Design of Numbering Machine Control System based on Omron CJ2M PLC with Omron NB10 Touchscreen HMI for Improving Manufacturing in Motorcycle Assembling Industry PT XYZ

Abstract

Engine numbering process is the earliest step in assembling a motorcycle engine and it is strictly prohibited to make slightest mistake. Because if it happens, it will disrupt the next process and / or jeopardize vehicle engine registration process required by National Police Department. However, in 2017 alone there have been no fewer than 200 engines produced with wrong number. This is because the existing machines are prone to errors, with inadequate protection system, and unavailability of human machine interface (HMI) for operator monitoring the machine. In this paper we present a new design for numbering machine control system with more reliable protection logic, so that zero mistakes can be realized. Improved protection system includes checking repetition of process for the last 100 data, better type selection protection, protection of sequential numbering process, and acknowledgment using fingerprint scanner. The programming language used was made using structured text language which making it easier for programming, monitoring and troubleshooting. An intuitive interface has also been made using HMI touchscreen. Testing all input data protection logic shows very good results with 100% success rate, so that it can fulfil zero mistake requirement. In this way this machine can be declared ready for mass production.