Modification of Pick & Place Cam Part in

SDKZ Semi Auto Machine

MUHAMAD AZRUL AZIM BIN RAMLI

(2013860692)

A thesis submitted in partial fulfilment of the requirements for the award Of

Bachelor of Engineering (Hons.) Mechanical

Faculty of Mechanical Engineering

Universiti Teknologi MARA (UiTm)

JULY 2016

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 ACKNOWLEDGEMENT

Alhamdulillah, first of all praise to Allah upon finally completing this thesis in the
most unpredictable condition and all in all that happened regardless obstacles and
challenges in the journey to complete this research, a requirement for my degree
certificate.
Firstly I would like to put ahead, my utmost appreciation, directed to my own
family members, especially and of course my parents for their unending support regardless
any terms. Regardless any miscommunications and misunderstandings, quarrels and
hardships, it is my greatest honors and pride to be your bundle of joy since the very day
both of you held me in your hands on the day I was brought into this world.
Other than that, I would like to gratefully acknowledge Dr Kausalyah A/P
Venkatason upon his wonderful kind and attentive supervision during this research. All
of which without his experience and valuable knowledge, patience, calm guidance, care
and concern during this research, it would have not been completed as it is today. Thanks
to her from the bottom of my heart for always motivating me and providing solutions to
any arising problems.
Last but not least, I would like to thank to the ALPS ELECTRIC (M) Sdn Bhd for
giving permission to use the facilities and assisting me in the area of my research. Also all
my appreciations goes to everyone who was there on helping me to complete this project
whether directly or indirectly.

THANK YOU

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 ABSTRACT

This project investigated the effectiveness and efficiency of the machine after had been
upgrade from manual to semi auto part. The experimental studies were conducted on
studying the process of two machine which is SDKZ and RD 708 machine. In this project,
the machine will be explained very detail how it can operate and works. Even SDKZ is
categorized in semi auto machine; there are still some parts that operate manually. It will
cause the operation time of the manual part is taking shorter than the semi auto machine.
So, each process of the machine will be investigated to make sure that the machine can
reduce its operation time. By studying the process, the problem is caused by the pick and
place of cam in the machine is manually operated. Besides that, the productivity of the
SDKZ product need to be increased is one of the objectives in this project work. So, by
study the concept of pick and place from RD 708 machine, the process and design will be
applied to the SDKZ machine. The process of process, assemble, electrical and
programming will be discussed in this project. From 2D CAD, it will be generated to the
3D model. After the design has finished, it will modified so it can assemble to the SDKZ
machine. Furthermore, the analysis was applied to the machine to make sure that the
machine will be more effective and more efficient.

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 TABLE OF CONTENTS

CONTENT PAGE

PAGE TITLE i

ACKNOWLEDGEMENT ii

ABSTRACT iii

TABLE OF CONTENTS iv

LIST OF TABLES

LIST OF FIGURES

CHAPTER I INTRODUCTION

1.1 Background of study

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 1.2 Problem statement

1.3 Project methodology

1.4 Important of study

1.5 Objective of study

1.6 Scope of Study

1.7 Expected Results

CHAPTER II LITERATURE REVIEW

2.1 Introduction

2.2 Definition of Engineering Design

2.3 Automation Machine

2.3.1 Manual Machine

2.3.2 Semi Auto Machine

2.3.3 Fully Auto Machine

2.4 SDKZ Machine

2.4.1 SDKZ Manual Line

2.4.2 SDKZ Semi Auto Line

2.4.3 SDKZ Switch Product

2.4.4 SDKZ Switch (cam)

2.4.5 SDKZ Manual Line Process Flow

2.4.6 SDKZ Semi Auto Line Process Flow

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2.5 Rd 708 Machine

2.5.1 Assembly RD 708 Machine

2.5.2 Caulking RD 708 Machine

2.5.3 RD 708 Product

2.5.4 Potentiometer (EL Supply)

2.5.5 Assembly RD 708 Process Flow

2.5.6 Caulking RD 708 Process Flow

2.6 Pick & Place Process

2.6.1 Definition

2.6.2 SDKZ Machine

2.6.3 Rd 708 Machine

2.7 Design Part

2.7.1 Introduction

2.7.2 Mechanical Part

2.7.3 Standard Part

2.8 Improvement of Design

2.8.1 Kaizen

2.8.2 Operational Time

2.8.3 Usage of Labor

2.8.4 Productivity

2.9 Conclusion

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CHAPTER III METHODOLOGY

3.1 Methodology of the Project

3.2 Research Methodology

3.3 Flow Chart of Project Work

3.3.1 Problem Identifying

3.3.2 Literature Review

3.4 Workflow of Study Process

3.4.1 Process

3.4.2 Design

3.5 Design 3d Cad

3.6 Modification of Design

3.6.1 SDKZ Semi Auto Machine

3.6.2 SDKZ Semi Auto Pick & Place Part

3.6.3 Rd 708 Pick & Place Part

3.6.4 Apply the Concept

3.7 Conclusion

CHAPTER IV RESULT & DISCUSSION

4.1 Introduction

4.2 Before Modification of Pick & Place Part

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 4.3 Operational Time

4.3.1 Operational Time of SDKZ Manual Line

4.3.2 Operational Time of SDKZ Semi Auto Line

4.3.3 Discussion

4.4 Usage of Labor

4.4.1 Usage of Labor SDKZ Manual Line

4.4.2 Usage of Labor SDKZ Semi Auto Line

4.4.3 Discussion

4.5 Productivity

4.5.1 Productivity in SDKZ Manual Line

4.5.2 Productivity in SDKZ Semi Auto Line

4.5.3 Discussion

4.6 After Modification of Pick & Place Part

4.6.1 Operational Time

4.6.2 Usage of Labor

4.6.3 Productivity

4.7 Discussion

CHAPTER V CONCLUSION & RECOMMENDATION

5.1 Conclusion

5.2 Recommendation

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REFERENCES

References

APPENDIX

Appendix A 2D Drawing

Appendix B Project Schedule

Appendix C Poster

Appendix D Technical Report

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 LIST OF TABLES

TABLE TITLE PAGE

2.1 Elements in Automation Machine

2.2 SDKZ Machine Process Flow

2.3 RD 708 Machine Process Flow

2.4 Example of Standard Part Products

4.1 Time Taken for manual Line 1

4.2 Time Taken for manual Line 2

4.3 Time Taken for manual Line 3

4.4 Time Taken for manual Line 4

4.5 Time Taken for manual Line 5

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4.6 Time Taken for manual Line 6

4.7 Time Taken for manual Line 7

4.8 Average Time Taken for Manual Line

4.9 First Time Taken for Semi Auto Machine

4.10 Second Time Taken for Semi Auto Machine

4.11 Third Time Taken for Semi Auto Machine

4.12 Average Time Taken for Semi Auto Machine

4.13 Time Recorded by Using Stopwatch

4.14 Productivity of Manual line SDKZ per Shift

4.15 Productivity of Semi Auto SDKZ per Shift

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 LIST OF FIGURES

FIGURE TITLE PAGE

1.1 Industrial Machine

1.2 Project Methodology

2.1 Phase of Engineering

2.2 Automation Machine

2.3 Manual machine

2.4 Semi Auto Machine

2.5 Fully Auto Machine

2.6 SDKZ Machine

2.7 Assembly RD 708 Machine

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2.8 Caulking RD 708 Machine

2.9 Example of Pick & Place Part

2.10 3D view Pick & Place SDKZ Machine

2.11 Side view Pick & Place SDKZ Machine

2.12 Front View Pick &Place SDKZ Machine

2.13 Cam Component on SDKZ Machine

2.14 3D view Pick & Place RD 708 Machine

2.15 Top view Pick & Place RD 708 Machine

2.16 Potentiometer Component in RD 708 Machine

2.17 Example of 2D Drawing

2.18 Sample of Mechanical part

2.19 Sample of blaaaaaaaaaaaaaaaaa

2.20 Sample of blaaaaaaaaa standard part

2.21 Before kaizen

2.22 After kaizen

2.23 Time Recorded by using Stopwatch

2.24 Usage of Labor in Manual Line

2.25 Usage of Labor in Semi Auto Machine

2.26 Table of SDKZ switch productivity

2.27

2.28

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2.29

2.30

2.31

2.32

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