PT.

KAYABA INDONESIA DOCUMENT NUMBER : FR-1116-O-002

PCM DEPT. ISSUE DATE : 15-02-2019
N0 DATE ITEM REASON START DONE BY TECH. ADV QA EHS MAINT PROD. PROCESS ENG & MAINT
APPROVED BY APPROVED BY APPROVED BY APPROVED BY APPROVED BY APPROVED BY EVALUATED BY PREPARED BY

REVISION
FACILITY REQUIREMENT & EVALUATION SHEET
T Sawano Hasoloan M Jefri A Heri Subhan Edu A Andy MD Harijawan W Zainal A

Auto Press, Weld & Mark U/B For new product STANDARD AND RULES Drawings of related products REQUIRED DIMENSIONS OF EQUIPMENT NO DETAILED SPECIFICATION CHECK
EQUIPMENT NAME
Comp For production increase Water Pollution Control Law Process ＦＭＥＡ sheet General View Machine -Press Servo

REFERENCE
Increase of efficiency Air Pollution Prevention Act Process plan sheet 1 Press process use servo press, part must use DAIICHI DENTSU brand
INSTALLATION PLACE Line Under Bracket Complete 2 All pneumatic part must used FESTO/ SMC brand

PURPOSE INSTALLATION

ENVIRONMENT
Quality improvement Noise Control Law Experienced fault table 3 Pneumatic operating pressure designed Max 4,5 Kgf/cm2
Press
Labor shortage Vibration Registration Law Standard work combination sheet Servo 4 All machine body plate use solid plate (no hollow)
MANUFACTURE QTY 1 Unit
In-house manufacture Fire Protection Law Layout drawing IN 5 Setting body machine use adjuster pad min L : 100 mm
BUDGET Thousand-yen Environmental improvement High-pressure regulation Machining condition table 6 Equipped with confirmation sensor for Total Leght Under Bracket Complete
RESULT (As specified in completion report) Thousand-yen Safety measures Equipment accuracy table 7 Equipped with mechanic confirmation for Key Hole position Steering Shaft
Rotary CO2

DOCUMENT
INSTALLATION DATE Date: August 1, 2019 Process way change Operation Manual of Parameter Table Welding 8 Equipped with Load Press working value confirmation & displayed in monitor
MANUFACTURE NO. Date: Update Operation Manual of Machine 9 Equipped interlock program
MACHINE NO. Used outside company Industrial Safety and Health Law Dayli Check Sheet 10 Double push button for start operation

SAFETY
INVESTMENT NO. Space saving Robot Safety Standard Process Facility Requirement OUT 11 Use sensor area for safety operation
Marking
Description of system 12 Painting use Kayaba cream
13 Install independent operation panel at each process and one main panel
REQUIRED VALUE <<Evaluation>> Checked by： Check date： ／ 14 Use PLC system for control all squence
CHARACT MEASURING JUDGEMENT RESULT Data No. 15 PLC and other electrical part must use OMRON brand (except PB, E/S, selector switch, lamp use FUJI)
REQUIRED QUALITY SPECIFICATION VALUE Ppk JUDGEMENT
.CLASS METHOD CRITERIA n x Ppk 16 MCCB, MCB, Contactor, Overload Protector (power management) must used FUJI or Sneider brand
-Press Servo 17 Each of end movement of mechanism must install confirmation sensor
Length St Shaft to Under Bracket A 319,5 ±0,2 1,67 Height Gauge Visual 18 Must design warning alarm system for probability system fault
Key Hole Angle A 44° ± 1° - Rotary Bevel Visual

Slitting Angle A 0° ± 0,5° - Rotary Bevel Visual - CO2 Welding

MACHINING ACCURACY

Detection Slotting Position A - Pin Locater Sensor 1 Robot welding use OTC Daihen Almega AX-V6 (standart type)
Key Hole Height A 130 ±0,5 - Dig. Caliper Visual 2 Robot repeatability ± 0.2 mm
Detection Load Press Force B min 0,5 ton - Load Cell Visual 3 Robot must have a safety fence device
All surface Bracket & St Shaft B No Scratch - Visual 4 Robot must be able to display the position coordinates (for setting and correction)
- CO2 Welding 5 Simple teaching for difficult movement (Using wire type pendant conection for program teaching)
Welding Tensile Strength S 78400 N - Strength Test 6 Ambient temperature 30~40ºC
Bead height A Max 4mm - Dig. Caliper Visual 7 Use OTC Daihen for Welding Power Source, Remote Controller and Wire Feeder
Diameter of Welding S 30mm with No Oval - 8 Additional display ampere meter and Voltage meter at front machine
No Sparter in Screw and shaft S 9 Use overload Current & Ampere welding
- Marking 10 Robot covered welding cabin
Marking Type Dot marking styluss - Visual 11 PLC and other electrical part must use OMRON brand (except PB, E/S, selector switch, lamp use FUJI)
Height of font 2.5 - 3 - 12 MCCB, MCB, Contactor, Overload Protector (power management) must used FUJI or Sneider brand
Work environment 13 Use overload Current & Ampere welding
Noise <85 dB 14 Door & Exhaust fan control must be sinkron with welding controller
15 Nagara switch for start operation
REQUIRED VALUE RESULT VALUE EXPLANATORY DRAWING OF PRODUCTS
EVALUATION ITEM
MIN MAX MIN MAX - Marking
Total leght Under Bracket Complete (A) 220 388 1 Use COUTH brand for marking machine
Diameter of Steering Shaft (B) 25 30 2 Easy to change jig marking when changing models
PROCESS RANGE

Under Bracket Heigt (D) 25 80 Upper limit of width 2800 mm 3 Easy to operate the controller of marking machine
PROCESS CAPABILITY

Width of Under Bracket (F) 60 100 Upper limit of height 2500 mm 4 Double push button for start operation
Leght of Under Bracket (G) 180 260 Upper limit of depth 3000 mm
Diameter Inner Under Bracket (H) 25 51 1) Equipment size, control panel, Starting
Switch position
Steering Shaft Height (I) 170 388
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 31,26 sec Welding area No QUALITY ASSURANCE ITEM CONTENTS OF EQUIPMENT CHECK CONTENT (IJIWARU TEST) OPERATIONAL CONDITION JUDGMENT

Abnormal pressure control Sec Sec 1 Abnomal Pressing Pressure Program to check load, ala Start without material Machine stop, Alarm red Tower ligth & buzer
60
Change Jig Sec Sec 2 Abnormal Flow Process PLC module, alarm Start press m/c then start press m/c again Machine stop, Alarm red Tower ligth & buzer
SETUP

Leght (Setting position changemodel) 60 Sec Sec 3 Abnormal Total Leght U/B Complete PLC module, alarm Check use sample in manual operation Machine stop, Alarm red Tower ligth & buzer
Sec Sec Marking area 4 Abnormal Key Hole position S/Shaft PLC module, alarm Start with reverse Key Hole position S/ShaftMachine stop, Alarm red Tower ligth & buzer
Total time 120 Sec Sec 5 Abnormal Welding Current & Voltage Welding Controll, Alarm Start after reduce setting condition Machine stop,Alarm Tower ligth
6 Abnormal CO2 gas Pressure Pressure switch Alarm Start after reduce CO2 Pressure Machine stop,Alarm Tower ligth
ITEM CONDITION VALUE MODEL NAME PRODUCT NAME PART NO 7 Abnormal position grooving S/Shaft PLC module, alarm Start with reverse position grooving Machine stop, Alarm red Tower ligth & buzer
-Press Servo Machine stop, Alarm red Tower ligth, buzer
8 Protection for operator Area sensor Something part in area proces
3 phase 380 V ±10% & information no alarm
First side electricity voltage
Servo press stroke 250 mm 9 Emergency Stop
MACHINING CONDITION

Servo press load capacity 20 ton 10 Reset original position

- CO2 Welding
First side electricity voltage 3 phase 380 V ±10%
Wire Welding Huwatong HTW-50 Ø1.2
Gas Pure CO2 WORKING EQIPMENT SPECIFICATION Note (know-how, etc.)
- Marking Power capacity 3 φAC 380 V KVA
EXPANATORY DRAWING

First side electricity voltage 2 phase 220 V ±10% Air consumption 0,5-0,6 Mpa
- Rotary Table Hydraulic source KW kgf/c㎡ L
First side electricity voltage 3 phase 380 V ±10% Capacity
<Requirements about durability/reliability> * Operation without fault is kept for 2 years after the equipment has been installed. (Primary target) Height ㎜
Depth ㎜
Weight ton
PT. KAYABA INDONESIA
PCM DEPT.

FACILITY REQUIREMENT & EVALUATION

SHEET

NO DETAILED SPECIFICATION CHECK

- Rotary Table
1 All machine body plate use solid plate (no hollow)
2 Setting body machine use adjuster pad min L : 100 mm
3 Equipped 4 arms for material transfer (1 cycle rotation is 90 degress)
4 Equipped Press Jig in each arms
5 Equipped confirmation sensor grooving Steering Shaft
6 Equipped fence machine for safety operation
7 Equipped interlock program
8 Equipped counter operation
9 Painting use Kayaba cream
10 Install independent operation panel at each process and one main panel
11 Use PLC system for control all squence
12 PLC and other electrical part must use OMRON brand (except PB, E/S, selector switch, lamp use FUJI)
13 MCCB, MCB, Contactor, Overload Protector (power management) must used FUJI or Sneider brand
14 Each of end movement of mechanism must install confirmation sensor
15 Must design warning alarm system for probability system fault

Safety Device
1 Double push button for start operation in press and marking station
2 Nagara switch for start operation in welding and rotary table station
3 Use sensor area for safety operation in each station
4 Emergency push button in each station
PT. KAYABA INDONESIA
PCM DEPT.
FACILITY REQUIREMENT & EVALUATION
SHEET
NO DETAILED SPECIFICATION CHECK

1 Cycle Flow

Work Unloading & Loading

0
Start Sw ON

Rotary run 1 cycle (90°)

Treatment NG
Pressing ・ Cycle stop
・ Clamp cylinder closed
・ Show abnormal monitor
NG ・ Red light tower lamp sign
Press MC check
・ Monitor HMI display NG
OK ・ Reject by operator (identifikasi)
・ Cycle original position (HOME)
Rotary run 1 cycle (90°)

CO2 Welding

Rotary run 1 cycle (90°)

Marking

Rotary run 1 cycle (90°)

Work Unloading & Loading

PT. KAYABA INDONESIA DOCUMENT NUMBER : FR-1110-A-002
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 U/B Comp. Press MC
For production increase Water Pollution Control Law Process ＦＭＥＡ sheet General View Machine GENERAL

REFERENCE
Increase of efficiency Air Pollution Prevention Act Process plan sheet 1 All machine body plate use solid plate (no hollow)
INSTALLATION PLACE Line Under Bracket Complete 2 Setting body machine use adjuster pad min L : 100 mm

PURPOSE INSTALLATION

ENVIRONMENT
Quality improvement Noise Control Law Experienced fault table 3 Equipped with confirmation sensor for Total Leght Under Bracket Complete
Labor shortage Vibration Registration Law Standard work combination sheet 4 Equipped with mechanic confirmation for Key Hole position Steering Shaft
MANUFACTURE QTY 1 Unit Under
In-house manufacture Fire Protection Law Layout drawing Bracket 5 Equipped with Load Press working value confirmation & displayed in monitor
BUDGET Thousand-yen Environmental improvement High-pressure regulation Machining condition table Steering 6 Equipped interlock program
Shaf
RESULT (As specified in completion report) Thousand-yen Safety measures Equipment accuracy table 7 Double push button for start operation

DOCUMENT
INSTALLATION DATE Date: August 1, 2019 Process way change Operation Manual of Parameter 8 Use sensor area for safety operation
MANUFACTURE NO. Date: Update Operation Manual of Machine 9 Painting use Kayaba cream
MACHINE NO. Used outside company Industrial Safety and Health Law Dayli Check Sheet

SAFETY
INVESTMENT NO. Space saving Robot Safety Standard Process Facility Requirement SERVO PRESS & PNEUMATIC SYSTEM
Description of system 1 Press process use servo press, part must use DAIICHI DENTSU brand
2 All pneumatic part must used FESTO/ SMC brand
REQUIRED VALUE <<Evaluation>> Checked by： Check date： ／ Layout Line U/B Comp 3 Pneumatic operating pressure designed Max 4,5 Kgf/cm2
CHARACT JUDGEMENT RESULT Data No.
REQUIRED QUALITY SPECIFICATION VALUE Ppk MESURING METHOD JUDGEMENT
Press
.CLASS CRITERIA n x Ppk Servo ELECTRICAL SYSTEM
Length St Shaft to Under Bracket A 319,5 ±0,2 - Height Gauge 1 Install independent operation panel at each process and one main panel
MACHINING ACCURACY

Key Hole Angle A 44° ± 1° - Rotary Bevel 2 Use PLC system for control all squence
Slitting Angle A 0° ± 0,5° - Rotary Bevel CO2 3 PLC and other electrical part must use OMRON brand (except PB, E/S, selector switch, lamp use FUJI)
Welding
Detection Key Hole Position A Right location - Pin Locater 4 MCCB, MCB, Contactor, Overload Protector (power management) must used FUJI or Sneider brand
Key Hole Height A 130 ±0,5 - Dig. Caliper Rotary 5 Each of end movement of mechanism must install confirmation sensor
Transfer
Detection Load Press Force B min 0,5 ton - Load Cell 6 Must design warning alarm system for probability system fault
All surface Bracket & St Shaft B No Scratch -
Marking

Work environment
Noise <85 dB

REQUIRED VALUE RESULT VALUE EXPLANATORY DRAWING OF PRODUCTS

EVALUATION ITEM
MIN MAX MIN MAX
Total leght Under Bracket Complete (A) 220 388
Diameter of Steering Shaft (B) 25 30
PROCESS RANGE

Under Bracket Heigt (D) 25 80 Upper limit of width 600 mm

PROCESS CAPABILITY

Width of Under Bracket (F) 60 100 Upper limit of height 1700 mm

Leght of Under Bracket (G) 180 260 Upper limit of depth 800 mm
Diameter Inner Under Bracket (H) 25 51 1) Equipment size, control panel, Starting
Switch position
Steering Shaft Height (I) 170 388
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 31,26 sec No QUALITY ASSURANCE ITEM CONTENTS OF EQUIPMENT CHECK CONTENT (IJIWARU TEST) OPERATIONAL CONDITION JUDGMENT

Abnormal pressure control Sec Sec 1 Abnomal Pressing Pressure Program to check load, ala Start without material Machine stop, Alarm red Tower ligth & buzer
60
Change Jig Sec Sec 2 Abnormal Flow Process PLC module, alarm Start press m/c then start press m/c again Machine stop, Alarm red Tower ligth & buzer
SETUP

Leght (Setting position changemodel) 60 Sec Sec 3 Abnormal Total Leght U/B Complete PLC module, alarm Check use sample in manual operation Machine stop, Alarm red Tower ligth & buzer
Sec Sec 4 Abnormal Key Hole position S/Shaft PLC module, alarm Start with reverse Key Hole position S/Shaft Machine stop, Alarm red Tower ligth & buzer
Total time 120 Sec Sec Machine stop, Alarm red Tower ligth, buzer
5 Protection for operator Area sensor Something part in area proces
& information no alarm

ITEM CONDITION VALUE MODEL NAME PRODUCT NAME PART NO 6 Emergency Stop

First side electricity voltage 3 phase 380 V ±10% 7 Reset original position
250 mm
MACHINING CONDITION

Servo press stroke

Servo press load capacity 20 ton WORKING EQIPMENT 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 ㎜
Weight ton
PT. KAYABA INDONESIA
PCM DEPT.

FACILITY REQUIREMENT & EVALUATION

SHEET
NO DETAILED SPECIFICATION CHECK

1 Easy set Up jig and change model for ergonomics manner

• Set up jig all model
• Inspection Key Hole

2 Standart for Data Operation Panel

• Set up data download otomatic with input code item model
• Setting data for each model

・Length Shaft
・Total length shaft Assy (and + tolerance)
・Length STD Jig
・Inspection Load
• Data Set up mesin

・Parameter servo press

・Off set reference point machine and reference point press

Detail Maintenance Spec

1 Placement for part machine must consider maintenance aspect, replacement, control, etc
• Easy uninstall and enough space for servo press replacement
• Easy to calibration servo press
2 Design must be consider when spare part replacement or overhoul
3 for all actuator must use the correct SW
4 Speed adjuster for all actuator must be easy to control
5 For all actuator, proximity, photoelectric SW must installed name plate ( IO number, name,Etc)
at each SOL must installed name plate too
6 Nipple grease installed at convenient place
7 Wirring for moveable part must protection from broken and easy to change
8 Relay box, Cable bare placed at correct condition
9 At control panel add identity power (kVA) and machine weight
10 Part sensor, area sensor not interfere operator movement