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EDC Profile 2014
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Introducing EDC
PT. Astra Otoparts, TbkEngineering Development Centre Division
Trustworthy & Reliable ǀ Customer Focus ǀ Passion for Excellence ǀ Team Work
Greenland International Industrial Center (GIIC)
Kav. AA No. 25, Deltamas City KM.37
Central Cikarang, Bekasi
Tel: +62-21-8257-8888
Web: www.component.astra.co.id
2014
EDC VISION, MISSION, AND VALUES
Our Vision
“To be a world class Product Design & Verification, Dies Mold Design & Manufacturing to create Unique & Competitive Automotive Component.”
Employee To create excellent engineering competence through innovation based on AOP Core Value
Deliverable To deliver valuable & innovative product
Customer To be a highly reliable partner to create best development solution
OUR VISION OUR MISSION
CORE VALUE
1. TRUSTWORTHY & RELIABLE
2. CUSTOMER FOCUS
3. PASSION FOR EXCELLENCE
4. TEAMWORK
EDC PROFILE
Location : Greenland International Industrial Center Kav. AA No.25, DeltaMas City, Central Cikarang,
Bekasi (Exit KM.37)Office Hour : Mon – Fri (7.00 ~ 16:00)Land Area : 5 haBuilding Area : 7560 m2Employee : 92 member EDC (+58 member DMC)
(Nov’13) EDC Building Front View
Area of Competence
Product Design
Sample Evaluation
Dies & Mold
Exit Toll KM37
Jakarta Area
CawangHighway
EDC Map
CikampekHighway
EDC Building
COMPANY STRUCTURE
PT Astra Otoparts, Tbk since 19767 Business Unit 42 Subsidiaries Companies
PT Astra International, Tbk since 1957158 Subsidiaries Companies168.703 Employees (by 31 Dec 2011)
EDC Division
Admin Advisor
CENTRAL FACILITY SUPPORT
PRODUCT DEVELOPMENT
Die and mold design and making
Unique process development
ENGINEERING DEVELOPMENT CENTER
Equipment / facility
Product Design, Testing & Verifying.Job scope
DIE & MOLD CENTER
Centralized testing laboratory
Metallographic Microscope
Scanning Electron Microscope w/ EDS
- Material laboratory
- Metrology & Data Acquisition lab.
- Chasis Dyno lab. 2W
CAD / CAMCNC millingEDMCNC wirecutDie Spotting, etc
Prototyping
ORGANIZATION
3D CAD/ CAE Solidworks3D CAD Catia
EDC with Unique & Innovative Solution
EDC commited to deliver best solution of full range product design & engineering program from investigation, design untill verification .....
Investigation & Benchmark
Design Concept Prototyping Verification
By leveraging Idea’s, knowledge, and experience together with you as our distinguished customer , we will create new horizon of opportunities ahead......Metrology &
Measurement
Product Design & Development
PrototypeDevelopment
5X CNC3D Printer
Craftmanship
Proto strategy
3D Scanner Optical Measurement
CAD & CAE
Content,Composition, properties
Material Characterization
On VehicleData Aquisiton
Part Perf’mance & Durability
Std Inspection & Custom Test
• Develop New Product more focusing on:
– Cost Competitiveness
– Performance
– Comfort ability, Environmental Friendly, Safety, Energy Consumption, Safety
• Join product development with AFFCO in AOP group (included Car Manufacturers) as a product based alternative/second supplier, for example : commercial seat
DESIGN ACTIVITY
PRODUCT DEVELOPMENT
INNOVATION & RESEARCH
Cooperated with University and Professional expertise, meanwhile to built up the R&D center, especially work for the primary of pre-research , and for supporting the following development of application fields.
Until December 2013 already have 2 patent, next year target in 2014 is 11 patent
NO APPLICATION TYPE INVENTION TITLE PATENT NO REGISTER DATE
1 SILENT CHAIN RANTAI TAK BERSUARA DENGAN GERAKAN CHORDAL YANG RENDAH
P00201201065 29 NOV 2012
2 TENSIONER ALAT PENGENCANG RANTAI CAMSHAFTDAN METODE PENGUNCIAN PLUNGERPADA ALAT TERSEBUT.
P00201200651 10 AUG 2012
Gerakan Chordal Profil tooth plate dapatmengurangi gerakan chordal
SILENT CHAIN ILLUSTRATION TENSIONER ILLUSTRATION
On Vehicle Condition
Central Facility Support
• System Performance
• System Durability• Dimensional
Analysis (Metrology)
• Parts Quality Check
• Material Properties (Mechanical, Physical, Chemical)
• Environmental Health & safety compliance
• Performance evaluation
• Durability Evaluation
• Quality Problem Analysis
Mat’l Evaluation
MetrologyCustom
Durability DAQStandard
Inspection /Test
Parts System Evaluation
Material Evaluation
CFS FOR PRODUCT DEVELOPMENT SUPPORT
Polymer
Chemical
Field 2
Field 3
Analyzer Application
• UTM• Rockwell/Vickers Hardness• Charpy Impact • Micr. Stereo/ Metallographic• Immersion Test• Crack Check• SEM
• Immersion Test•Crack Check•UV-Vis Spectroscopy•X-R Fluorescence
•Mechanical Properties•Physical properties•Composition•Phase & grain size•Material character
Modification• Failure Analysis
•Ultrasonic Terra Cleaner•Specimen Dryer•Chemical Liquid
• Izod/DuPont Impact• Melt Flow Indexer/MFR• FTIR Spectroscopy• Thermo Gravitimetri / Digital
Thermo Analysis
•Anti Corrosion•RoHS Cr6+•SoC Free check•Mat’l Composition
•Melting/Softening temp•Mat’l Contents•Mat’l Composition•Material purities•Coating strength
MATERIAL EVALUATION
Field 1
Metal
Preparation
•Band Saw•Fine Cutter•Muffle Furnace •Hot Mounting Press•Grinding/Polishing
MATERIAL EVALUATION
Next
• Scanning Electron Microscope
Pre
par
atio
nIn
spec
tio
n
Chemical Composition
MicroStructure Hardness Impact
Metal Inspection
PolymerInspection
Chemical Composition
Thermal Analysis Flow rate Immersion Impact
ChemicalInspection
RoHS/ Chemical Composition
QuantitativeElement
General Application
Ultras onicCleaner
Precision Weight
Mechanical Properties
Heat Treatment
Surface Thoughness
Visual Macro Structure
MATERIAL CHARACTERIZATION
Material Characterization
(1) Preparation
(2) Inspection
Metal Inspection
ChemicalInspection
General Application
PolymerInspection
(3) Analysis & Report
Spectro
CHARPY
Hardness
Micro Structure
SEM
Furnace Weight
UltrasonicCleaner
UTM
Dupont/Surface Impact
Micro Structure
XRF
UV-VIS
FTIR TG/DTA
MFIImmersion
IZOD
MEASUREMENT & METROLOGY
3d
2.5d
2d
• Hi precision up to 2.5d measuring (3mm)• Hi precision 3d measuring (20 mm)• Scanning & Measuring 3d X-Section• Provide solid data.stl file
Optical Profile Projector
3d Optical Scanner
① Capture 3D Surface& Reverse Engineering
② Dimensional Inspection
③ Deformation, Compare Actual Part vs 3d CAD
④ 2D/Section Analysis
Capability / Feature :
Accuration : 10 – 20 µm
METROLOGY - 3D OPTICAL SCANNER
EDC DATA ACQUISITION | SERVICES
Concept | Complete Configuration
4W 2W
Data AquisitionServices
Wheel/TireSpeedTemp
EngineSpeedOil PressureCoolant Temp
ControlSteer positionPedal PositionBrake Pressure
AccelerometerPitch Roll YawLateral, Long Accel
TransponderTrack PositionStart/Finish
SuspensionTravelAccelreationForce
Camera SystemVideoAudio
Data Aquisition
Data Aquisition Program | Installation
On Vehicle Realtime Data Processing & Analysis
DATA ACQUISITION OVERVIEW | ON VEHICLE
Trip Plan
Data Plan
Data Processing
Data Analysis
Z
Temperature
Temperature/Humidity Sound/
Noise
Displaydata logging
Gas sensor
Gyroscopesensor9 axis
GPSsensor
Vibrationsensor
X
X
EDC DATA ACQUISITION | SERVICES
▫ Vibration due to engine/road load▫ Critical stress structure▫ Charging/Loading history▫ Impact/vibration▫ Noise & Vibration Characteristic▫ Temperature/humidity▫ *Gas contain in cabin
Measuring Condition in car current, vibration, temperature, comfort abilityfor database to support product development seat, battery, noise problem (transmission)
Measurement Data
CUSTOM DURABILITY | CONFIGURATION
• Position (controls, suspension travel),
• temperature • Pressure • Accelerometers, • video and sound recorders, • IR transponder, • GPS receiver
Sensor
Off Board
Computer
Actuators &
ControllerStorage
Sensors Processor Transmitter
T Slot, Frame
Rigs & Jigs
# Sample Test /
Specimen
• 32 Bit | CAN• 16 Bit | BUS 8 Channel• 8 Bit
Processor• T Slot | Big – Med – Small• Frame | Big – Med – Small• Jigs | Manual – Auto
T/F/R/J• Hi Frequency• Medium Frequency• Low Frequency
Actuator
Propeller shaftFatigue durability
Seat- Head rest Impact Seat- Frame
Strength Durabl’y
Chassis TruckStatic Strength
CUSTOM DURABILITY TEST | APPLICATION EXAMPLE
① Confirm performance test
② Running test simulation
Capability / Feature
FUNCTION – TYPE TEST – CHASSIS DYNO
Silent Chain Development
Gasoline Cleaner Effected on Spark Plug
Piston Development
Guide TensionerDevelopment
Data Graph
NO. 1 (m Strain)PRE- : 20ACTUAL : 34CAE : 433
Capability / Feature
① Verification for CAE analysis
VS actual stress
Recorder &
Analyzer
Strain gage
VS② Stress calculation for failure
prediction of part / component
Life strength prediction
Critical point
Strain meas.
OTHER TEST – STRAIN LOGGER
DSA
Accelerometer sensor
Capability / Feature① 3D Vibration measurement to indicated abnormal function of part/component
② Vibration verification of part/component related to allowed standard/regulation(example : human vibration on ISO std)
Application example : Vibration test on part, lifter tensioner
X
Y
Z
Vibration level allowed
OTHER TEST – VIBRATION MEASUREMENT
DSA : Digital signal analysis
OTHER TEST – THERMAL IMAGER
Thermal analysis of surface/area represented on image
Thermal imager
Ex. : Mapping temperature of cover cyl. Head and cover crankcase while engine running
Capability / Feature
Climatic Chamber
FUNCTION - TYPE TEST – CLIMATIC TEST
Capability / Feature1) Temperature measurement to -40 to 150 deg2) Humidity control from 15 to 98% Rh3) Temperature increasespeed 6 deg/min4) Temperature decrease speed 40 deg/hr (from 150 deg Celcius)
-40.0
-20.0
0.0
20.0
40.0
60.0
80.0
100.0
Stability of Temperatur
Machine
Thermometer
Temperature Stability Control
Test Stability in 70’C
Humidity Control
PROTOTYPING | 5 Axis CNC
UG NX
M/C DMC 75 V Linear (EDC)
Sp
ecif
ica
tio
n
X-Axis : 750 (885) mmY- Axis : 600 mmZ- Axis : 560 (600) mmB- Axis : +10 / -110 degC-Axis : 360 degRPM Spindle : 28000 rpmTool Mount : HSK A63Feed rate : 90.000 mm/menitWork Table : Ø 750 mm
Max workpiece weight : 800 KgTool Magazine : 30 PocketsMax. tool length : 300 mmController : Heidenhein iTNC 530
CA
M
PrototypeDevelopment
5X CNC3D Printer
Craftmanship
Proto strategy
AREA
1st Floor = 2592 m2 Machining and setting 2nd Floor = 576 m2 Design, CAM and
Meeting roomMANPOWER
CurrentADMIN : 1PPIC : 5 DESIGN : 8MANUFACTURING : 38ENGINEERING : 5ADVISOR : 1
TOTAL 58
DIE & MOLD CENTER PROFILE
DMC focus on Design and Manufacture for Aluminium HPDC Dies and Plastic Injection Mold for Supporting AOP Group.
Part Name: Support Control LinkCustomer: Nusa Metal
Design & Manufacture by EDC- DMC
DIES & MOLD MACHINE & SOFTWARE
MACHINE Qty
MA
NU
FAC
TUR
E M
AC
HIN
E
CNC Milling Small size 4 Units
CNC Milling Medium size 4 Units
CNC Milling Large size 2 Units
CNC EDM 2 Units
CNC Wire Cut 1 Unit
CNC Graphite Milling 1 Unit
Die Spotting 1 Unit
Surface Grinding 2 Units
Manual Milling 1 Unit
Manual Lathe 1 Unit
Manual Radial Drill 1 Unit
Cylindrical Grinding 1 Unit
Manual tool Grinding 1 Unit
CMM Large Size 1 Unit
SOFTWARE Qty
CAD
Catia 1
UG NX 8.5 5
SolidWork 10
CAMUG NX 8.5 3
PowerMill ( Delcam ) 2
CAEProCast 1
Mouldex 1
MACHINE (New 2014) Qty
CNC EDM 1 Unit
CNC Wire Cut 1 Unit
HPDC 650T 1 Unit
CNC Graphite Milling 1 Unit
Manual Radial Drill 1 Unit
DMC Machine Spec
• Editing• Modification• Revision
PART
• Shrinkage• Parting line• Mold & Dies Design• Component Design• Flow Analysis
DESIGN
• Dies / MouldConstruction
• BOM• 3D & 2D
Drawing
ASSY 3D/2D
• Preparation & cutting strategy
• Generate tool path
CAM MAKING
• Verification cutting
CAM CHECKING
•Machining •Setting•Assembly
MANUFACTURING
❶ ❷ ❸
❹ ❺ ❻
ACTIVITY OBJECTIVE 4W 2W
DrawingVerification
Making 3D/2D drawing component to make
Dies/Mold Component
Body Water Pump (NM/AISIN)Support Control Link (NM/ADM)Cover Control Shaft (NM/ADM)
Brake Shoe (NM/AHM)Upper Bracket (NM/KYB)Cover R Engine (NM/AHM)Cover L Engine (NM/AHM)Cover Head (NM/AHM)Rear Grip (NM/AHM)Base Stator (NM/AHM)Swing Arm (NM/AHM)
DIES & MOLD ACTIVITY
DIE
S C
AST
ING
INJE
CTI
ON
MO
LDDIES & MOLD CAPACITY
0
50
100
150
2013 2014 2015
Units Dies30
100
120
0
10
20
30
40
2013 2014 2015
Units Mold
20
30
Notes:Mold for big size started in 2015
Description 3D Dies & Product Mfg Dies & Product
SUPPORT CONTROL
LINK
COVER COMP HEAD
SWING ARM
COVER CONTROL
SHAFT
DMC PRODUCT
Description 3D Dies & Product Mfg Dies & Product
UPPER BRACKET
BODY WATER PUMP
TEPO
L CRANK CASE
DMC PRODUCT
Description 3D Dies & Product Mfg Dies & Product
R CRANK CASE
R CRANK CASE
DMC PRODUCT
Description 3D Mold & Product Mfg Mold & Product
SEAT BOTTOM
TERE
HANDLE
DMC PRODUCT
We will do the works with passion by maximizing our facilityContact Person
Position Name Contact No Email
EDC Div Head / Product Development Gilbert P.D. 0899-8002-552 [email protected]
Central Facility Support Dept Head Edwin A. 0815-9817-902 [email protected]
Material Evaluation Fenny T.K. 0898-9376-052 [email protected]
Metrology Jefri P. 0821-3453-3772 [email protected]
Testing & Durability Aji W. 0812-8442-9751 [email protected]
Prototype Adi C.
Die & Mold Center Dept Head Jojok P. 0812-9054-413 [email protected]
Marketing Nina A.S. 0812-8289-4636 [email protected]
CONTACT PERSON
Trustworthy & Reliable ǀ Customer Focus ǀ Passion for Excellence ǀ Team Work
THANK YOU........
