Design and Analysis of Tungsten Carbide Sludge Removal Machine for Maintenance Department in Cutting Tool Manufacturer

Abstract

In Cutting Tool Industries, the grinding process for producing cutting tools creates carbide sludge which is a combination of carbide waste from the product material and coolant from the grinding machine. Since carbide sludge will be filtered in the filter machine, a monthly maintenance is necessary for the filter machine which includes transferring accumulated carbide sludge into the waste barrel. The current process of removing carbide sludge from the filter machine requires 2 to 3 person and takes a considerate amount of time. The process also requires several types of equipment such as jack and forklift which requires skilled workers to operate. The aim of this research is to develop a carbide sludge remover machine that fits perfectly into ABC Cutting Tool Industries production line. The methodology used for this research is by following Deming Cycle Approach (PDCA), observation, conceptual generation through PUGH method and design software (CATIA). The benefit of this research is a design and analysis of carbide sludge remover machine that could reduce the number of workers required for the waste removal process. It also simplifies the operation of removing carbide sludge from the filter machine. This research may contribute to the cost reduction for the carbide sludge removal process over time and also improve the safety of the operator. A fully automated Carbide Sludge Remover can also be the next part of this research as well as the intelligent carbide sludge indicator sensor that linked with the operation of the company.