Introducing EDC

PT. Astra Otoparts, Tbk

Engineering Development Centre Division
Trustworthy & Reliable Customer Focus Passion for Excellence 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 ha
Building Area : 7560 m2
Employee : 92 member EDC (+58 member DMC)
(Nov13)
EDC Building Front View
Area of Competence
Product Design
Sample Evaluation
Dies & Mold
Exit Toll
KM37
Jakarta
Area
Cawang
Highway
EDC Map
Cikampek
Highway
EDC
Building
COMPANY STRUCTURE
PT Astra Otoparts, Tbk since 1976
7 Business Unit
42 Subsidiaries Companies
PT Astra International, Tbk since 1957
158 Subsidiaries Companies
168.703 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 / CAM
CNC milling
EDM
CNC wirecut
Die Spotting, etc
Prototyping
ORGANIZATION
3D CAD/ CAE Solidworks
3D 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 Ideas, knowledge, and
experience together with you as our
distinguished customer , we will create new
horizon of opportunities ahead......
Metrology &
Measurement
Product Design
& Development
Prototype
Development
5X CNC 3D Printer
Craftmanship
Proto strategy
3D Scanner
Optical
Measurement
CAD & CAE
Content,Composition, properties
Material
Characterization
On Vehicle
Data Aquisiton
Part Perfmance
& 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 CAMSHAFT
DAN METODE PENGUNCIAN PLUNGER
PADA ALAT TERSEBUT.
P00201200651 10 AUG 2012
Gerakan Chordal Profil tooth plate dapat
mengurangi 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
Matl
Evaluation
Metrology
Custom
Durability
DAQ
Standard
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
Matl Composition
Melting/Softening temp
Matl Contents
Matl 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
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Chemical
Composition
Micro
Structure
Hardness Impact
Metal
Inspection
Polymer
Inspection
Chemical
Composition
Thermal
Analysis
Flow rate Immersion Impact
Chemical
Inspection
RoHS/ Chemical
Composition
Quantitative
Element
General
Application
Ultras onic
Cleaner
Precision
Weight
Mechanical
Properties
Heat
Treatment
Surface
Thoughness
Visual Macro
Structure
MATERIAL CHARACTERIZATION
Material
Characterization
(1) Preparation
(2) Inspection
Metal
Inspection
Chemical
Inspection
General
Application
Polymer
Inspection
(3) Analysis & Report
Spectro
CHARPY
Hardness
Micro Structure
SEM
Furnace Weight
Ultrasonic
Cleaner
UTM
Dupont/Surface Impact
Micro Structure
XRF
UV-VIS
FTIR TG/DTA
MFI Immersion
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
Capture 3D Surface
& Reverse Engineering
Dimensional Inspection
Deformation, Compare
Actual Part vs 3d CAD
2D/Section Analysis
Capability / Feature :
Accuration : 10 20 m
METROLOGY - 3D OPTICAL SCANNER
EDC DATA ACQUISITION | SERVICES
Concept | Complete Configuration
4W 2W
Data
Aquisition
Services
Wheel/Tire
Speed
Temp
Engine
Speed
Oil Pressure
Coolant Temp
Control
Steer position
Pedal Position
Brake Pressure
Accelerometer
Pitch Roll Yaw
Lateral, Long Accel
Transponder
Track Position
Start/Finish
Suspension
Travel
Accelreation
Force
Camera System
Video
Audio
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
Display
data logging
Gas sensor
Gyroscope
sensor
9 axis
GPS
sensor
Vibration
sensor
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 ability
for 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 &
Controller
Storage
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 shaft
Fatigue durability
Seat- Head rest
Impact
Seat- Frame
Strength Durably
Chassis Truck
Static Strength
CUSTOM DURABILITY TEST | APPLICATION EXAMPLE
Confirm performance test
Running test simulation
Capability / Feature
FUNCTION TYPE TEST CHASSIS DYNO
Silent Chain Development
Gasoline Cleaner
Effected on Spark Plug
Piston Development
Guide Tensioner
Development
Data Graph
NO. 1 (m Strain)
PRE- : 20
ACTUAL : 34
CAE : 433
Capability / Feature
Verification for CAE analysis
VS actual stress
Recorder &
Analyzer
Strain gage
VS
Stress calculation for failure
prediction of part / component
Life strength
prediction
Critical
point
Strain
meas.
OTHER TEST STRAIN LOGGER
DSA
Accelerometer
sensor
Capability / Feature
3D Vibration measurement to indicated abnormal function of part/component
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 / Feature
1) Temperature measurement to -40 to 150 deg
2) Humidity control from 15 to 98% Rh
3) Temperature increasespeed 6 deg/min
4) 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 70C
Humidity Control
PROTOTYPING | 5 Axis CNC
UG NX
M/C DMC 75 V Linear (EDC)
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X-Axis : 750 (885) mm
Y- Axis : 600 mm
Z- Axis : 560 (600) mm
B- Axis : +10 / -110 deg
C-Axis : 360 deg
RPM Spindle : 28000 rpm
Tool Mount : HSK A63
Feed rate : 90.000 mm/menit
Work Table : 750 mm
Max workpiece weight : 800 Kg
Tool Magazine : 30 Pockets
Max. tool length : 300 mm
Controller : Heidenhein iTNC 530
C
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Prototype
Development
5X CNC 3D Printer
Craftmanship
Proto strategy
AREA
1
st
Floor = 2592 m2 Machining and setting
2
nd
Floor = 576 m2 Design, CAM and
Meeting room
MANPOWER
Current
ADMIN : 1
PPIC : 5
DESIGN : 8
MANUFACTURING : 38
ENGINEERING : 5
ADVISOR : 1
TOTAL 58
DIE & MOLD CENTER PROFILE
DMC focus on Design and Manufacture for AluminiumHPDC Dies and Plastic
Injection Mold for Supporting AOP Group.
Part Name: Support Control Link
Customer: Nusa Metal
Design & Manufacture by EDC- DMC
DIES & MOLD MACHINE & SOFTWARE
MACHINE Qty
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M
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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
CAM
UG NX 8.5 3
PowerMill ( Delcam) 2
CAE
ProCast 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 / Mould
Construction
BOM
3D & 2D
Drawing
ASSY 3D/2D
Preparation &
cutting strategy
Generate tool path
CAM MAKING
Verification cutting
CAM CHECKING
Machining
Setting
Assembly
MANUFACTURING

ACTIVITY OBJECTIVE 4W 2W
Drawing
Verification
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
D
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C
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M
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DIES & MOLD CAPACITY
0
50
100
150
2013 2014 2015
Units Dies
30
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 facility
Contact Person
Position Name Contact No Email
EDC Div Head / Product Development Gilbert P.D. 0899-8002-552 gilbert.dewanto@component.astra.co.id
Central Facility Support Dept Head Edwin A. 0815-9817-902 edwin_a@component.astra.co.id
Material Evaluation Fenny T.K. 0898-9376-052 fenny.kurniawati@component.astra.co.id
Metrology Jefri P. 0821-3453-3772 jefriyanto.patalo@component.astra.co.id
Testing & Durability Aji W. 0812-8442-9751 aji.wibowo@component.astra.co.id
Prototype Adi C.
Die & Mold Center Dept Head Jojok P. 0812-9054-413 jojok.purnomo@component.astra.co.id
Marketing Nina A.S. 0812-8289-4636 ninarista@gmail.com
CONTACT PERSON
Trustworthy & Reliable Customer Focus Passion for Excellence Team Work
THANK YOU........