PENGEMBANGAN PROSES PRODUKSI

DI PT INKA (PERSERO)
MENUJU INDUSTRY 4.0

KULIAH UMUM
UNIVERSITAS NEGERI JEMBER
4 September 2019

PT Industri Kereta Api (Persero)

Jl. Yos Sudarso No.71, Madiun, East Java, Indonesia
Telp. +62 351 452271-74 | Fax +62 351 452275 | Email: sekretariat@inka.co.id

1
PT INKA (Persero)
PROFILE

2
 COMPANY PROFILE
VISION
To be a world-class manufacturer of rolling stock and urban MISSION
transportation products in Indonesia
Creating integrated solution for railway and urban transportation with
business competitive superiority and proven technology to support
sustainable transportation development

Status : State Owned Enterprise (SOE)

Employees : ± 850
Land Area : 22.5 Ha
Production Facilities : +/- 660 Machineries, jigs and
facilities
Engineering Facilities : CAD and CAE system, test
equipment
Business Activities : - Rolling stock manufacturing &
Diversification
- Overhaul and heavy maintenance
- After sales support
Annual Production : - 400 passenger coaches
Capacity - 1000 freight wagons
- 40 diesel multiple units
- 30 locomotives
- 186 LRT

3
MARKET SHARE
PRODUCT
FREIGHT WAGON
PRODUCT
LOCOMOTIVES
PRODUCT
Electric Multiple
Unit (EMU)
PRODUCT
PASSENGER
COACH

PRODUCT
REGIONAL
TRANSPORT

PRODUCT
LRT

PRODUCT
Special Vehicles

4
 POTENTIAL MARKET
Passenger Coach
Bangladesh
PGC & Passenger Coach
Malaysia

Ballast Wagon
Thailand
Amerika DMU
Phillipines
Myanmar
Mesir Well Wagon
Singapore
Senegal NigeriaSudan
Sri Lanka
Zambia

Mozambik

Wagon Center Part

Australia

(Potensial Customer)

(Negara mengoperasikan Produk INKA)

5
ROAD MAP INKA (1982 – 2030)
CABLE WAYS

LORI LISTRIK OTOMATIS

KERETA WISATA
HIGH SPEED TRAIN

HIGH SPEED TRAIN

ARTICULATED BUS 350 km/jam

EPC Product MIDDLE SPEED TRAIN

160 km/h
MSA, Service dan Retail 250 km/jam standard
Product Diversification MIDDLE SPEED TRAIN
160 Km/h
gauge
Main Product for Domestic Market
Main Product for Export Market DRIVERLESS TRAIN Narrow Gauge
Component LRT

KRD Carbody Alumunium

KRL LOCOMOTIVE
DRIVERLESS
KERETA ARGO TECHNOLOGY
KA PENUMPANG SPEED OF 160 REMOTE RELIABILITY &
KM/HOUR MAINTENANCE MANAGEMENT
SYSTEM

AC PROPULSION SYSTEM
ON BOARD SYSTEM

1982 1984 1992 1995 2016 2017 2018 2019 2020 2022 2023 2030

6
 INKA Corporate
INKA Group
IT Restructuring
- SAP Full control all module 2020
- Preparation & implementation - SAP for PLANNING &
manufacture 4.0 MONITORING
- INKA Group IT integration system - Paperless Drawing Ouput
(Blue print & Implementation) Teknologi s/d Produksi
- Implementasi Full Scale di (Implementation)
Workshop AC - Manufacture 4.0 :
- SAP IMPLEMENTATION - Preparation for
- PAPERLESS Drawing - SAP IMPLEMENTATION Procurement Machine
(Preparation) - SAP HR Management & Tools
- PAPERLESS Drawing - Implementasi
(Implementation) Workshop AC
- INKA Group IT integration 2021
system (Mapping business 2019
- SAP for PLANNING - SAP for PLANNING &
proses)
- Paperless Ouput Teknologi s/d CONTROLLING
Produksi (Implementation) - Manufacture 4.0 :
- Manufacture 4.0 : - Manufacturing 4.0
SAP FIRST
- Mapping Production implementation
LAUNCHING
tool and machine - Set Up new Production
- SAP HR Management : Plan
2018
- Personal Recording
- SAP for PLANNING
- Personal Performance
- Paperless Ouput Teknologi Group
- Career Path
s/d Produksi (preparation)
- Personal Database
Target End of 2018 - Blue Print Business Process 2020
- ERP IMPLEMENTATION 2021
ERP PREPARATION

2020 7
2010 2018 2019 2021
 IT Restructuring
Ready Society 5.0

IT Integrated
System
for Production Plan

Fully Automatic New Workshop Ready

Robotic Welding
HR Management Manufacture 4.0

SAP
Mass
AC Production

Industry 4.0
On Board
System Existing Workshop RnD
Hightech
Compone
Remote Reliability & Center for:
Maintenance Management
nt
System - Product Ready 5.0
- Process Ready 4.0
Supply Sub Full
Labour Simple Assembly Assembly
Part

2010 2020 2030

8
9
ENGINEERING ANALYSIS, DETAIL DESIGN & PRODUCTION TECHNOLOGY
Software Analisa Intensitas Cahaya

Software Simulasi Dinamik Bogie Software Simulasi Dinamik Bogie

CAD : 3D, 2D, PRO-E, INVENTOR, 3D MAX

10
 PENGENALAN DIAGRAM ALUR KERETA
KERETA Carbody Shell
(General Arrangement)

Installation

Carbody Set
Exterior & Interior

Bogie

11
 PENGENALAN DIAGRAM ALUR KERETA
CARBODY SHELL Underframe
Front Part
Bolster
Midle Part
Floor Construction
Supporting Frame
Sidewall Welded Duct
To Carbody Set Welded Bracket

Frame work & Ext. Sheating

Welded Duct
Welded Bracket
Body End
Frame work & Ext. Sheating
Gangway
Welded Duct
Welded Bracket

Roof Frame work & Ext. Sheating

Frame Work Of Ceiling
Welded Duct
Welded Bracket

Partition
Assembly DN
Optional (bisa LN/DN)
Frame Work
Welded Duct
Lokal/Dalam Negeri 12
Welded Bracket
 PENGENALAN DIAGRAM ALUR KERETA
BOGIE

To Generall BOGIE Bogie Frame Bogie Frame

Arrangement
Welded Bracket

Wheel Set Assy Axle 8607.19.00.00

Wheel 8607.19.00.00

Axle Box Axle Box

Bearing 8607.19.00.00

Primary
Spring 7320.20.90.00
Suspension
Spring Seat
Scondary
Spring 7320.20.90.00
Suspension
Dumper 8607.19.00.00

Brake
TB398 Equipment

Painting & Painting

Marking Marking
Carbody
Centre Pivot
Conection
Side Bearer
Assembly DN
Optional (bisa LN/DN)
Lokal/Dalam Negeri
13
Import
PRODUCTION FACILITY

 Type : CNC PRESS BRAKE

 Brand : ERMAKSAN
 Max Thickness of work sheet: 16 mm
 Bending length : 4100 mm

14
PRODUCTION FACILITY

 Type : CNC LASER

CUTTING
 Brand : TRUMPH
 Max Thickness of work sheet : 6 mm up to 12
mm
 Max cutting length : 3050 mm

15
PRODUCTION FACILITY

 Type : STRETCH FORMING

 Brand : SASEBO
 Max/min. distance between jaws: 6000/500 mm
 Max/min. die length for 180 degree bend : 3500/2000 mm
 Tension cylinder stroke : 750 mm

16
 PRODUCTION FACILITY

CNC INDIRECT SPOT WELDING ROOF

CNC INDIRECT SPOT WELDING SIDEWALL

17
 PRODUCTION FACILITY

CNC PLANO MILLER

CNC MILLING

18
PRODUCTION FACILITY

BOGIE LOAD TEST

CAR LIFTER 19
INKA MENUJU INDUSTRI 4.0

20
Sejarah Revolusi Industri

21
Karateristik Industry 4.0

• Komunikasi Real-time: Operator,

Mesin dan Perangkat dapat
bertukar informasi secara instan.
• Informasi Digital: pengirim dan
penerima, adalah sebuah mesin.
• Automatisme: sistem logika harus
digunakan untuk memungkinkan
pengoperasian otomatis mesin atau
seluruh pabrik.

22
 INKA INDUSTRI 4.0 GOALS
PRODUCT

Speed Vibration Passenger Experience

Temperature

Engine
Passenger Information
AC Wheel
Room
Door
Equipment Inverters
Performance
Brake System
23
Industry 4.0 Implementation
Manufacture 4.0

24
Industry 4.0 Implementation
Manufacture 4.0

Smart Plant Information System

Smart Office System

Smart Maintenance System

Smart Integrating Business System

25
Industry 4.0 Implementation
Manufacture 4.0

Smart Plant Information System

WORKSHOP AC INKA

26
 Industry
Manufacture 4.0
4.0 Implementation
1.Operator log in
Smart Plant Information System
2.Benda kerja log in
3.Konfirmasi proses mulai
4.Konfirmasi proses selesai
5.Benda kerja log out
6.Proses diulang dari (2)
sampai tidak ada benda
kerja lagi
7. Operator log out

Catatan: selama proses pengelasan berlangsung, Power

Consumption Module akan mencatat penggunaan energi listrik
27
 Industry
Manufacture 4.0
4.0 Implementation
Smart
Data yangPlant Information System
diperoleh
• Operator in - out
• Benda kerja in - out
• Peralatan produksi on - off
• Proses mulai - selesai
Informasi yang diperoleh a.l.:
a. Durasi kerja efektif & non-
efektif operator
b. Informasi tenaga kerja di
workshop (jumlah, siapa)
c. Durasi proses efektif &
non-efektif benda kerja
d. Durasi penggunaan peralatan
produksi (akumula f → umur
peralatan, proses perawatan,
tarif mesin)
e. Penggunaan sumber daya pada
peralatan produksi
f. Jumlah produk yang dihasilkan
g. Work in process di workshop
h. Lokasi operator, benda kerja di
workshop
i. Prosentasi progress pembuatan
produk
28
 Industry 4.0 Implementation
Manufacture 4.0

Smart Plant Information System

AVAILABILITY EQUIPMENT (PRODUCTION MACHINE)

29
 Industry 4.0 Implementation
Manufacture 4.0

Smart Office System PAPERLESS

INKA MOBILE
4 5

2
13

RFID ATTENDANCE

SPPD DINAS

INKA MOBILE
SISTEM
PARKIR 30
 Industry 4.0 Implementation
Manufacture 4.0

PAPERLESS
Smart Office System
E-DCR & LOG BOOK

31
 Industry 4.0 Implementation
Manufacture 4.0

PAPERLESS
Smart Maintenance System MSA

32
Industry 4.0 Implementation
Manufacture 4.0

Smart Integrating Business System PAPERLESS

AUTODESK VAULT

33
 TERIMA KASIH

PT Industri Kereta Api (Persero)

Jl. Yos Sudarso No.71, Madiun, East Java, Indonesia
Telp. +62 351 452271-74 | Fax +62 351 452275 | Email: sekretariat@inka.co.id

34