DEVELOPMENT OF PRODUCTION UNIT MONITORING SYSTEM IN LABOR-INTENSIVE INDUSTRIES BASED ON CONFIGURABLE VIRTUAL WORK STATION

• Main Author: Hartono, Rachmad
• Format: Dissertations
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/57080
• Institution: Institut Teknologi Bandung

The manufacturing industry must be able to produce fine and cheap products according to a predetermined and must also be able to meet fast-changing customer demands. The manufacturing industry products must be more adaptable to the customer demands so that the competitiveness of the manufacturing industry remains high. The current challenge in the manufacturing industry is to produce customized products in limited quantities and with production costs approaching the costs of producing mass products. The manufacturing industry must apply customized and flexible mass production technologies to make customized products at low production costs in order to meet the demands. This application requires a manufacturing system consisting of independent and intelligent production elements (products, materials, machine tools, tools, and operators). These production elements work independently or coordinate with each other and always work following the common set goals to produce customized products to customer desires. A manufacturing system consisting of intelligent production elements refers to an intelligent manufacturing system which is the main feature of Industry 4.0. In general, an intelligent manufacturing system is created by duplicating production elements in the real world as models for production elements in the virtual system. For this purpose, every production element in the real world has a monitoring and control device that can sense changes that occur in each virtual production element and at the same time updates the conditions of the production element model in the virtual system. Production element models in virtual systems have the intelligence to communicate with other elements and make decisions to achieve common goals. To create an intelligent manufacturing system described in the previous paragraph, it will be relatively easier for manufacturing industries that have implemented the Industry 3.0 paradigm and more difficult for others that are still applying the Industry 2.0 paradigm due to stepping. The transition from Industry 2.0 to 4.0 will require a lot of expense to replace manual processes by humans with automatic processes carried out by automated equipmentIn addition, labor-intensive industries will find it difficult to replace the workers with automatic machines. Not all production elements can be equipped with monitoring and controlling devices due to limitations in size, nature, and these production elements processes. However, besides the limitations found in this manufacturing system, the process flexibility of most processes, because it carried out by humans who can take adjustment actions according to their abilities, is considerable potential. The focus of this study is to find a way to increase the capability of a manufacturing system in Industry 2.0 conditions to become Industry 4.0 at an affordable cost are due to most of the manufacturing industries in Indonesia are still in the Industry 2.0 condition. In general, the problem faced by the manufacturing industry in Indonesia is the integration that does not work well between the components in the factory because the flow of data and information does not run smoothly. This condition causes the resolution of the problem to be local and not done comprehensively. In addition, production activities are carried out almost without a plan or planned without being based on data following current conditions in the factory. One way to overcome data and information flow constraints in the manufacturing industry in Industry 2.0 is by developing the concept of a Configurable Virtual Workstation (CVWS). In this concept, the production unit divides into several work areas that coincide with each other. There is no area in the production unit that does not become a work area for any workstation. Each workstation is equipped with monitoring and controlling devices and can recognize every production element in its work area. Every time a production element enters the workstation work area, the production element register as a member of the workstation by scanning the identity of each production element. It can be a sticker containing a barcode or an RFID card. By utilizing the CVWS concept, the monitoring and control devices embedded in each production element replace with stickers or RFID cards containing the identity of the production element. Thus the cost of monitoring and controlling is cheaper. The CVWS concept has been used as the basis for developing a production operation monitoring system in one of the manufacturing industries in Indonesia to monitor production operation activities. Several operating data were recorded from this monitoring. Some information related to the condition of the production unit can be obtained based on this data, such as material requirements, the progress of product completion, the number of hours worked by the operator, the ability to trace the components of the product, and some information related to production control. The contribution of this research is that the production unit monitoring system can be utilized by the manufacturing industies which applies the labor-intensive concept. The monitoring system can also provide an overview of how to monitor the production unit without replacing existing production processes or production equipment.