Dharma Polimetal - SBU Automotive Component

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We are an ISO TS/16949 : 2002 company, as Tier 1 Automotive supplier in Indonesia

We are an ISO TS/16949 : 2002 company, as Tier 1 Automotive supplier in Indonesia

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  • 1. PT DHARMA POLIMETAL SBU : Automotive COmponent
  • 2. Vision :
    • “ Being innovative, Striving for the best and Contributing to the stakeholders are our commitment to be a world class manufacturing company”
    PT Dharma Polimetal is a group of business in metal-based manufacturing, mostly contribute to OEM’s of Motorcycle/Automotive industries in Indonesia Background :
  • 3. Name Dharma Polimetal, PT Headquarters JL Raya Serang, Km 24, Balaraja Tangerang Indonesia, 15610 Telp. 62-215951635 Dharma Groups
    • PT Dharma Polimetal
      • SBU Automotive Component
      • SBU Supermarket, Industrial Equipment (Trolley, Industrial Pallet, etc)
      • SBU Healthcare Equipment (Wheelchair, Bloodpressure Kit, etc)
    • PT Dharma Precission Mould (Dies,Mould,Jig)
    • PT Dharma Electrindo Manufacturing (Automotive/Motorcycle Wiring Harness)
    • PT Dharma Controlcable Indonesia (Automotive/Motorcycle Control Cable)
    • PT Dharma Poliplast (Plastic Parts/ Products)
    • PT Dharma Precission Parts (Precission Machining Parts)
    • PT Dharma Precision Tools (Special Precission Cutting Tools)
    • ASCHO
    Established 29 Maret 1989 Sales Turnover 2007 US $ 50,000,000 Group Sales Turnover 2007 US $ 110,000,000 President & CEO Theodore Permadi Rachmat Board of Director Irianto Santoso I Wayan Putraka Philipus Naftali E.A Zakaria Yosaphat Simanjuntak Sutejo Halim Employees
    • Dharma Polimetal : 2446 person
      • Automotive Comp Business Unit : 1520 person
  • 4. Continue.. Consolidated subsidiaries 8 (as of December 31, 2007) Main Products 4Wheeler : Underbody Crossmember, Guard Cabin Back, Pipe Exhaust (Truck), Seat Frame Component & Seat Hinges, Subassy Bracket, Bolt Special 2Wheeler : Frame Body Comp, Muffler Comp, Wheel Rim, Stepbar/Stand Comp, Steering Handle Comp, Swing Arm Comp, Bolt Special (Axle Bolt) Others : Metal Finishing - Zinc Plating, NiCr Plating, CED Black, Powder coating Major Clients Astra Honda Motor, Astra Daihatsu Motor, Armada Johnson Controls, Indomobil Suzuki Int’l, Tri Dharma Wisesa (Akebono), Nissan Motor Indonesia, Kayaba Indonesia, Showa Mfg Indonesia
  • 5. MANAGEMENT SYSTEM
    • Certification :
    • ISO/TS 16949 : 2002 (Quality Management System)
    • ISO 14001 : 2004 (Environment Management System)
    Certificate No. : IATF 20030 ENVIRONMENTAL SYSTEM Certified Environmental Management ISO 14001 Lic : 10042
  • 6. Our Current Customers
    • 4 Wheeler:
    • Astra Daihatsu Motor/TMMIN
    • Indomobil Suzuki Int’l (2 Wheel & 4 Wheel)
    • APM Armada Autoparts (AAA)/Armada Johnson Controls (AJC)
    • Korindo Heavy Industry
    • Nissan Motor Indonesia (Under Development)
    • Inti Panca Press Industry (IPPI)
    • Metal Finishing :
    • Tri Dharma Wisesa (TDW)
    • Kayaba Indonesia
    • Showa Mfg Indonesia
    • 2 Wheeler:
    • Astra Honda Motor
    • Indomobil Suzuki International
    • Kawasaki Motor Indonesia
    • Kanzen Motor Indonesia
  • 7. Competency Base
    • Stamping Press Work (Range: 35 T - 500 T)
    • CNC/NC Bending Work
    • Welding Assy Manual
    • Welding Assy Robotic
    • Jigs & Fixtures / CF Design & Making
    • Small & Medium Automotive Component
    • Automotive Seat Components
    • Motorcycle Muffler & Frame Body
    • Metal Finishing Process (NiCr / Zinc Plating / Painting / Powdercoat, ED Paint)
  • 8. New Product Development Procedure Feasibility Study Material Incoming Procedure of Product Preparation Distribution of PPAP, FMEA, PQCS, BOM, "Quality Standard" MassProd "OJT" Drawing/ sample product Costing Product By Eng SBU Product Analyze Draft Time Frame Draft Investasi Draft Flow Process Plan Board Of Project (BOP) Team Planning Facility preparation plan Project plan Bill Of Material Sample Tools Process Making Material Preparation Tools & Product Preparation Facility & Equipment Preparation Sample Making Draft FMEA Draft PQCS Draft Quality Standard Quality Document PP1 Evaluation of PP1, CP, FMEA, PQCS PP2 Evaluation Of PP2, CP, FMEA, PQCS CUSTOMER
  • 9. Strenght of Our Team : Resources Personel Remarks Business & Product Dev 6 Person Product Quality Engineer 16 Person Lead Eng=3; Technician=13 Process & Tools Dev 19 Person Design Process = 6 Design Tool = 5 Tool Eng = 8 Process Engineer 44 person Lead Eng = 3 ; Technician = 41 Welding Engineer 3 Person Certified from “API” – B4T Industrial Engineer 6 Person Quality Assurance 35 Person QA Project;Process Auditor; Product Auditor; Our Subsidiary Company Mould Designer 4 Person Dharma Precision Mould Dies Designer 4 Person Dharma Precision Mould Dies Engineer 3 Person Dharma Precision Mould
  • 10. Dharma Polimetal Lay Out (120,000 Sq Meters) 2W/ Frame & Comp Rim & Fastener Muffler & Plating
  • 11. List of Current Machines and Equipment No DESCRIPTION Qty SPECIFICATION MAKER A CUTTING               1 Shearing Machine 2 Units 1200 mm x 2400 mm, t = 8 mm   Japan 2 Circulaw saw     Base on Need       B STAMPING               1 Press Machine 35 T 2 Units 850 mm x 400 mm , Die Height = 220 mm Taiwan 2 Press Machine 40 T 2 Units 700 mm x 460 mm , Die Height = 120 mm Taiwan 3 Press Machine 60 T 7 Units 950 mm x 500 mm , Die Height = 260 mm Japan/Taiwan 4 Press Machine 80 T 11 Units 1000 mm x 550 mm , Die Height = 310 mm Japan/Taiwan 5 Press Machine 100 T 3 Units 1150 mm x 600 mm , Die Height = 330 mm Japan 6 Press Machine 110 T 1 Units 1150 mm x 600 mm , Die Height = 330 mm Taiwan 7 Press Machine 160 T 1 Units 1250 mm x 800 mm , Die Height = 430 mm Taiwan 8 Press Machine 260 T 2 Units 1500 mm x 840 mm , Die Height = 500 mm Japan 9 Press Machine 300 T 1 unit 1600 mm x 960 mm ,Die Height = 670 mm Japan   10 Press Machine 450 T 1 Unit   2400 mm x 1300 mm Die Heigh 800 mm England C Assembly               1 Robot Welding   45 Units 6 Axis     Japan 2 Argonshield /Brazing     Depends on needs     Japan 3 Spot Welding Gantry 1 Units Dagensha     Japan 4 Spot Welding Fix Type 15 Units       Taiwan 5 Riveting Machine 2 Unit Small and big size Taiwan D BENDING               1 CNC Bending   15 Units OD = 1 - 2 Inch     Taiwan 2 NC Bending   7 Units OD = 1 1/2 - 3 Inch     Taiwan
  • 12. No DESCRIPTION Qty SPECIFICATION MAKER E METALFINISHING             1 Nickel Chrome Plating 1 Unit Double Layer Nickel, Carousel Type   USA H x W x L = 1200 mm x 400 mm x 700 mm 2 Nickel Chrome Plating 4 Unit Tri Layer Nickel, Center Anode Gate Type   Taiwan H x D = 1800 mm x 1000 mm   3 Zinc Plating 2 Unit Carousel Type, Color : Yellow, Green, White Taiwan H x W x L = 900 mm x 200 mm x 400 mm   4 Painting 2 Units Spray & Dipping Paint   Local H x W x L = 1500 mm x 200 mm x 400 mm 5 Powder Coating 1 Unit Electrostatic Spray     Local H x W x L = 1500 mm x 200 mm x 400 mm 6 Shoot Blasting 3 Unit For Muffler, using steel ball Taiwan 7 CED Painting 1 Factory Metal Finishing Process for Frame Body & Automotive Component   OK   Feb ’ 06 Operation F Workshop   For Regular Dies/Jig/Tools Maintenance   1 Milling   5 Units SM 3 , SM 5     Japan/Taiwan 2 Lathe   2 Units 1500 mm x 2000 mm   Taiwan 3 Cylindrical Grinding 1 Unit D 50mm x 100mm 4 Surface Grinding 1 Units 650 mm x 300 mm   Taiwan
  • 13. New Investment Planning 2009 G Quality Facility 1 Universal Testing machine 1 Units Tensile, Bending, Breaking elongation test, etc 2 Polishing machine 1 Units For material testing 3 Metallurgy Microscopic/Hardness Test/Profile Projector 1 1 1 Units For material testing/Welding Penetration 4 Concentricity & Straightness Mc 1 Unit For Bolt & Nut Checking 5 SST & Thickness Tester 2 Unit 6 Faro 3D Measuring Arm 1 Unit Brand : FARO 67 CNC Lay Out Machine Wenzel 1.2 m x 2.5 m No DESCRIPTION Qty SPECIFICATION REMARKS A Manufacturing               1 4 Wheel Factory 2 ’ nd Step 1 Line 4 Wheel Plant - Completing Lay out (Stamping Line) Start Dec 2008 2 Stamping Press 500 T 1 Unit Add on 4 Wheel Plant (Under Negotiation) Jun 2009 3 Stamping Press 350 T 1 Unit Add on 4 Wheel Plant (Under Delivery) Install Nov 08 4 Stamping Press 250 T 1 Unit Add on 4 Wheel Plant (Under Negotiation) Jun 2009 5 Stamping Press 160 T 1 Unit Add on 4 Wheel Plant (Under Negotiation) Jun 2009 6 New Welding Line 1 Line Add on 4 Wheel Plant 7 Robot Welding 6 Unit OTC Oct 2008 8 Spectrometer 1 Unit Add on Metallurgy Laboratory
  • 14. Quality Facility
  • 15. 3 D FARO Arm Measuring & Wenzel Layout Machine Faro 3D Arm Wenzel CNC Layout Mc
  • 16. Metallurgy Lab. Test Precise Cutting Casting & Polishing Metallurgic Microscope Hardness Test Univ/Tensile Test Profile Projector
  • 17. Metal Finishing Test Salt Spray Test Thickness Test
  • 18. List of Measurement tools availability:
    • 3D Measurement
    • Welding Penetration
    • Hardness (Rockwell/Vickers)
    • Tensile Strenght
    • Photo Micro
    • Salt Spray Test/Cast Test
    • Plating/ Painting Thickness Test
    • Glossmeter
    • Torque Wrench
    • Welding Output amperemeter
  • 19. Product Line Up
    • AUTOMOBILE CROSSMEMBER
    • AUTOMOBILE DAIHATSU PARTS,
    • SEAT COMPONENTS FRAME & MECHANISM
    • STAMPING & WELDING COMPONENT
    • FRAME BODY FOR HONDA MOTORCYCLE
    • WHEEL RIM
    • MOTORCYCLE MUFFLER (HONDA, KAWASAKI, SUZUKI)
    • REAR GRIP (HONDA, SUZUKI)
    • CHAIN CASE
    • WHEEL LOCK
    • MOTORCYCLE FOOT REST & STEERING HANDLE
    2 WHEEL PARTS : 4 WHEEL PARTS :
  • 20. 4 WHEEL COMPONENT Suzuki APV P.U - Cross Member Comp Tail APV - Insulator Deck side; Press 250 T Press 80 T s.d 260 T Carry Futura – Cover Radiator Upper, Press 250 T
  • 21. 4 WHEEL COMPONENT Suzuki APV Pick Up – Cross Member Fuel Tank Suzuki APV Pick Up - Guard Comp Cabin Back
  • 22. 4 WHEEL COMPONENT Suzuki APV Pick Up - Cross Member Leaf Hanger Daihatsu Zebra - Br. Assy Mounting
  • 23. 4 WHEEL COMPONENT Zebra - Reinf Fr. Side Member LH Zebra - Panel Heat Roof Mach 110 T Mach 250 T
  • 24. Some of RUSH/TERIOS Part (Total : 14 Item) R/f Transport Hook R; Press 60T Rf Center Body Pillar R/L; Press 80 T Rf Rocker Panel No 4 R/L; Press 400 T Patch Floor Side Member R/L; Press 110 T
  • 25. Some of D40D/D88 NEW GranMax (Total 46 Item) XMbr Subassy Frame no 2 Plate Sub-asy Rr Floor Finish Support Parking Brake Lever Assy Bracket Cable Support 1 Bracket Cable Support 2
  • 26. PT AAA PARTS – X 11J Panel Sub 2’nd Seat Back RH Panel Sub 2’nd Seat Back LH Bracket Sub-assy Inner 2’nd Seat Back Panel Sub 2’nd Seat Cushion RH Hinge Subassy 3 rd seat outer RH/LH Hinge Sub assy Center 2’nd Seat
  • 27.
    • STEEL WHEEL RIM
    • SIZE 17 x 1.2” * SIZE 17 x 1.4”
    • SIZE 17 x 1.6” * SIZE 14 X 1.4”
    • SIZE 14 X 1.6’
    FRAME BODY COMP 2 WHEELS PARTS
    • HONDA - TIGER 2000
    • HONDA - MEGA PRO/GL PRO
    • HONDA - WIN
  • 28. Motorcycle Muffler HONDA - Muffler New Supra Fit SUZUKI - Pipe Comp Exhaust Shogun 125SP
  • 29. HONDA - Muffler Supra X 125 Kawasaki - Muffler Kaze ZX130 HONDA – Muffler New Tiger 2000
  • 30. REAR GRIP HONDA Supra X Finishing = NiCr Plating HONDA Supra Fit Finishing = Powder Coating HONDA -Astrea Grand Finishing = Powder Coating
  • 31. GRAB RAIL CHAIN CASE Supra X 125 New Supra Fit Shogun 125 XFD Rubber Injection with inside Steel Reinforcement
  • 32. Motorcycle Parts Sub Frame Assy Footstep Assy In Complete assy unit
  • 33. Metal Finishing Process A. Nickel Chrome Plating
  • 34. Metal Finishing Process B. Zinc Plating Acid and Alkali Zinc Plating
    • MF Cr 3 +
    • MF Cr 6+
    Loading Capacity : ± 50 %
  • 35. ROBOT WELDING 45 Units Welding Process (Manual / Automatic / Robotic) Some Figures of our Facility & Production Line
  • 36. Stamping Press 300 T Stamping Press 450 T
  • 37. CNC Bending Line 15 Units CNC
  • 38. CED Painting Line – Black Top Coat
  • 39. Loading Area Masking Treatment ED Paint Unloading Area E.D PAINT PROCESS
  • 40. Fastener Factory Heading & Threading Washing Furnace/Chamber Tempering
  • 41. Dharma Precision Mould
    • Dies Manufacturing Support
    • Jig and Checking Fixture manufacturing
    • Special Purpose Machinery and Equipment manufacturing
    • Injection And Casting Mould
    • Location : Dharma Polimetal Area
    Tools Making Support :
  • 42. High Speed CNC Milling Machine High Precision Process CNC Milling Machining CNC EDM Machining High Speed CNC Milling Machine
  • 43. Machine List CNC Milling Machine 4 Units CNC Lathe Machine 2 Units NC Mill Machine 3 Units EDM Machine
    • Units
    Wirecut Machine
    • Unit
    Milling Machine 10 Units Lathe Machine 2 Units Furnace Harden
    • Unit
    CMM Measurement
    • Unit
    Surface Grinding 4 Units
  • 44.
    • Contacts : Johannes Soelistyo (Marketing Specialist – Mgr)
    • Email : [email_address]
    • [email_address]
    • Mobile: 62-811944190