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SAFETY EQUIPMENT

MAGHNETO HANDLE SAFETY GUARD


(MANODELASEGURIDAD)

ARRANGED BY:

ALTERI UMT
(Faculty of Industrial Engineering University of Muhammadiyah Tangerang)

1. YOGI PRASETIO ID Number 14-26-201-108


2. ZAINUR ROHMAN ID Number 14-26-201-166

INDUSTRIAL ENGINEERING STUDY PROGRAM

ENGINEERING FACULTY

UNIVERSITY OF MUHAMMADIYAH TANGERANG

Street of Perintis Kemerdekaan 1/33 Cikokol, Tangerang City

2016/2017
APPROVAL SHEET

SAFETY EQUIPMENT

MAGHNETO HANDLE SAFETY GUARD


(MANODELASEGURIDAD)

ARRANGED BY:

ALTERI UMT
(Faculty of Industrial Engineering University of Muhammadiyah Tangerang)

1. YOGI PRASETIO ID Number 14-26-201-108


2. ZAINUR ROHMAN ID Number 14-26-201-166

Approved
Tangerang, Desember 23th 2016

Chairman of the Industrial Supervisor and Mentor


Engineering Supervisor

Faculty of Engineering UMT

Tri Widodo, MT H. Joko Supono, MT.


STATEMENT OF AUTHENTICITY

Hereby declare that:


1. The design of this product is genuine and has not been mass produced in
Indonesia.
2. The design of this product pure ideas, formulation, and evaluation of our
team, without the help of other parties, except for the direction of a
supervisor and mentors.
3. In the design of this product there is no work or opinions that have been
written or published by others, except in writing clearly listed as a
reference in the script to the so-called name of the author and are listed in
the bibliography.
4. This statement we made with real and if there are irregularities in the
future and untruth in this statement then we are willing to accept the
sanction of the team organizers DESCOMFIRST.

Tangerang , Desember 23 th 2016


Who make a statement,

ALTERI UMT
ABSTRACT

In the industrial, usage of safety equipment required as mandatory. Based


on data Safety Departement at Metal manufacture in Tangerang there is high rate
accident namely hand pinched and even broken the hand of operator, mostly at
Stamping process. The purpose of this product design is to fulfill management
target achieve zero accident at stamping machine.
At stamping machine, process load and pick material still interact directly
between hand’s operator and machine. There is no safety equipment for hand’s
operator. High rate of worker's hand injuries become the main reason this
equipment has designed. Maghneto Handle Safety Guard (Manodelaseguridad)
designed by Alteri UMT Team is a suitable hand safety equipment to avoiding risk
hand’s injured at stamping process which is concern with metal material load
and pick at stamping machine. This equipment working principle is a magnetic as
the primary function to replace function of hand. Manodelaseguridad has suitable
specification with metal or alloy can be used in Metal industry with advantages:
simple design, ergonomic, economic cost & Eco-friendly
Cost of making 1 unit manodelaseguridad is IDR 77.233. Using
Manodelaseguridad at metal nindutry can increase productivity 24.05%,
productivity up also IDR 4,810,000, efficiency up to 1,3 second/cycle and could
reduce risk work accident achieve to zero accident at hand’s injured case.

Keywords: Descomfirst, Alteri UMT Team, Metal Industry, Manodelaseguridad,


ergonomic, hand’s safety equipment, zero accident, stamping machine
FOREWORD

AssalamualaikumWr.Wb.
Thank God we pray to Allah SWT. which has given mercy and grace so
that we can finish the race proposal Design Competition for Industrial System and
Environment (DESCOMFIRST) without a hitch. Sholawat and greetings
hopefully tercurahkan the great Prophet Muhammad.
The preparation of this proposal can be completed thanks and support and
a helping hand from various parties. And on this auspicious occasion the author
would like to thank:
1. Dr. H. Achmad Badawi, S.Pd., SE, MM. as Rector of Muhammadiyah
Tangerang University.
2. Saiful Haq, ST., M.Si. as Dean of the Faculty of Engineering, University
of Muhammadiyah Tangerang.
3. Rohmat Taufiq, M.Kom. as vice Dean of the Faculty of Engineering,
University of Muhammadiyah Tangerang
4. Tri Widodo, MT. as Chairman of the Industrial Engineering Department
for his guidance during the composer this paper to follow Descomfirst
event.
5. H. Joko Supono, MT. as mentors who helped prepare everything to follow
the event.
6. Both parents who have supported both morally and materially.
7. Friends - comrade in arms, which has helped the smooth preparation of
this proposal, Expecially Novita Pristiyani, ST..
In conclusion, the authors expect criticism and constructive suggestions for
the sake of this proposal perfect..
Tangerang, Desember 23 th 2016

Composer

i
LIST OF CONTENT
Cover
Approval Sheet
Statement of Auntheticity
Abstract
Foreword ................................................................................................................ i
List of Content ....................................................................................................... ii
INTRODUCTION .................................................................................................. 1
1.1. Background .................................................................................................. 1
Figure 1.1. Number of work accident Production process on Oct-Dec 2016 ....... 2
1.2. Problem Formulation ................................................................................... 2
1.3. Purpose ......................................................................................................... 2
CONTENTS OF PRODUCT DESIGN .................................................................. 3
2.1. Product Description and Visualization......................................................... 3
Figure 2.1 Manodelaseguridad with handling adapted human hand grip ............... 3
Figure 2.2 Manodelaseguridad with Height Adjuster Magnet ................................ 4
Figure 2.3 Manodelaseguridad Visualization ......................................................... 4
Figure 2.4 Visualization How it Works Manodelaseguridad ................................. 5
2.2. Product Specification ................................................................................... 5
Table 2.1. Specification detail of Manodelaseguridad ........................................... 5
Figure 2.5. Manodelaseguridad Dimension ........................................................... 6
2.3. Estimation Cost Making of Manodelaseguridad .......................................... 7
Detail estimation cost of making Manodelaseguridad seen on Table 2.2. .............. 7
Table 2.2. Estimation Cost of Manodelaseguridad Production ............................. 7
2.4. Product Advantages ..................................................................................... 8
2.5. Productivity and Efficiency Up .................................................................... 9
Table 2.3. Comparation Productivity Before and After Using Manodelaseguridad 9
Table 2.4. Comparation Efficiency Cycle Time Before and After Using
Manodelaseguridad ............................................................................................... 10
CONCLUSSION ................................................................................................... 11
BIBLIOGRAPHY ................................................................................................. 12
CURRICULUM VITAE ....................................................................................... 13

ii
INTRODUCTION
1.1. Background
In the industrial, usage of safety equipment required as mandatory. Safety
equipment includes one implementation of occupational safety and health (K3).
K3 is a thought and effort to ensure the integrity and perfection of both body and
spirit. That the occurrence of workplace accidents is largely due to human factors
and a small part due to technical factors. That in order to ensure the safety and
health of the workforce and other persons at work, as well as production sources,
production processes and working environment in a safe condition, it is necessary
to apply the Occupational Safety and Health Management System (PerMen
No.05/MEN/1996). Usage of safety equipment intended to protect the safety of
workers and the environment in order to improve the effectiveness and
productivity results are expected. Additional safety equiment is intend to
protecting the body portion of workers from the possibility of potential accidents
and as preventive the risk of work accidents.
The paradigm of Human factor engineering and occupational Ergonomic’s
in industrial engineering study state that in order to create a high productivity at
work. Whether it is equipment factor or environtment must be fitted to the needs
of humans and their work activities (Descomfirst, 2017).
Design Competition for Industrial System and Environment
(DESCOMFIRST) is one event race national level organized by the Faculty of
Engineering, University of Sebelas Maret Surakarta used to promote and develop
innovation and creativity of the students at the Industrial Engineering Indonesia
are concentrated in product design / equipment that can be useful in industry,
which includes manufacturing and services.
With the event of the competition encourages innovation and creativity of
students at the University of Muhammadiyah Tangerang with Team Alteri UMT
(Faculty of Industrial Engineering University of Muhammadiyah Tangerang) to
download the design safety equipment which is a subtheme of Descomfirst.
Selection of this sub-theme due to the prevention of occupational accidents
industries.

1
PT XYZ is one of metal manufacture locate in Tangerang. Based on data
Safety Departement, figure 1.1 describe number of works accident in main
production process at PT XYZ for October-December 2016.
5
4
3
2
1
0

STAMPING WELDING
PAINTING CHROME

Figure 1.1. Number of work accident Production process on Oct-Dec 2016


From figure 1.1. Stamping process has the most work accident. In
percentage rate of accident stamping process is 67% with 4 times work accidents,
Welding process is 17% with 1 work accident, Painting process has 0 accident,
and Chrome process is 17% with 1 work accident. Kind of work accident in
stamping process are hand pinch (3 times) and broken fingers (1 time).
Regarding to target management in safety and health occupational to
achieve zero accident, and level up productivity and efficiency to increase
company’s competitiveness, Alteri team design a hand safety equipment to reduce
risk hand injured for workers at stamping process. Hand safety equipment named
by Alteri team with MANODELASEGURIDAD which is acronym of Magneto
Hand Safety Guard.
1.2. Problem Formulation
Based on the description of the background which has been described,
problem formulation could be define as follow:
1. What kind of hand safety equipment could eliminate work accident in
Stamping Process ?
2. How much productivity and efficiency could be resulted?
1.3. Purpose
The purpose of the product design Magneto Handle Safety Guard
(Manodelaseguridad) by ALTERI UMT is as follows:
1. To Create hand tools safety which is could reduce or eliminate work accidents.
2. To Calculate the productivity and efficiency by implementation
Manodelaseguridad.

2
CONTENTS OF PRODUCT DESIGN

2.1. Product Description and Visualization


Maghneto Handle Safety Guard or called by Manodelaseguridad designed
by ALTERI UMT Team is a product designed as safety equipment by using
magnets. Manodelaseguridad used in industrial manufacturing, especially in the
stamping process where the risk of workplace accidents during the production
process is. Manodelaseguridad is a product specifically designed to replace the
function of the hand at the time of the production process. These products are
used for safety in the transfer of product / part is made of metal. The products are
designed with the handling adapted to structural human finger so it is used in
industry as well as ergonomically designed with height adjustment magnet that
can adapt to the needs of adhesion magnets used for releasing the product. The
products are also designed an innovative, attractive, and economical and easily
affordable.

Figure 2.1 Manodelaseguridad with handling adapted human hand grip


Source: base on Alteri team research, 2017

Design Manodelaseguridad with handling that has been adapted to


structural human fingers and adapted to the extremely ergonomic lever so as to
provide comfort and safety for the user Manodelaseguridad.

3
Figure 2.2 Manodelaseguridad with Height Adjuster Magnet
Source: base on Alteri team research, 2017

Manodelaseguridad design with height adjustment magnet is very helpful


in releasing-right part/product. This is due to the differences in the magnetic
adhesion required to lift a load. For example, for a light load of course will require
adhesion magnets are smaller than with a heavier load. if there is no adjuster
magnet, then a light load will be difficult to be released.
Manodelaseguridad is one of the innovations Safety Equipment by Alteri
UMT Team with various advantages that can be visualized as follows:

Figure 2.3 Manodelaseguridad Visualization


Source: base on Alteri team research, 2017

4
Push handle by
Pull up thumb
of part Push Pull up
handle of part
by
thumb

Release

Release

Figure 2.4 Visualization of how to Manodelaseguridad works


Source: base on Alteri team research, 2017

2.2. Product Specification


Dimensions of Manodelaseguridad are follows length 240 mm, weight of
manodelaseguridad product 192,51 grams, load maximal that can carried 750
grams, weight of magnetic chip 6,30 grams and force of magnet 3026 GS.
Manodelaseguridad specification are as seen in Table 2.1

Table 2.1. Specification detail of Manodelaseguridad


A. Magnet chip
1. Weight of magnet chip : 6.30 grams
B. Product Manodelaseguridad
1. Weight of product : 192.51 grams
2. Length of product : 240 mm
3. Force of magnet chip in product *) : 3026 GS
4. Max. load lifted **) : 750 grams
Source: base on Alteri team research, 2017
*) based on External test No. 17008/MI-GV and
**) based on trial
Material used in Manodelaseguridad consist of:
a. Permanent magnet chips
b. Stainless
c. Bold, nuts, rings, spring
d. Kamper wood

5
6

Figure 2.5. Manodelaseguridad Dimension

Source: base on Alteri team research, 2017


2.3. Estimation Cost Making of Manodelaseguridad
Detail estimation cost of making Manodelaseguridad seen on Table 2.2.
Table 2.2. Estimation Cost of Manodelaseguridad Production

2
Actual Actual price
No Material spec Unit Plan (mm ) 2 Presentation Price (IDR) Information
(mm ) (IDR)
1 Plate Strip Stainless type 201 3 mm x 30 mm x 6M 1 rod 180.000 1.800 1,00% 150.000 1.500 Rod
2 Plate Stainless type 201 1,22 M x 2,44M 1 sheet 2.976.800 27.000 0,91% 2.500.000 22.675 Release lever and stoper
3 Maghnet ø 15 mm t 5mm 1 unit 15.000 15.000 Magnet
4 Kamper wood 40 mm x 60 mm x 6M 1 rod 14.400.000 45.450 0,316% 72.000 227 Handle
5 4pcs 1.500 6.000
7

Bold L M4 x 25 mm
6 Nuts M4 3pcs 3.500 10.500
7 Ring 3pcs 500 1.500
8 Spring 1pcs 2.000 2.000
Total 59.403
Overhead 30% 17.821
Total cost 77.223

Source: Data processing, 2017

As a note, thickness of Stainless Steel is 1,5mm and kind Magnet that used is permanent magnet because it can last longer than temporary
magnet. Base on calculation on Table 2.2 cost of making 1 unit Manodelaseguridad is IDR 77.223,00
2.4. Product Advantages
Manodelaseguridad the safety equipment products have special advantages
and specifications. Manodelaseguridad advantages are as follows:
1. Safety
Manodelaseguridad is one of the safety equipment, which means safety is
the primary objective of such products. This tool is used for the safety of
hands at the making of metal material at the time of the engine output is
ergonomically designed. And to Avoiding Risk of worker’s hand injured,
Manodelaseguridad made regarding to OHS for worker.

2. Innovations
Products Manodelaseguridad by Team Alteri UMT is designed with new
innovations with the main function of the hand with the principle of
magnetic safety. Manodelaseguridad made especially for Stamping
process which is interact with metal material.

3. Aesthetics
Design concern to ergonomic and comfortable especially for metal
manufacturing industries and also simple design.

4. Affordable
Cost of making is economical value compare with functional. Cost only
arround IDR 77.233/unit. And for details could seen at table 2.2.

5. Easy to realize
This product is simple design with material commonly so very easy to
realize.

6. Eco Friendly
Manodelaseguridad product is safety equipment products that are
environmentally friendly because it is designed Made by Not harmful and
easy recycle material.

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2.5. Productivity and Efficiency Up
One of purpose Manodelseguridad has designed is to achieve productivity
and efficiency up at stamping process. Comparation before and after using
Manodelaseguridad in stamping production could seen on Table 2.3.

Table 2.3. Comparation Productivity Before and After Using


Manodelaseguridad
BEFORE AFTER
Productivity
No Date Output (Pcs) Productivity (%) Date Output (Pcs)
(%)
1 Nop 1, 16 7.580 94,75 Apr 1, 17 9501 118,76
2 Nop 2, 16 7.580 94,75 Apr 2, 17
3 Nop 3, 16 7.590 94,88 Apr 3, 17 9502 118,78
4 Nop 4, 16 7.588 94,85 Apr 4, 17 9512 118,90
5 Nop 5, 16 7.563 94,54 Apr 5, 17 9502 118,78
6 Nop 6, 16 Apr 6, 17 9500 118,75
7 Nop 7, 16 7.580 94,75 Apr 7, 17 9500 118,75
8 Nop 8, 16 7.580 94,75 Apr 8, 17 9500 118,75
9 Nop 9, 16 7.580 94,75 Apr 9, 17
10 Nop 10, 16 7.580 94,75 Apr 10, 17 9509 118,86
11 Nop 11, 16 7.580 94,75 Apr 11, 17 9507 118,84
12 Nop 12, 16 7.583 94,79 Apr 12, 17 9509 118,86
13 Nop 13, 16 Apr 13, 17 9508 118,85
14 Nop 14, 16 7.580 94,75 Apr 14, 17
15 Nop 15, 16 7.582 94,78 Apr 15, 17 9510 118,88
16 Nop 16, 16 7.582 94,78 Apr 16, 17
17 Nop 17, 16 7.586 94,83 Apr 17, 17 9510 118,88
18 Nop 18, 16 7.581 94,76 Apr 18, 17 9510 118,88
19 Nop 19, 16 7.582 94,78 Apr 19, 17 9509 118,86
20 Nop 20, 16 Apr 20, 17 9510 118,88
21 Nop 21, 16 7.580 94,75 Apr 21, 17 9506 118,83
22 Nop 22, 16 7.580 94,75 Apr 22, 17 9500 118,75
23 Nop 23, 16 7.582 94,78 Apr 23, 17
24 Nop 24, 16 7.580 94,75 Apr 24, 17
25 Nop 25, 16 7.580 94,75 Apr 25, 17 9500 118,75
26 Nop 26, 16 7.580 94,75 Apr 26, 17 9506 118,83
27 Nop 27, 16 Apr 27, 17 9510 118,88
28 Nop 28, 16 7.580 94,75 Apr 28, 17 9500 118,75
29 Nop 29, 16 7.581 94,76 Apr 29, 17 9500 118,75
30 Nop 30, 16 7.580 94,75 Apr 30, 17
Average 7.581 94,76 9505,26 118,82

Source: Alteri team research, 2017

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1. Based on data at Table 2.3. about enhancement productivity in % can see
before using this equipment productivity is 94.76% and after using this
equipment the productivity is uping up to 118,82%. It’s mean
enhancement productivity is 24.05% .
2. Based on data at Table 2.3 about enhancement productivity in IDR there
are:
a. Before using Manodelaseguridad can produce part average 7,581 pcs
in November 2016 and after using can increase become 9,505 pcs in
April 2017. It is means enhancement produce or output is 1,924 pcs.
b. Selling price part 1 pcs is IDR 2,500.
c. Enhancement productivity in IDR = 1,924 pcs x IDR 2,500
= IDR 4,810,000/ month
Table 2.4. Comparation Efficiency Cycle Time Before and After Using
Manodelaseguridad
CYCLE TIME (SECOND)
EXPERIENCE BEFORE AFTER
1 3 1,7
2 3 1,6
3 3 1,8
4 3 1,7
5 3 1,7
6 3 1,7
7 3 1,7
8 3 1,7
9 3 1,7
10 3 1,7
11 3 1,7
12 3 1,7
13 3 1,7
14 3 1,7
15 3 1,7
16 3 1,7
17 3 1,7
18 3 1,7
19 3 1,7
20 3 1,7
Average 3 1,7

Source: Alteri team research, 2017

Based on observation, cycle time before using manodelaseguridad is 3


second and after using manodelaseguridad is 1,7 second. There is efficiency 1,3
second / cycle.

10
CONCLUSSION

1. Maghneto Handle Safety Guard or called by Manodelaseguridad designed


by ALTERI UMT Team is a suitable hand safety equipment to avoiding
risk hand’s injured at Stamping Process which is concern with metal
material load and pick at machine. This equipment working principle is a
magnetic as the primary function to replace function of hand.
Manodelaseguridad has suitable specification with metal or alloy can be
used in Metal industry with advantages: simple design, ergonomic,
economic cost & Eco-friendly

2. Rate of work accident at stamping process could reduce to zero accident


by implement Manodelaseguridad at stamping process.

3. Estimation Cost of making 1 unit Manodelaseguridad is IDR 77.233,00


Using Manodelaseguridad at metal Industry could increase productivity up
to 24.05% or convert to IDR is Rp 4,810,000/month, efficiency up to 1.3
seconds/cycle.

11
BIBLIOGRAPHY

Puspitasari, 2014. Analysis and Proposed Improvement Safety and Health


Management System (SMK3) At PT. Fumira Semarang, Industrial
Engineering Online Journal, Vol. 3 No. 3: Semarang.
Regulation of the Minister of Manpower No.05/MEN/1996 on Occupational
Safety and Healty Management
http://descomfirst.ft.uns.ac.id/

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CURRICULUM VITAE

GROUP/TEAM ` : ALTERI UMT

MEMBER :2

1. Name : Yogi Prasetyo

Student ID Number : 14-26-201-108

Faculty/Major : Industrial Engineer

University : University of Muhammadiyah Tangerang

Phone : 0812-9734-9524

Email : yogibrahmastha31@gmail.com

STUDENT ID CARD

13
2. Name : Zainurrohman

Student ID Number : 14-26-201-166

Faculty/Major : Industrial Engineer

University : University of Muhammadiyah Tangerang

Phone : 0857-7655-3321

Email : zainurrohman17@yahoo.com

inurohman31@gmail.com

STUDENT ID CARD

14