FINAL YEAR

PROJECT
PAPER COMPACTOR
PREPARED BY :
MUHAMMAD HAIQAL BIN MANSOR
NUR AISHAH BINTI DAUD

INTRODUCTION
Waste paper compactor machine is a machine use in industry to reduce the size of
waste paper. Commonly the function of this machine is shredded paper and reduces
the size of paper trough compaction. This machine is used in recycling industrial
waste. For the process this machine is divided into three processes.

Shredder
Compaction
Sealing
Heating and shrinking

PROBLEM STATEMENT

The machine totally malfunction since 2010

The cost of maintenance vendor is too high
Having defect combination of electrical and mechanical inside the system
Existing PLC programming
Too long and hard too understand
Hydraulic not function
Not have manual book
Take time to study

OBJECTIVE
Identify defect electrical and mechanical element of the system
Rectify defect element of the system
Prepare manual of the system

LITERATURE REVIEW
JOURNAL TITLE

METHOD

RELIABILITY CENTERED MAINTENANCE

System selection and data collection

System boundary definition
System description and functional block
System function and functional failures
Failure mode effect analysis
Logic tree diagrams
Task selection

PREVENTIVE MAINTENANCE

Maintenance Theories
Mathematical model
Framework

LITERATURE REVIEW
JOURNAL TITLE

METHOD

EQUIPMENT MAINTENANCE PLAN

Type of work
Procedure number
Estimated time to perform the task
Special tool, material and equipment to perform the task

FAULT FINDING

Define problem area

Identify possible causes
Determine most probable cause
Test and repair

CORRECTIVE MAINTENANCE

Study technical document

Identify the possible cause
Estimated time to perform task
Test and repair

METHODLOGY
MECHANICHAL
Method used is fault finding
Brainstorming
Ishikawa diagram or fishbone diagram

Organize and carry out various action allowing to check the assumption
Diagnostic form

Diagnose and carry out the corrective action

FISHBONE

DIAGNOSTIC FORM

OBJECTIVE
Rerun the system with new PLC program (Grafcet)
Create SCADA Layout.
To complete manual of machine.

LITERATURE REVIEW
JOURNAL TITLE

METHOD

FREE TRANSFER SYSTEM

Identify method for detect the condition of devices.

Study method of create Grafcet

COMPACTEUSE DE DECHETS PAPEIR

Study the sequent of waste compactor machine.

CX-Programer

create program using Grafcet

CJ1M manual

PLC

METHODOLOGY
Study process sequence for each process
Construct a ladder diagram
Separated it into division and construct GRAFCET
SHREDER AND BLOWER
COMPACTER HYDRAULIC & OUTLET
SEALING
HEATING AND SHRINK

RESULT AND DISCUSSION

Rewiring the power circuit, PLC circuit and control circuit related with
first objective from hardware side .

Improvement on technical document

The machine can running in proper sequence

RESULT AND DISCUSSION

Upgrade the ladder diagram to Grafcet programming

ALPHA TESTING
TESTING

RESULT(SHRINK PROCESS)

1ST

2 MIN

2ND

3MIN

3RD

5MIN

OUTPUT RESULT

TEST 3

TEST 2

TEST 1

VIDEO

CONCLUSION

The machine can rerun follow the sequence using new PLC program.
Reduce the department maintenance cost

Testing the capability to handle the project

To finish the project based on Gantt chart
Be one of student that expert in automation technologies

RECOMMENDATION
ADD NETWORK CARD TO PLC
HYDRAULIC MAINTENANCE EVERY MONTH
CAN USE AS GO GREEN PROJECT

THANK YOU