Reverse Engineering of Welding Positioner and It’s Manufacturing Cost Estimation

• Main Author: Baskara Hadikusumo, Andiyoga
• Format: Final Project
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/40402
• Institution: Institut Teknologi Bandung

PT. Great make the turbin runner by assembling and welding the ring, cone, and the blade into one unit of the turbine runner. There are many sections to be welded and some of them are in a difficult position to reach resulting fixture had to be dismantled of the table. But the fixture-dismantled step will add the time of runner assembly process, and the risk of assembly errors that exceeds the allowed tolerance could have occurred. Therefore, a tool such as welding positioner is needed to address these probelms. However, welding positioner that is available in the market has a very high price. The purpose of this final project is to reverse-engineering the welding positioner and estimates the cost of manufacturing welding positioner. The reverseengineering is limited on the model. The methods in reverse-engineering are problem identification, digging technical information, seek knowladge of welding positioner, modeling and analysis. After thatm the estimated cost of manufacture is performed to determine the cost of a welding positioner unit. The results of redesign product are then compared with equivalent product. The results of the comparison indicates the unit price of a reverse engineering product is Rp.89.000.000,- compared with the price of equivalent products worth Rp. 330.000.000,-. The limitations of reverse-engineering product are the table-tilting mechanism which can onlu be up to 111 degrees, and automation system is not yet fully integrated. If necessary, the manual version can be made that by using the crank to rotate and tilt the table, and the hydraulic actuator to adjust the height of the table. Author expects this article can give the contributions to the growth of manufacturing in Indonesia.