Design Semi-Automatic Control System using PLC for Stalling Materials in the Forming Machine

Abstract

This research was conducted in Manufacturing Industry in Indonesia. The company, especially at the Plant, does the TPM (Total Productive Maintenance) activity carried out by a small group of various divisions, especially maintenance. Maintenance implements these results into the LOR (Line Operation Ratio). LOR standards is set by the company is 85%. So it can be made the target of a higher LOR future. For it must lower the existing downtime. Downtime highest Fin Forming machines are Dandori Models that are equal to 2,608 minutes or about 9.30% of LOR. Standard downtime allowed 5% of LOR. In the process, dandori models required a process of stretching aluminum material manually along with the crank process forming roller. In this process the operator must perform movement to the uncoiler machine to stretch the material and the operator moves to the forming to crank on forming roller. There is no time which required operators to perform movements from the uncoiler to forming. We design a special controller using the PLC (Programmable Logic Controllers) to turn on the motor servo feed rollers on the fin forming machine. The material can move automatically when operators do crank forming roller, and the operator does not need to move to the position of the engine to stall uncoiler material reels manually.