1. Progress & Activity Plan Machining Chip Improvement
Report to：
Board of Directors
Progress & Activity Plan Machining Chip Improvement
PT. Akebono Brake Astra Indonesia
Mar 20, 2017
Copyright Akebono Brake Industry Co., Ltd. All Rights Reserved.

2. Current AAIJ condition
Chip stuck at machine walls, jig & fixtures because of small flow and pressure of coolant :
Low power pumps  AAIJ 0.75 kW, ACG 7 kW
Small volume chip conveyor
Small drum filter
No magnet to catch fine chips & body casting carbon
Capacity of drum only 230 litre/min if use high volume pumps flooding chip conveyor

3. Activity Plan
Permanent countermeasures
Based on ACG benchmark, to clean up machine room inside (jig, tables, tools, walls) we need to replace all machining pumps with bigger size from 0,75 kW to 7 kW for each machine.
We also need to increase chip conveyor size from 500 – 600 litres to 2,000 litres for 4 machines equipped with magnet scraper and magnet separator
Option 1 (chip conveyor with 3 drum filter with magnet separator)

4. Activity Plan
Permanent countermeasures
Option 2 (chip conveyor with no drum filter with magnet scraper & separator) : ACG
Investment needed (estimation) 1 chip conveyor :
IDR 200,000,000 (new) – local supplier
IDR 100,000,000 (modification) – local supplier
Lead time : 3 weeks

5. Activity Plan Additional body shower inside machine
Permanent countermeasures
Additional body shower inside machine
Replace washing machine
Investment needed

6. Activity Plan
Temporary countermeasures
For non thru coolant machines, remove the drum filter replace it with mesh plate and connect it with high flow pumps

7. Activity Plan
Temporary countermeasures
For thru coolant machines, make buffer tank with bag filter and cyclone and equipped it. Coolant supplied from chip conveyor before drum filter.
Buffer tank :
300 litre

8. Equipment list to improve
Matrix what each line needed
Line
Chip Conveyor
Body washer
Washing machine
Magnet scraper
Sel 2
4 (New)
10 units X
Sel 4
4 (modify)
15 units
1 unit
4 units
Sel 5
Sel 3
Sel 7
Sel 8
Sel 9
3 (modify)
3 units
Sel 6
2 (new)
13 units
5 units
MWC1
2 (modify)
2 units
MWC2
MWC3
6 units
PWC

9. Equipment investment Equipment Investment/unit Qty Total Chip conveyor
In IDR millions
Equipment
Investment/unit
Qty
Total
Chip conveyor
(modify)
100
22 units
2,200
(new)
200
10 units
2,000
Washing machine
250
6 units
1,250
Buffer tank with filter bag & cyclone 60
4 units
240
Body shower (piping) 10
101 units
1,010
Pumps & accessories 30
202 units
6,060
TOTAL
12,760

10. Schedule (short term)