Professional Documents
Culture Documents
Written by:
Industrial Coordinator
Ferry D Mongan
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HR. Business Partner
This report has approved and authorized as one of the practical working
requirement at the 4th semester in SMKN 1 Batam
On May 2020 By :
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Lea Lindrawijaya Suroso, M.Pd
NIP. 1969 0124 1995 03 2005
PREFACE
Praise and gratitude we pray for the presence of Allah SWT, who has
given His grace and guidance to all of us, so that I am still given strenghth in
finishing my internship practices and completing this final report, whick this
report is an obligation for every internship student at PT. Schneider Electric
Manufacturing Batam in the period January 2020 to May 2020
h. Mr. Mervyn Manurung,Quality Engineer 1st Floor PEL Plant and who
been my Mentor.
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j. Mrs. Asti Rakhmawti as Sr.CS&Q Engineer of PT. Schneider Electric
Manufacturing Batam Eletronic Plant.
k. All of Maintenance Technician who has helped me directly or indirectly.
l. All staff and employees of PT. Schneider Electric Manufacturing Batam
(SEMB).
Finally, wish this Internship Industrial’s report can be useful for everyone
who read it,for me as well,finally auhor say thank you.
Batam,May 2020
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TABLE OF CONTENTS
INTERNSHIP REPORT........................................................................................i
MOTTO..................................................................................................................ii
TABLE OF CONTENTS....................................................................................vii
CHAPTER I............................................................................................................1
CHAPTER II ....................................................................................................3
CHAPTER III......................................................................................................12
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3.3 General Descriptrion of Poka Pick Sensor in Intelligent Screwdriver....12
Advantages :............................................................................................17
Disadvantages :.......................................................................................17
CHAPTER IV.......................................................................................................18
2.4 Conclusion.......................................................................................18
2.5 Suggestion........................................................................................18
BIBLIOGRAPHY................................................................................................19
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CHAPTER I
INTRODUCTION
In this Industrial 4.0 era,where technology growth has entered the era of
digitalization don’t let the students who are in productive age miss this era.
When they do the Internship Program they will face the digitalization
industries 4.0 for example Internet of Things (IoT) that transfer data from
network without human touch and use Artificial Intelligent (AI) instead.
Therefore,the students will learn and think more critically for future
technological industry advancements.
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1.2 Background of Title
The most important thing in Schneider electric is safe and reliable,
efficient and sustainable, open and connected. Always give priority to
customer satisfaction therefore,so lot of company implement an efficient
system called Poka Yoke System.
Poka Yoke it’s a mechanism to prevent mistakes. This mechanism can
Eliminates the cause of an error at the source, detects an error as it is being
made, and detects an error soon after it has been made but before it reaches the
next operation. Poka Yoke is part of process before inspection. There lot of
Poka Yoke mechanism to detect mistake/error,there are warning system for
example color coding and alarm. This made a big impact to prevent mistake of
human-worker.
There’s lot of interesting machine in Schneider Electric but author take
interesting topic entitled “APPLICATION OF POKA-PICK SENSOR AS
PART OF THE POKA YOKE SYSTEM IN INTELLIGENT
SCREWDRIVER”. With this,readers will know what method industry use to
prevent mistake,how amazing this system to reduce the mistake and how it
works.
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CHAPTER II
GENERAL PROFILE OF PT SCHNEIDER ELECTRIC
MANUFACTURING BATAM
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Here are author’s result search for a brief history of PT Schneider Electric
Manufacturing Batam. Schneider Electric, founded by Group Schneider, and
are now scatter in more than 100 countries. PT Schneider Electric
Manufacturing Batam a factory assembly line with specialized industrial
controls. This means that to get a type of product semi finished products is
carried out manually and automated process, where the process is done
manually by staff - manpower and for the automatic process done by high tech
machines and modern.
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Then on 1 November 1994 PT Telemecanique Manufacturing Batam
renamed PT Schneider Electric Manufacturing Batam. Onwards on April 30,
1997 PT Schneider Electric Manufacturing Batam receive approval from the
Ministry of Industry of the Republic of Indonesia to be "ISO 14001 Pilot
Project". This is an award given the Government of the Republic of Indonesia
to the industries that is friendly to the environment. This award was given on
December 10, 1997.
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1. Empower all to make the most of their energy and resources,
ensuring Life Is On everywhere, for everyone, at every moment
2. Provide energy and automation digital solutions for efficiency and
sustainability.
3. Combine world-leading energy technologies, real-time automation,
software and services into integrated solutions for Homes, Buildings,
Data Centers, Infrastructure and Industries.
4. Committed to unleash the infinite possibilities of an open, global,
innovative community that is passionate about Meaningful Purpose,
Inclusive and Empowered values.
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organizational structure, duties and responsibilities of each part is as
follows.Organizational of PEL Plant can find in picture 2.1 below.
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a. SEMB Plant
Hide Plant is a General Manager responsible for determining strategies
to achieve corporate objectives contained in the vision and mission. Hide
plant is also authorized to provide command and motivation to the
operation of existing managers to cooperate in the unit that he leads to
achieve company goals. To answer people commitment, product or
process engineering and monitor industrial process.
b. Manufacturing
Manufacturing Manager is responsible for helping hide plant
determining strategies to achieve company goals, monitor the work of
al departements and negotiate with costumers or consumers, in
collaboration with Plant Hide top of From Manufacturing Manager is
responsible for management of all factories production directly
answerable to the plant manager for on time delivering product,
manufacturing defect sale, scrap and product manufacturing lead time.
c. Plant Control
Plant Control in chare of control finance and purchasing of
company. Finance charge of inspection and financial control is
recording of all transactions that occurred at Schneider Electric
Manufacturing Batam (SEMB) both income and expenditure and profit
and loss to be reported to the company’s managers. Finance is also
authorizing budgets and make sure all the forms of loans and
receivables that exist at Schneider Electric Manufacturing Batam
(SEMB).
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Human Resources Businesses Partner Departement in charge of
take care all employees in the Plant, employee pay roll and all things
that related to employee. HRBP also has authorized to perform
termination of employment for employees who violated company rules
set.
e. Engineering
Engineering is responsible to take care all things related to
production machine. Maintenance, Manufacturing Engineering,
Method, Project Support are part of engineering department.
f. Quality
Quality function of the plant develop quality action plant, takes
care of customers complaints, manufacturing defects, scrap, work
commits of application of sheet works instructions & fixed operations
procedures, responsible for simple production settings. Quality System
ensures that the quality system meets the standards and facilities the
production of Quality System in operation in order produce quality
product to satisfy customers. Quality System in section authorities
monitoring system and production system to conform to the desire then
reported to the management about ISO, CCC, and OHSAS.
g. Supply Chain
Supply Chain in charge of making a purchase od components
or materials requires in a production activity from the supplier of
Schneider Electric Manufacturing Batam (SEMB) to produce a quality
product that will be sold to customers. Also to manage upstream,
downstream and internal material flow.
h. Technical Antenna
Technical Antenna in charge of engineering change related to
continue improvement for product based on customer.
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i. Part Industrialization
Part Industrialization in charge of all parts is use in
industrialization manufacturing and tooling. Tooling charge to
checking and control of all tooling for which is on the supplier can be
still used in accordance with company standards there. Tooling can
also determine what tools are to be used by suppliers to produce a
good material to be produced by the company. Renew tools or check
the capacity of tool.
m. Safety Deployment
Safety Deployment in charge of ensures that the safety of
employment on working process at the production line is safe for the
worker healthy. And Safety Deployment also takes care of the Plant
environment that is clean and hygienic for working place.
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2.4 Company Rules
a. Deploy or provide documents or spreadsheets , brochures , leaflest /
posterinside or around the area and enterprise environments.
b. Carry / use items / equipment and supplies the company out of the area
without the permission of the employer company or management
company.
c. Smoking during working hours in the area of the company where there is a
smoking ban in place.
d. Employees are able to enjoy living in mobile dormitory is prohibited from
accepting , allowing visitors or guests into the cross beam type room or
space not to the public.
e. Doing business and personal Holding company in the area.
f. Gambling in any form within the corporate area.
g. Sleeping during working hours .
h. Commit immoral acts in the area that could damage the Company's
reputation and interfere with the Company or one or disturbing public
order.
i. Carry weapons or sharp objects in the enterprise area
j. Drink on the job because of alcohol .
k. Carrying , storing and using drugs and the like.
l. Eating at work place and in the restroom / toilets
m. Making commotions , threatening other works or his / her Superiors ,
arguing fighting etc. roommates may disturb the public order in the
company.
n. Receive dues or monetary rewards / payments etc. from parties in doing /
performing his/ her duties.
o. Doing / performing some roommates job is not his / her own duty and
entering any other room roommates is not his / her own department except
by order / at the approval of his / her superior.
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CHAPTER III
APPLICATION OF POKA-PICK SENSOR AS PART OF THE POKA
YOKE SYSTEM IN INTELLIGENT SCREWDRIVER
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Picture 3.1 Intelligent Screwdriver Integrated with Poka Pick sensor
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Intelligent Screwdriver is a screwdriver that controls the tightening
torque to accurately tighten small and micro screws. In Schneider Electric
Manufacturing Batam (SEMB) the Intelligent Screwdriver also connected to
a screen for show all the Poka Pick sensor signals . The example of
Intelligent Screwdriver shown below.
The Poka Pick sensor is a capasitive proximity sensor that can detect
anything that get close to the area,that’s why after we pick the object inside
the Poka Pick sensor area the sensors light will automatically turn off. This
sensor not just prevent a wrong picks of bolts,but also prevent from
damaged product because operator insert the wrong size of bolt.
The warning system that Poka Pick sensor have is light. It will show
green to indicated that bolt that we should pick . The example of Poka Pick
sensor indicated green light shown below.
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Picture 3.4 Green Light on Poka Pick sensor
But there is some operator still can’t focus to the green light and instead
picks up the bolt near it, the incorrect place that operator hand reach will
turn on a red light shown below.
3.2 Work Process Picture 3.5 Red light on Poka Pick sensor of Poka
Pick sensor in
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The screen
Part of product The operator The screen
shows how
come to the scan the show where to
many bolts are
station barcode bolt first
needed
1. Part of product come to the Intelligent Screwdriver station after pass all
the station before.
2. The operator scan the existing barcode with a scanner.
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3. The screen show how much and where to install the bolt. Its shows the
exact position of where the bolt should correctly installed.
4. The screen shows where to install bolt
first with flashing yellow light .
5. The Poka Pick sensor in the rack will
turn on green ( Picture 3.8 ). That
indicated the correct bolt we should
pick and install in the current step. If
we pick another bolt that not shown in
the display screen,the incorrect bolt
area will turn on red light ( Picture 3.9 ).
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6. After we pick the bolt the light green turn off,because the proximity sensor
detect something (in this case operator hand) take the bolt from the Poka
Pick sensor area.
7. The bolt tightly attached and all sign is green. if the bolt not tightened
firmly the display screen will indicated red light until the bolt attached
tightly and the red light will turn green.
8. The operator marked all the tighten bolt with visible permanent marker.
Make sure all bolt tighten.
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3.3 Advantages and Disadvantages
Advantages :
1. No waste paper order (checklist paper),when we use paper order it’ll take
time to read the order,then search for the order,after that we repeat the
same things for another order.
2. Easy and safe operation.
3. Reliable user guide and pick up quality, compared to order picks.
4. Flexible order processing and detailed stock management.
5. Stock control through the inventory function.
6. Highest availability possible through standalone hardware checks.
7. Transparent order tracking.
8. Easy maintenance.
9. Short introduction training in an easy and clear system.
Disadvantages :
The Pick to Light System performs best when the picks are smaller and the
pick face area is dense, permitting pickers to concentrate on the work.
CHAPTER IV
CLOSING
2.4 Conclusion
a. Poka Pick sensor is part of Poka Yoke system that prevent mistake
from all human-worker and avoid cost losses for the company.
b. Poka Pick sensor in Intelligent Screwdriver have a strict warning to
make sure the operator pick the correct bolt and not damaged the
product by install the wrong size of bolt.
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c. Poka Pick sensor in Intelligent Screwdriver reduce waste time because
it can speed up the work process by automatically shows the correct
how much and where the bolt should be installed.
d. It’s easy to learn by operator how the Poka Pick sensor work in
Intelligent screw driver because the purpose of Poka Pick sensor to
simplify the work of the operator.
2.5 Suggestion
a. It is suggested to operator, to learn first about Poka Pick sensor is a
part of Poka Yoke system in Intelligent Screwdriver station and always
put safety as priority like handgloves and face mask.
b. It is suggested to the operator dont forget to always focus to pick the
correct bolt and not damaged the product because install a wrong size
bolt.
c. It is suggested to Quality team, to always check the Operation
Working Standard (OWS) in every station to make sure the OWS still
valid.
d. It is suggested for Method Team, to put more Poka Pick sensor in other
station that still don’t use Poka Pick sensor.
e. It is suggested to Maintenance tim to always do the preventive
maintenance to this Poka Pick sensor.
BIBLIOGRAPHY
Automation, A. (2018, January 12). Allied Automation Inc. Retrieved from Poka-
Yoke, Pick-to-Light error proofing system: allied-automation.com/poka-
yoke-pick-light-error-proofing-system/
Banner, T. (2018, February 2). Picking parcels to pizza’s – the rise of pick-to-
light technology. Retrieved from DPA Magazine:
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http://www.dpaonthenet.net/article/150969/Picking-parcels-to-pizza-s-the-
rise-of-pick-to-light-technology.aspx
Denso. (2018, June 1). Intelligent Screwdriver PRO-FUSE. Retrieved from Denso
Wave: https://www.denso-wave.com/en/robot/product/3rdparty/002.html
Elektronik, B. (2018, August 15). Pick To Light | Poka Yoke - Binar. Retrieved
from Youtube: https://www.youtube.com/watch?v=vFO-V5iapR0
ssi-schaefer.com. (2017, Desember 7). Pick by Light and Put to Light. Retrieved
from ssi-schaefer.com: ssi-schaefer.com/id-
id/produk/pengambilan-/pengambilan-manual-/pick-by-light-dan-put-to-
light-163438
Sudong. (2018, June 5). Precision Electric Screwdriver SD-BA Torque Adjustable
Intelligent Briushless Power Screwdirver with Counter Compact (SD-
BC2000L). Retrieved from Amazon:
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https://www.amazon.co.uk/Screwdriver-Adjustable-Intelligent-Briushless-
Screwdirver/dp/B07DJBH612
Wave20. (2017, August 23). Arti pokayoke dan contoh. Retrieved from Wave20:
https://wave20.blogspot.com/2017/08/arti-pokayoke-dan-contohnya.html
Yolanda. (2018, August 8). Apa Itu Barcode scanner? Mengenal Definisi.
Retrieved from Olsera: https://www.olsera.com/id/blog/apa-itu-barcode-
scanner-mengenal-definisi-dan-jenis-jenis-barcode-scanner/41
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