Standard Process Facility Requirement 3 Side sliding door for robot maintenance process
Description of system 4 Attached stairs and upper fence
5 Equipped with welding jig
REQUIRED VALUE <<Evaluation>> Checked by： Check date： ／

CHARACT JUDGEMENT RESULT Data No. Welding Power

REQUIRED QUALITY SPECIFICATION VALUE Ppk MESURING METHOD JUDGEMENT
.CLASS CRITERIA n x Ppk Press 1 Use OTC Daihen for Welding Power Source, Remote Controller and Wire Feeder
Servo
Welding Tensile Strength S 78400 N - Strength Test 2 Additional display ampere meter and Voltage meter at front machine
Bead height A Max 4mm - Dig. Caliper
MACHINING ACCURACY

Diameter of Welding S 30mm with No Oval - Dig. Caliper

CO2 Pneumatic System
No Sparter in Screw and shaft S Welding 1 No leak for conection system
Rotary 2 Use Air Regulator SMC
Transfer 3 Pneumatic Cylinder follow existing dimension
4 Use Festo/ SMC for pneumatic equipped with anti spatter pneumatic hose
Marking

Electric Control system

1 Use Fuji/ Mitsubishi for MCB and Contactor
2 Use PLC Omron for electric control
3 Use overload Current & Ampere welding
Work environment 4 Door & Exhaust fan control must be sinkron with welding controller
Noise max 85dB 5 Equipped interlock program

REQUIRED VALUE RESULT VALUE EXPLANATORY DRAWING OF PRODUCTS

EVALUATION ITEM
MIN MAX MIN MAX
Total Length Under Bracket Complete ( A ) 220 388
Diameter Of Stering Shaft ( B ) 25 30
PROCESS RANGE

UnderBracket Height ( D ) 25 80 Upper limit of width 1300 mm

PROCESS CAPABILITY

Width of Under Bracket ( F ) 60 100 Upper limit of height 2500 mm

Length of UnderBracket (G) 180 260 Upper limit of depth 2300 mm
Diameter Inner Under Bracket ( H ) 25 51 1) Equipment size, control panel, Starting
Switch position
Stering Shaft Height ( I ) 170 388
Height of Bead Welding 4 2) Motion of operator, work flow
3) Location of the divided equipment

Machine processing time 10 Sec Sec 4) Poistion of related equipment in arround

Manual work time 7 Sec Sec

Total time (including walking time) 17 Sec/pcs Sec REQUIREMENT ITEM OF QUALITY ASSURANCE/SAFETY AND CHECKING OF THESE ITEM Checked by: Check date: ／
Tact Time 31,8 sec No QUALITY ASSURANCE ITEM CONTENTS OF EQUIPMENT CHECK CONTENT (IJIWARU TEST) OPERATIONAL CONDITION JUDGMENT

Abnormal Pressure Control Sec Sec 1 Abnormal Welding Current & Voltage Welding Controll, Alarm Start after reduce setting condition Machine stop,Alarm Tower ligth
60
Change Jig Sec Sec 2 Abnormal CO2 gas Pressure Pressure switch Alarm Start after reduce CO2 Pressure Machine stop,Alarm Tower ligth
SETUP

Length (setting position change model) 60 Sec Sec Machine stop, Alarm red Tower ligth, buzer
3 Protection for operator Area sensor Something part in area proces
Sec Sec & information no alarm

Total time 120 Sec Sec 4 Emergency Stop

5 Reset original position
ITEM CONDITION VALUE MODEL NAME PRODUCT NAME PART NO
First side electricity voltage 380 (V) ± 10% (3 Phases)
Wire Welding Huwatong HTW-50 Ø1.2
MACHINING CONDITION

Gas Pure CO2 WORKING EQUIPMENT SPECIFICATION Note (know-how, etc.)

Power capacity 3 φAC 380 V KVA

EXPANATORY DRAWING

Air consumption 0.5 - 0.6 Mpa

Hydraulic source KW kgf/c㎡ L
Capacity
Width ㎜
<Requirements about durability/reliability> * Operation without fault is kept for 2 years after the equipment has been installed. (Primary target) Height ㎜
Depth ㎜
 EXPANATORY DRAWING
Weight
ton