Partner in Excellence

Sistem Pembuatan Lanjut MNS-01

Iwan Harianton, B.Sc., M.Eng

Assoc. Prof. Bidang Tek. dan Sistem Manufaktur
Politeknik Manufaktur Bandung
Jl. Kanayakan No. 21 Bandung 40135
Telp.: +62 22 2500241, WA.: +62818422700
Email: ihar@polman-bandung.ac.id
Mfg. Proses dan Sistem Mfg.
• Manu = made,
• Faktus = by hand,
• Manufaktur = made by hand,
• Standard Manufaktur = Memberi nilai tambah
• Standard Mutu Produk Manufaktur di kelola
dengan ISO9001:2015
Reso
Sistem Manufaktur urce

Input Mfg. Proses Output

Feedback
Proses Manufaktur

1. Pemotongan: konvensional, non-

konvensional;
2. Pembentukan: dingin, panas (berubah fasa,
tidak berubah fasa);
3. Penyambungan: Tetap, tidak tetap;
4. Pelapisan: Lunak (perChrom, perNikel,
Blacken), Keras (PVD, CVD);
5. Penambahan (Additive Manufacturing):
polimer, logam, keramik;
6. Nano teknologi (Atomic Manufacturing).
1. Pemotongan
Konvensional:
• Alat potong keras memotong benda yang lebih lunak
– Cutting, Blanking pelat, gerinda, broaching, honing, filing,
Scraping

Turning Drilling Milling

Bubut Bor Milling

 Justifikasi Investasi

• Lathe Machine Cost ~ USD 25,000.--,

technical life time 5-7 years.
• Milling Machine Cost ~ USD 30,000.--,
technical life time 5-7 years.
• Drilling/Jig Boring Cost ~ USD 20,000.--
technical life time 5-7 years.
• CNC Lathe cost USD 100,000.--, technical
life time 3-5 years.
• CNC Milling cost ~ USD 100,000.--,
technical life time 3-5 years.
• So, what should we understand? Derived
from technology concept of creation
Pemotongan

Non-Konvensional:
• Alat potong tidak selalu lebih keras dari benda yang
dipotong dengan bantuan teknologi
– Electro Discharge Machine (EDM)
– CNC Waterjet
– Chemical Manufacturing
– Electro Chemical Manufacturing
– Laser Cutting
– Plasma Cutting
 Justifikasi Investasi

• CNC EDM cost ~ USD70,000. –

200,000.--, technical life time
4-6 years.
• Wire EDM USD75,000. –
200,000.--, technical life time
4-6 years.
 Justifikasi Investasi

• Waterjet Cutting Machine cost ~ USD30,000.– to USD50,000.-,

technical life technical expectation 5-7 years
• CNC Plasma Cutter cost ~ USD10,000. – 12,500.--, technical
life time 3-5 years.
2. Pembentukan

Proses Dingin
• Forming Pelat
• Deep Drawing
• Cold Forging
 Justifikasi Investasi

Progressive Dies cost

~USD10,000.- to 25,000.– can
produce 100,000 part or more.

Forming Dies cost ~ USD5,000

– 15,000.– can produce ~
100,000 part or more.
 Pembentukan
Proses Panas
• Berubah Fasa (Foundry, Plastic Moulding, DieCasting,
SemiSolid Forming)
 Justifikasi Investasi
• Sand Moulding cost is low
~ USD20.-- to 50.—
• Sand Casting Furnace and
Heat control by Induction
cost ~ USD 200,000.– to
250,000.– for 50kg steel
charging.
• Crucible furnace for Al and
Mg cost less ~ USD50,000.–
for 25kg Al/Mg charging.
Handling System Infrastructure required, such as sand mixing,
fix and mobile cranes, as well as material composition testing
such as microscope electron, wet analysis
 Justifikasi Investasi

Die casting for Gear housing ~

USD20,000 – 30,000.– can produce ~
10,000 pcs gear housing or more.

Moulding for Mirror production

cost ~ USD10,000 – 15,000.– can
produce ~ 100,000 mirror cover
or more.
Proses panas
• Tidak berubah fasa (Forming bulk material) Hot
Forging, Ekstrusi, SemiSolid Forming

Forming Bulk Material Extrusion

 Justifikasi Investasi

Hot Forging Process:

• Closed Die, Open Die, and Upset Die: Dies were design
for several stage until product finish, cost ~
USD10,000 to 25,000.– depending on stage and size for
thousands part production.
3. Penyambungan

Sambungan:
1. Sambungan Permanen – create a permanent
joint.
• Contoh: welding, brazing, soldering, and
adhesive bonding, riveting.
2. Sambungan Tidak tetap – fastening by
mechanical methods
• Contoh: use of screws, bolts, nuts, other
threaded fasteners; press fitting,
expansion fits; Pasak;
Justifikasi Investasi

• 4 main types of welding. MIG

– Gas Metal Arc Welding
(GMAW), TIG – Gas
Tungsten Arc Welding
(GTAW), Stick – Shielded
Metal Arc Welding
(SMAW) and Flux-cored –
Flux-cored Arc Welding
(FCAW). Stick welding and
Wire feed welding.
• Cost per 10 cm approximately
USD10.-- to 15.– depending
on the thickness.
 4. Pelapisan
Lunak
• PerChrom
• PerNikel
Keras
• PVD
• CVD Physical Vapor Deposition

Chemical Vapor Deposition

 Justifikasi Investasi

• Physical Vapor Deposition cost USD200,000 to 300,000 hard

coated ferro based material by hard material such as
Tungsten, Chromium, Nickel, Carbide, and other alloy.
• Chemical Vapor Deposition cost USD200,000 to 300,000,
coated takes place when the coated material vapored and
deposited to positive pole of the electric current.
 5. Additive Manufacturing

Data
• 3D CAD
• Transfer data per
layer
Proses
• Mesin RP bahan
Polimer, Keramik,
Logam
Additive Manufacturing
• Fused Deposition Modelling
(FDM): material laid up layer
by layer based on the data
from CAD that had been
sliced undel stl-file format,
Similar to DIW.
• Selective Laser
Melting/Sintering (SLM/SLS):
Powder are spread on the
table bed of about 0,3 mm,
laser melt and bound powder
as selected based on stl.file
format, cut the surface for
0,02 mm layer thickness.
Additive Manufacturing
• Stereolithography (SLA)
similar to Inkjet printing,
where the resin liquid is
solidified by UV Light and
mirror for certain thick so
that it will stick to the based
of the build stage, either
vertically build or draw.
Limited material available
for this machine.
• Cost of the machine range
from USD500,000 to
2,5Million (metal). Returned
after 3000 hours of service.
Justifikasi Investasi

• Markforge metal
X, powder are
delivered through
laser nozel and
laid up layer per
layer based on
the stl.file format
to form part.
Complex part will
be assisted by
rotational axis
both part and
evolving nozzle.
 6.Nano Manufacturing
Data
• 3 D CAD
• Translate to atomic level by nano
system beserta tahapan
meletakkannya
• Part yang berbeda bisa dari bahan
yang berbeda
Assy Shaft

Bearing

Nano Electronic
 Justifikasi Investasi

FeCrx
Nano Manufacturing
FeSi

• It is not yet real,

Al2O3 Mg2O3
predicted in the
year 2045. A
machine that can
Nylon Polymer build a complete
product from
scratch possible
Rubber TiN through Nano
Manufacturing
Al Mg Fe Zn Ti
Thank you ……………..