Design Control Systems to Detect Applied Grease Machine Based on Programmable Logic Controller in Manufacturing Industry

Abstract

This research was conducted in a company engaged in the manufacture of Automotive Spare Parts, especially the manufacture of automotive components in particular four wheels. One of the products manufactured by this company is a door lock manufactured product for a variety of models and brands of four-wheeled vehicles. Applied grease machine is one of many machines which is used to apply some grease to the parts of door lock product in production line. This machine is developed in a manufacturing Industry in Indonesia. This apply grease machine only uses one process mechanism that is applying some grease to selected part. In this process, it is still general, that means there is no different between one product and the other product in applying grease process, and it causes waste of the grease, because each product has differential of grease portion. Base on the condition, Equipment Development Section has an order to make a new machine, the machine detects apply grease machine that could detect the product at the first step, to avoid some mistake and give different portion of grease to each other model. This machine is using PLC (Programmable Logic Controller) MITSUBISHI FX3U as main control system. By using this machine, production process can be processed more effectively in case of detecting product and applying grease to each other product model because of part product detector sensors, to avoid human error and decrease costumer claim to 0% in production line ASDL09.