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Mold Maint GORIKA OTHERS

Dept

Subject REDUCE MATERIAL & CUTTING OVERVOLT AFTER PLATING

Out line DIS USE OVERVOLT , MOLDING RAD LOWER 'D' D80N

view part :
Technical
Point

2 1
OVERVOLT OVERVOLT
改善前 (Before) 改善後 (After)
A. FLOW PRODUCTION PROCESS A. FLOW PRODUCTION PROCESS

RESIN INJECTION HANGER PLATING RESIN INJECTION HANGER PLATING


2 OVERVOLT 2 OVERVOLT 1 OVERVOLT 1 OVERVOLT

AFTER PLATING PART AFTER PLATING PART


CUTTING 2 OVERVOLT CUTTING 1 OVERVOLT
BEFORE QUALITY CHECK BEFORE QUALITY CHECK

1 2 1
NO CUTTING
OVERVOLT 2
1 SECOND EFFICIENCY
PRODUCT + M/P COST

B. MOULD ( CORE SIDE ) B. MOULD ( CORE SIDE )


改善内容 PROCESS REPAIR

(Detail)

ZOOM
OVERVOLT POSISITION

WELDING MATCHING POLISHING

OVERVOLT POSISITION OVERVOLT


SLIDER CORE
CLOSED

SCHEDULE
TUTUP OVERVOLT

MERIT
a
Resin cost Oktober November Desember AVG
Qty Prod 1926 2126 1081 1711
Berat kontak point 1.75 gr
2994.25 gr
Total berat / bulan
2.99425 kg
Harga material 32,500 / Kg
Profit / bulan 97,305

Plating Februari Maret AVG


QTY Prod 1400 840 1120
Berat kontak point 0.9 gr
1008 gr
Total berat / bulan
1.008 kg

: 1.008 x 136500
coper : Rp 137592

: 1.008 x 299000
Nickel : Rp 301392

: 1.008 x 70850
Chromium : Rp 71416

Total 510400

TOTAL COST ### / BULAN


b c
Plating Oktober November Desember AVG M/P cost/month Oktober
QTY Prod 1926 2126 1081 1711 QTY Prod 1926
Berat kontak point 2.88 gr
4927.68 gr
Total berat / bulan
4.92768 kg M/P cost

Material Cost/ Kg Cost/month


coper 136,500 672,628
Nickel 299,000 1,473,376
Chromium 70,850
Total a+b+c
349,126
Total cost 2,495,131
cost/month

Total Total cost/month x 12


cost/year
c
November Desember AVG Item
2126 1081 1711 Proses 4
3,647,000 month Spare part 1
182,350 day
22,794 hour
380 sec
650,002 month

a+b+c 3,242,438

Total cost/month x 12 38,909,250

3,266,000 month
163,300 day
20,413 hour
340 sec

1120 pcs/month
381,033 month
Cost
hour ( 25.000 ) #REF!
#REF!
pcs 20,400
a b
Resin cost MARET APRIL MEI AVG Plating cost
Qty Prod 200 264 232 QTY Prod
Berat kontak point 4 gr Berat kontak point
928 gr
Total berat / bulan Total berat / bulan
0.928 kg
Total berat / tahun
Harga material 32,500 / Kg
Profit / bulan 30160 Material
Profit / tahun 361920 coper
Nickel
Chromium
Total cost/ bulan
Total cost/ tahun

Plating cost MARET APRIL MEI AVG


QTY Prod 200 264 ###
Berat
kontak 4.8 gr
point
Total 1113.6 gr
berat /
bulan 1.1136 kg

: 1.1136 x 136500
coper : Rp 151924

: 1.113 x 299000
Nickel : Rp 332787

: 1.113 x 70850
Chromium : Rp 78856

Total 563567

TOTAL COST / BULAN


b c
MARET APRIL MEI AVG M/P cost/month MARET APRIL MEI
200 264 232 QTY Prod 200 264
4.8 gr 3,643,820
1113.6 gr 182,191
1.1136 kg 22,774
M/P cost
13.3632 kg
380
Cost/ Kg Cost/month 88,059
136,500 152,006
299,000 332,966
Total
70,850 78,899
cost/month
( a + b + c ) x 4 CONTACT POINT 946,267
563,871
6,766,456

Total
cost/year
d x 12 11,355,208

c
M/P cost/month MARET APRIL MEI
QTY Prod 200 264
3,643,820
21,063
M/P cost 2,633
44
176
40832
898304
10779648
AVG
232
month
day
hour

sec
month

946,267

11,355,208

AVG
232
month
day
hour
sec

month
year
BULAN: SEPTEMBER 2016
TANGGAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
REPAIR I
COMMENT JUGDE
23 24 25 26 27 28 29 30
TUTUP 2 POSISI OVERVOLT OK
W S
N E
N E
a b
Resin cost MARET APRIL MEI AVG Plating cost MARET
Qty Prod 404 404 404 QTY Prod
Berat kontak point 4 gr Berat kontak point
1616 gr 193
Total berat / bulan
Total berat / bulan 1.616 kg 1.9
Total berat / tahun 23.2
Harga material 32,500 / Kg
Profit / bulan 30160 Material Cost/ Kg
Profit / tahun 361920 coper 136,500
Nickel 299,000
Chromium 70,850
Total cost/ bulan
Total cost/ tahun
b c
APRIL MEI AVG M/P cost/month MARET APRIL MEI AVG
404 404 404 QTY Prod 404 404 404
4.8 gr 3,643,820 month
1939.2 gr 21,063 day
1.9392 kg 2,633 hour
23.2704 kg 44 sec
M/P cost
176 cutt/sec
Cost/ Kg Cost/month 71104 4 contact point
136,500 264,701 1564288 month
299,000 579,821 18771456 year
70,850 137,392
981,914
Total cost/
11,782,967
year
{( a + b ) x 2 overvolt }+ c = 43,061,230
Mold Maint
Dept
Subject REDUCE MATERIAL & C
Out line DIS USE CONTACK POINT
Technical
Point
CHANGE E
view part :
改善前 (Before)
A. Seting part pada hanger

D
A
E

Contact point use:


A,B,D,E,F,G

Mekanisme mold :
Posisi insert core :
改善内容

(Detail)

Insert core sebelum diwelding

SCHEDULE

MERIT
MERIT
GORIKA OTHERS
ATERIAL & CUTING CONTACK POINT AFTER PLATING
NTACK POINT , MOLDING BACK DOOR GARNISH ( YL
CHANGE EJECTOR KONTACK POINT

(Before) 改善後 (After)
A. Seting part pada hanger

F
B A
G C

New contact point:


C
Efect part
deform
Mekanisme mold :
EJ PLATE LWR

EJ PLATE UPR

EJECTOR PIN
BASE CAV

INSERT CAV

Proses welding insert :

Proses matching insert core :


R PLATING
NISH ( YL8 )

 (After)

No deform
MOULD NO

PART NO

PART NAME
EJ PLATE LWR
CUSTOMER
EJ PLATE UPR
MODEL

TONAGE
EJECTOR PIN
PROD/MONTH
BASE CAV

INSERT CAV
MOULD NO : 303

: 83944-77M10

PART NAME : MOLDING BACK DOOR GARNISH

CUSTOMER : SIM

: YL8

: 650

PROD/MONTH : 4000 Shot


a b
Resin cost APRIL MEI AVG Plating cost
Qty Prod 3152 3152 3152 QTY Prod
Berat kontak point 1.87 gr Berat kontak point
11,788 gr
Total berat / bulan Total berat / bulan
11.78848 kg ( X2 )
Harga material 32,500 / Kg
Profit / bulan 383,126 Material
coper
Nickel
Chromium
Total cost

Plating Februari Maret AVG


QTY Prod 1400 840 1120
Berat kontak point 0.9 gr
1008 gr
Total berat / bulan
1.008 kg

: 1.008 x 136500
coper : Rp 137592

: 1.008 x 299000
Nickel : Rp 301392

: 1.008 x 70850
Chromium : Rp 71416

Total 510400

TOTAL COST 895,073 / BULAN


b c
APRIL MEI JUNI AVG M/P cost/month APRIL MEI JUNI
3152 3152 3152 3152 QTY Prod 3152 3152 3152
3.75 gr 3,643,820
23,640 gr 148,455
23.64 kg( X2 ) M/P cost 18,557
309
Cost/ Kg Cost/month 1,949,703
136,500 3,226,860
299,000 7,068,360
Total
70,850 1,674,894 ( a + b + c ) x 2 cav 14,302,943
11,970,114 cost/month
AVG Item Cost
3152 Proses 4 hour ( 25.000 ) #REF!
month Spare part 1 pcs 20,400
day
hour
sec( x2 )
month

14,302,943

3,266,000 month
163,300 day
20,413 hour
340 sec

1120 pcs/month
381,033 month
Cost
#REF!