DESIGN, FABRICATION, AND TESTING OF AUTO INSOLE LOGO SCREENING MACHINE FOR FOOTWEAR INDUSTRY

• Main Author: Muhammad Malikul Adil, Nur
• Format: Theses
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/61686
• Institution: Institut Teknologi Bandung

Footwear industry is a labor intensive industry that needs huge number of worker to conduct manufacturing process. It implies that labor cost is one of the biggest expense for the company, and it may cause inappropriate profit gained. To cope with this issue, many factory leaders decide to modernize manufacturing process from manual into automation. This study develops auto insole logo screening machine as future technology to substitute current existing manual insole logo printing process. Research started by identifying the needs. Needs identification is carried out by observing directly into factory production line, and performing interview with the automation leader in one of the top leading footwear factory, located in Subang, West Java, Indonesia. Scope of work for this study consists of design, analysis, fabrication, and machine testing. Functional based design approach is chosen as design methodology to propose some alternative design concept. Pugh matrix is selected as a tool to choose the most suitable design concept. Detail drawing of selected design concept are built in Solidworks. FEA (Finite Element Analysis) is used as numerical method to evaluate the behavior of the structure using ANSYS Workbench R.19, and PLC (Programmable Logic Controller) is selected to control whole insole screening process sequences. After machine fabrication, machine testing is performed to ensure the established automation technology can fulfill the expected benefit. There are four key initiatives during assessment, safety assessment, quality assurance, productivity improvement, and payback period calculation. Safety assessment follows ISO 12100 as guideline, and it requires additional safety guarding to cover machine in order to protect machine users from accident. Quality assurance and productivity improvement are analyzed experimentally. Experimental data shows that auto insole logo screening machine achieve 64% of quality rate, enhance 23% productivity, and get payback period within 2.13 years.