We concern on Cost Down themes

1. Nama : Faizal Amri
NRK : T0993
Dept : Die Casting / MTN - Dies
Re-use Plug Core Pin 12200-RB0-1114

2. Contents List
• On Job Training Schedule
• Themes Selection Improvement
• Background, Objective and Target
• Current Analys #1
• Current Analys #2
• Improvement Schedule
• Plug Core Pin Part A Design
• Actual Condition
• Flow Process Plug Pin Modification
• Inspections
• Summary and Next Improvement
Page 1

3. No Item
2012
Nov Des Jan Feb Mar Apr Mei
I II III IV I II III IV I II III IV I II III IV I II III IV I II III IV I II III IV
1 Training at Body Plant
2 Training DC Departemen
3 Maintenance Dies Section
4 Penelitian Thema Improve
5 Pembuatan Improvement
6 Evaluasi 3 OJT (6 bulan)
1-3 Bulan
 Training proses produksi LPDC & HPDC, maintenance dies, maintenance, quality control
 Spare Parts Inventory Data Collections
 Insert Pin Inventory Data Collections
 PIN Inspections every change Dies
4-6 Bulan
 Trial coating with HLP
 Spare Parts Inventory Data Collections
 Insert Pin data from Engineering
On Job Training Schedule Page 2

4. Maintenance Dies Die Casting Page 3
Seksi dies maintenance adalah seksi yang bertanggung jawab terhadap perawatan dies, sehingga bisa
mendukung kesiapan untuk proses produksi di Dept. Die Casting.
Tugas
• Melakukan proses perawatan/maintenance dies yang ada di die casting
• Melakukan kontrol terhadap ketersediaan spare parts dies seperti : insert pin, core pin dll.
• Melakukan perbaikan terhadap kerusakan yang ada pada dies ( crack, die chipped, dll ).
• Memonitor terhadap life time parts dies dan timing penggantiannya.
• Melakukan analisa dan action/countermasure terhadap lost time yang terjadi akibat problem dies

5. Themes Selection Improvement Page 4

6. 18 Point 12 Point 21 Point
VALUE :
1 = POOR
2 = ENOUGH
3 = GOOD
4 = EXCELLENT
5 = PERPECT
Themes Selection Improvement
Our theme for Improvement is
“Efficiency of Die Maintenance cost by Plug Core Pin modification “
Page 5

7. Background, Objective and Target
1. Plug Core Pin is the most used Insert Pin on Cylinder Head Dies
2. Plug Core Pin is the most expensive Pin on Cylinder Head Dies
Page 6
Background
Objective
1. We have insert plug pin that used on 88Ki but we can re-use in the next
productions
Target
1. Modify plug pin that used on 88Ki 58 Pcs, we estimated that 60% can be
re-use on 89Ki approximately 35 Pcs.
2. We dont need to order plug pin again on 89Ki

8. Current Analysis #1
We have 4 dies, every one dies have four
Plug Core Pin. So for mathematics
calculation we need 16 Plug Pin for
productions.
16 Plug Pin every Productions
Lifetime = 3000 shot
This pin is can use for two
month or more, because this
part is not affected by casting
process or allumunium.
Lifetime is over,
so for this point
Plug Pin is must
changed.
DIE DIE
Casting Process
Page 7
Plug Pin
Plug Pin
Dies 1 Dies 2 Dies 3 Dies 4
Pin Performance
3000 Shot

9. Curent Analysis
#2
At the time of the casting process,
Only the product area that
affected by aluminum casting.
Modification
Plug Pin is divided into two parts, Part A
and Part B. Part A is not affected by
the casting process, whereas part b is
affected by the casting process.
Part A
Part B
Plug Core Pin Modification
This Area is still Good
We want to re-use this
PIN for the next
production.
Stock Plug Core Pin after Production 56 Pcs
Page 8
ALL 650°C
ALL 650°C

10. Improvement Schedule Page 9
We have problem on countermeasure, caused by Hands Tap M16x1.5 is broken after
Used on 5th
or more step. So we waiting for new Hands Tap M16x1.5

11. Design Plug Core Pin Part A
Note :
After Plug Pin cutting until 222.14,
then tap the Hole with Hands Tap
M16x1.5
Page 10

12. Actual Condition
Plug Core Pin modification
Based on modified Plug Core Pin, so we get the ideas that we should try to re-use Old PIN
before modified and ex used to modified as like now.
Stock Plug Core Pin after Production 56 Pcs
Page 11
Part A Part AB Part C
Part A

13. Flow Process Plug Pin Modifications
1. Plug Pin
2. Cutting 3. Bor the Pin
4. Hand Tap M16x1.55. Clearance Test
6. The Results
Page 12
Modification into Part A

14. Inspections
Maker
Modify
Result Inspections
The pin between maker and modify is almost
Same, for inspection on Dimention, Dimention
Part A and Part B also Straight the Pin.
Page 13

15. Result Trial Material
We had been try Plug Pin on dies RB0-3, And the result was within standard
(OK).
127.9 mm
Material Dimention from Cutting
Inspections Results By Cutting
Plug Pin Standard Actual Remarks
1 127.9 mm 127.9 mm OK
2 127.9 mm 127.9 mm OK
3 127.9 mm 127.9 mm OK
4 127.9 mm 127.9 mm OK
Page 14

16. Summary and Next Improvement
After we finished this improvement, we have :
1. We dont need to order Insert Plug Core Pin.
2. Trial result inspection by cutting was within standard
3. Plug pin modified can apply to masspro.
Summary
Next Improvement
Adding Filter Strainer Cooling on Dies RB1#1 and RB1#2
Page 14

17. Thank You