REDESIGN OF WORKING SYSTEM IN CRANKCASE ASSEMBLY STATION

IN PT. TRIANGLE MOTORINDO

Bambang Purwanggono, Ratna Purwaninggsih, Novie Susanto, M.B. Widhy Eviyanti

Industrial Engineering Department, Faculty of Engineering
Diponegoro University

Email: purwanggono@yahoo.com
ratna_ti2005@yahoo.com

Abstract

PT. Triangle Motorindo is a motorcycle manufacturing company with national scale. In

order to increase its working productivity, it is very important to maximize the company’s
resources. One of the resources which is not yet been utilized optimally is the working system at
pre line workstation for engines and frames.
From existing problems it is important to improve the working system by applying
anthropometry aspect in facility scheme work and analyze working method during assembly
process. Based on the workstation design which has been made, operator’s performance can be
calculated by applying indirect work measurement method that is Pre Determined motion Time
Study method (PDTS).
The result from the proposed working facility design based on anthropometry data and
application of working method in accordance to motion economy principles shows improvement
in the operator’s working performance significantly. Based on the new process chart from the
redesign we could estimate time standard at proposed working station that is equal to 122.5
seconds. If time standard of this station is converted to output units, in one day work operator at
this workstation can now produce output equals to 176 units per day where before redesign is
equal to 140 units per day.

Keyword: Ergonomic, redesign workstation, operator process chart, Pre Determined motion
Time Study (PDTS)

1. Introduction
Transportation growth in Indonesia increases the need of better transportation. Modern
transportation could be in the form of four wheeled vehicles and also two wheeled vehicles. This
situation is seen in the ever-increasing demand level of transportation. PT. Triangle Motorindo as
a company which is oriented in the assembly of motorcycles also experiences increasing demand.
But this increased demand has not been balanced with the increasing of the production quantity
so that this bigger demand level is not explored maximally.
In the longer term, management wishes to increase market share. At present, market share of
PT. Triangle Motorindo is mostly in west Indonesia including Sumatra Island, Java, and
Kalimantan. While in the future, management wishes to expand market share to Indonesia’s east
area which is still getting less attention. Management plans to export to some neighboring
countries like Timor Leste, Sarawak Malaysia, Thailand, and other ASEAN countries. With this
plan of expansion management is targeting product increase of 150 units per day from 90 units
per day now.
In the effort of increasing productivity, it is required to utilize working system maximally.
Working systems which is not utilized optimally are engine pre line and also frame pre line. If
production level targeted by management is to be realized, one of the solutions is by adding
operators to engine line and also frame line by applying line balancing method, this can be
conducted because efficiency level at machine line is relatively high. However, this action cannot
be applied to engine and framework pre line sub-division since assembly working process at pre
line workstations is not done optimally.
From preliminary data processing and observation which is conducted to engine pre line it
can be seen that workstation times are not uniform, some of them have shorter times and some of
them have longer times. In order to increase the amount of outputs in every workstation by
minimizing station times it is required to design facilities and to have good working methods.
Based on preliminary data processing and observation, in engine pre line department there is a
workstation having long station time that is workstation engine pre line 3 so this workstation is
considered to be the critical workstation. This workstation supplies crankcase component to
workstation engine line 1. From workstation times engine pre line 3 is potentially becoming the
bottle-neck station if production target is to be realized. To prevent this, station times at all
workstations in engine pre line should be minimized so that the station times become smaller or
equal to engine line cycle-time.
2. Research Methodology

Problemformulation

Study of early
Book Study
Observation of early

Research
objectives

WorkStation Definition
the determination of work Station
to be evaluated by pursuant to station time

Work StationScheme Work MethodScheme

1.Taking data onwork bench tobe 1
evaluated. Studying operation process chart
.
2 used element Therbligs
The development of Desain of
. 2. Determinationelement work which is
workbench and facility work
pursuant to anthopometri. effective and ineffectiveTherbligs
3. Scheme of work facility layout as 3. Schemenewoperation process chart
according toanthropometri.

Result of the scheme work station

andwork method proposal.
Newstationtime determination with .
the approachof methodPDTS
(Predetermined Motion Time
)
System

Analyse result of research

Comparingold job stationtime
with the estimation of newjob station
time

Conclusion

Figure 1 Research Methodology

3. Result and Discussion
3.1 Results
3.1.1 Working Facility Design
 Table 1
Working Facility Dimension Redesign and Its Comparison with Initial Dimension of Workstation
Engine Pre-line 3
Initial Redesign
No Dimension Dimension Dimension
(mm) (mm)
Remarks
WORKBENCH
1 Length 5000 1520 Length of proposed table
accommodating the hand reach
2 Width 900 600 Width of proposed table
accommodating the hand reach
3 Height 810 870 Proposed table accommodating the
type of assembly job
MATERIAL BOX
1 Length 330 230 Length of proposed box
accommodating the width of hand to
reduce the table space needed
2 Width 200 130 Width of proposed box
accommodating width of hand to
reduce the table space needed
3 Height 180 160 Height difference of box not big and
negligible
4 Height of intake space 110 90 Height difference of intake space
not big and negligible
5 Angle formed with table 0° 10° Angle used to form forward
gravitation
RACK of PALET
CRANKCASE.
1 Length 600 580 Length difference of rack not big
and negligible
2 Width 500 480 Width difference of rack not big and
negligible
3 Height of lowest rack 210 550 Height of lowest rack as according
to hand reach downwards
4 Height of highest rack 1460 1300 Width difference of rack not big and
negligible
5 Distance between racks 250 150 Done by distance reduction at
proposed rack according to object
dimension
CRANKCASE BOX TABLE
1 Length - 550 Length of proposed table to suit
work piece dimension
2 Width - 450 Width of proposed table to suit
work piece dimension
3 Height - 700 Height of proposed table as to suit
hand reach downwards

Based on anthropometry calculation done to all work facilities in the workstation of the
engine pre line 3, proposed workstation design and dimensions can be seen in figure 2:
Figure 2 Redesign of workstation engine pre line 3
3.1.2. Work Methods Design

Table 2 Right and Left Hand Chart (Redesign) of Left Crankcase Assembly
Left Hand Symbol Right hand
Taking left crankcase and RE RE Taking ball bearing 6203
placing it G G
M M
RL RL
Holding left crankcase H P Positioning ball bearing and pressuring
RE handle
G
U
Taking tools RE RE Taking ball bearing 6001
G G
M M
RL
Delay D P Positioning ball bearing and depressing
Positioning tools P RE handle
G
U
Taking bolt B (2 units) RE D Delay
Positioning bolt G U Manual threading
M
P
Delay D RE Impacting twice
Holding left crankcase H
Moving left crankcase G M Return impact
M RL
RL
Taking the arm comp cam chain RE RE Taking pivot cam and manual
tensioner G G threading
Holding the arm comp cam chain M M
tensioner RL U
H
Holding left crankcase H RE Impacting
G
M
U
Taking the pin dowel (2 units) RE M Return impact
G RL
M
P
U
Installing the pin dowel P P Installing pin dowel
U U
Delay D G Returning work piece
U
Taking the sprocket 25 T RE RE Taking spindle cam chain guide
G G sprocket
M M
Turning around manually U H Holding spindle cam chain guide
sprocket
Taking screwdriver RE RE Impacting
Arrest the sprocket 25 T G G
M M
H U
Returning left crankcase work G M Return impact
U RL
Taking the rod comp cam chain RE RE Taking oil place and filling oil.
tensioner and including at hole G G
M M
U U
Taking and installing the spring cam RE RE Taking washer sealing + bolt sealing
chain G G and turning around manually.
M M
U
Delay D G Placing work piece
M
RL

Table 3 Right and Left Hand Chart (Redesign) of Right Crankcase Assembly
Left hand Symbol Right hand
Taking right crankcase and RE RE Taking ball bearing 6203
placing it G G
M M
RL RL
Holding left crankcase H P Positioning ball bearing and depressing
RE handle
G
U
Taking ball bearing 6201 RE RE Depressing handle
Positioning G G
Holding right crankcase M U
P
H
Taking bolt A (2 units) RE D Delay
 Positioning bolt G U Thread manually
M
P
Delay D RE Taking the impact and impacting twice
Holding right crankcase H G
M
U
Moving right crankcase G M Return impact
M RL
RL

Taking bolt drain plug + packing RE RE Impact

drain plug and turning around in G G
manual M M
Holding right crankcase H U
Taking screen oil filter and installing RE M Return impact
G RL
M
U
Taking pin shift return spring and RE RE Impact
Thread manual G G
Holding right crankcase M M
U U
H
Taking oil pump pivot RE M Return impact
G RL Delay
M D
U
Taking oil pump gasket RE RE Taking oil pump
G G
M M
Assembly A A Assembly
Holding right crankcase H U installing oil pump + gasket
Taking and installing screw pan 6 x RE RE Taking and installing screw pan 6 x 16
22 manually G G (2 units) manually
M M
P P
U U
Taking impact drill RE RE Assembly
Assembly G G Impact
Holding right crankcase M M
A A
H U
Delay D G Placing right crankcase
M
RL

From the above description, layout determination of material formation of material box have
to be altered according to the principles of motion economy, types of component to be assembled
at this workstation will also change. Assembly component in this new workstation can be seen in
the following table:
 Table 4
Types of Assembly Components after Redesign
No Components No Components
1 Bolt B cylinder stud 13 Oil pump
2 Radial ball bearing 6203 14 Spring cam chain tensioner
3 Radial ball bearing 6001 15 Screw pan 6 x 16
Bolt drain plug 12 mm + packing
4 Radial ball bearing 6201 16
drain plug 12,5 x 20
5 Bolt A cylinder stud 17 Screw pan 6 x 22
6 Arm comp cam chain tensioner 18 Oil filter screen
7 Pivot cam chain tensioner 19 Oil pump body gasket
8 Pin dowel 8 x 12 20 Pin shift return spring
9 Spindle cam chain guide sprocket 21 Oil pump pivot
10 Sprocket cam chain guide (25T) 22 Right crankcase
11 Washer sealing + bolt sealing 14 mm 23 Left crankcase
12 Rod comp cam chain tensioner

Meanwhile the arrangement of component layout in material box in the redesign workstation
is based on the new operator process chart as it can be seen in the figure 3 below (number in the
box indicates component type number).

5 3 2 1
l r left crankcase component

4 2 3 2
right crankcase component
l r
a a = number of component
r withdrawal sequence
1 3
2 1 a r = right hand
l r l l = left hand

Figure 3 Layout Arrangement of Component at Workstation PM 3-1 (Redesign)

 12 9
14 10
15 11 13 9
l l r r

10 7
16 4 17 10 11 11
l l left crankcase component
l r

right crankcase component

8 6
18 5 19 8 9 8
l l l r a a = number of component
r withdrawal sequence
6 4
20 6 21 7 7 5 a r = right hand
l l l r l l = left hand

Figure 4 Layout Arrangement of Component at Workstation PM 3-2 (Redesign)

3.1.3. Time Standard Measurement for Workstation of Pre line Engine no. 3 using
Pre Determined motion Time System (PDTS) Method.

Table 5
Work measurement example for assembling of ball bearing and left crankcase B bolt using PDTS
method at proposed workstation
Motion Motion
Left Hand TMU TMU Right Hand
Analysis Analysis
TAKE CRANKCASE TAKE BALL BEARING
Reaching left crankcase R20B 10,1 18,4 R18C Reaching ball bearing 6203
Grasping left crankcase G1A 2,0 7,3 G4A Grasping ball bearing 6203
Moving left crankcase M18C3 22,6 13,5 M10C Moving ball bearing 6203
Putting down left crankcase RL1 2,0 5,6 P1SE Positioning at hole
Grasping left crankcase H 10,1 2,0 RL1 Putting down ball bearing 6203
46,8 46,8
GRASP CRANKCASE PRESS HANDLE
Sliding left crankcase M6C 10,3 10,5 R14A Reaching handle
Grasping left crankcase H 91,1 90,9 (*) Pressing and releasing handle
101,4 101,4
TAKE JIG TAKE BALL BEARING
Reaching jig R6A 7,0 18,4 R18C Reaching ball bearing 6001
Grasping jig G1C1 7,3 7,3 G4A Grasping ball bearing 6001
Moving jig M6C 10,3 20,4 M18C Moving ball bearing 6001
Delay D 29,1 5,6 P1SE Positioning at hole
2,0 RL1 Putting down ball bearing 6001
Positioning jig P1SE 5,6 5,6 D Delay
59,3 59,3
GRASP CRANKCASE PRESS HANDLE
Grasping left crankcase H 190,3 10,5 R14A Reaching handle
 179,8 (*) Pressing and releasing handle
190,3 190,3
TAKE BOLT B PUT IN A SCREW BOLT B
Reaching bolt B R12C 14,2 42,3 D Delay
Grasping bolt B (2) G4C 12,9
Moving bolt B M12C 15,2
Positioning P1SE 5,6 63,0 (*) Screwing bolt B manually
Grasping bolt B H 57,4
105,3 105,3
GRASP CRANKCASE IMPACT
Delay D 37,2 13,1 R20A Reaching impact
2,0 G1A Grasping impact
24,3 M20C Moving impact
Grasping left crankcase H 63,5 63,5 (*) Impacting (twice)
Moving left crankcase M14B3 16,8 24,3 M20C5 Moving impact
Putting down left crankcase RL1 2,0 5,6 P1SE Positioning
Delay D 13,1 2,0 RL1 Putting down impact
134,8 134,8
Total normal time 637,9 637,9

3. Discussion
According to calculation of standard time estimation using the PDTS (Pre Determined
motion Time System) method, operator time assembling left and right crankcase is 122.5
seconds. Meanwhile based on the preliminary research of time measurement from workstation
using stopwatch time study, total standard time is 180.35 seconds. It can be calculated that time
reduction for assembly process is 57.85 seconds (32.08% improvement from initial workstation
time).
Time reduction for assembly process at proposed workstation resulted from some efficiency
applied at proposed workstation. These efficiencies for example are coming from:
1. Workload distribution between right and left hand operator.
There is a difference between proposed and initial operator’s process charts. This difference
is caused by changing of motion element usually done by right hand to be done by left hand.
2. Placement of assembly components according to hand movement direction in assembly
process will reduce operator’s thinking time.
Placement layout of components in material box can be seen in figure 3 and 4. From those
figures it can be seen the existence of symmetrical and successive hand movements so that it
can reduce the component seeking time (learning curve will progressively go down and
stable). This matter will be very different if operator is still working with the component
layout in a random arrangement in the material box. With this kind of arrangement that is not
in order, operator is forced to look for component from material box beforehand.
3. Distance reduction of work facility and assembly material is appropriate to human
anthropometry and is put in the permanent place to ease withdrawal (reducing thinking time).
Distance reduction and placement type of work facility from initial workstation to proposed
workstation can be seen in the following table:
 Table 6
Distance Reduction and Placement Type of Work Facility in Proposed Workstation.

Distances of work Proposed

No Initial workstation Note
facility workstation
1 Material box according to
± 60 cm ± 45 cm
hand reach
2 Sub-station distance ± 3m ± 60 cm -
3 Initial position of added crankcase
behind operator beside operator
crankcase box table
4 Final position of
on the table on the pallet rack -
crankcase
5 Pressure tool any place certain place -
6 Impact any place certain place -
7 Impact drill any place certain place -
8 Screwdrivers any place certain place -
9 Oil tank any place certain place -

According to standard time estimation in proposed workstation, estimation of outputs

(unit/day) produced by an operator in the crankcase assembly (left and right) could be calculated.
Based on calculation in data processing and analysis, estimation of outputs in proposed
workstation is equal to 176 units per day. With optimization of jobs applied to proposed
workstation, total output at this workstation has satisfied the demand quantity of crankcases. This
output in the proposed workstation has complied with the management wish to increase
production to 150 units per day.

4. Conclusions
From data processing and analysis, some conclusions can be taken as following:
1. Workbench dimension and work facility in proposed workstation in engine pre line 3 can
be seen in table 5. From the dimensions it can be seen that the dimension of proposed
workbench is re-designed by applying dimension data of anthropometry human body.
Application of anthropometry data is done to optimize assembly process by operator in
the workstation in engine pre line no. 3.
2. New working method as proposed which is designed through study method can be seen
in table 4, while comparison between initial and proposed working method can be seen in
table 5. New working method is designed through operator’s process chart conducted by
working efficiency through workload distribution between right and left hands. With this
workload distribution between both hands shorter process time is obtained.
3. Based on new operator’s process chart, estimation of time standard in proposed
workstation is equal to 122.5 seconds. If this new time standard is converted to output
units, in one day work operator at this workstation can now produce output equals to 176
units per day where before redesign is equal to 140 units per day.