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SMART ANDON SYSTEM BASED ON INDUSTRIAL INTERNET OF THINGS (IIOT) Purnomo , Wahyudi; Maulana, Gun Gun; Suryatini, Fitria; Sunarya, Adhitya Sumardi
Jurnal Rekayasa Mesin Vol. 15 No. 2 (2024)
Publisher : Jurusan Teknik Mesin, Fakultas Teknik, Universitas Brawijaya

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/jrm.v15i2.1532

In many industrial settings, there are several problems that can arise during the production process. These include machine breakdowns, quality issues, and unexpected delays, which can impact productivity, reduce overall efficiency, and result in lower quality output. In addition, without an effective monitoring system, it can be difficult to identify the root causes of these problems and take appropriate corrective actions.To address these challenges, the implementation of a smart andon system can be highly beneficial. This system enables real-time monitoring of the production process, allowing operators and management to quickly identify and respond to any issues as they arise. By providing instant notifications and alerts, the smart andon system can help reduce downtime, increase productivity, and improve product quality. It also enables more accurate and comprehensive data collection, facilitating better analysis and decision-making by management. Overall, the smart andon system can play a critical role in improving operational efficiency, reducing costs, and enhancing overall competitiveness in today's highly competitive industrial landscape.the implementation of a smart andon system has been shown to improve production efficiency, reduce downtime, and increase overall equipment effectiveness (OEE). The system allows for real-time monitoring of the production process, early detection of problems, and quick resolution of issues through timely alerts and notifications. This can result in significant cost savings for the industry, improved product quality, and increased customer satisfaction.

Koi Fish Pond Monitoring System Using IoT Sukarno, Setyawan Ajie; Maulana, Gun Gun; Andrea, Ferdyan
Emitor: Jurnal Teknik Elektro Vol 24, No 3: November 2024
Publisher : Universitas Muhammadiyah Surakarta

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.23917/emitor.v24i3.6732

The process of collecting water parameter data for koi fish ponds is still done manually. Each parameter from the manually collected samples is tested one by one. This process is inefficient and can cause delays in decisionmaking for koi fish farmers. If the manual testing reveals results that exceed the ideal threshold, it can have a negative impact on the fish. To address this issue, a koi fish pond water parameter monitoring system was designed using an automated method based on the Internet of Things. The sensors used in this study include an ultrasonic sensor, turbidity sensor, Total Dissolved Solids (TDS) sensor, and pH sensor. Based on the test results, when the values of the turbidity and TDS sensors exceed the set parameter limits of 40 NTU and 400 PPM, respectively, the system will activate the draining pump until the water level reaches the lower limit (10 cm), after which the filling pump will activate until the upper water level limit (18 cm) is reached. If the pH sensor value is below the lower limit set in the parameter, the system will activate the alkaline liquid pump to neutralize the pH to a value of 7. Conversely, if the pH sensor value exceeds the upper limit set in the parameter, the system will activate the acidic liquid pump to neutralize the pH back to 7. This automatic draining and filling system will stop working when the turbidity, TDS, and water level values fall within the parameters set in Blynk. The system also maintains the pond's water level at the upper limit set in the parameters.

Implementation of IoT-based SCADA in MPS Processing Station Integrated with CtrlX Automation Maulana, Gun Gun; Mada, Ridwan; Rokhim, Ismail; Rudiansyah, Hendy; Suhada, Muhammad Giri
Jurnal Rekayasa Elektrika Vol 21, No 2 (2025)
Publisher : Universitas Syiah Kuala

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.17529/jre.v21i2.40848

The increasing complexity of industrial automation technology today requires industries to upgrade their existing systems, such as IoT-based SCADA, which allows for real-time production monitoring from anywhere. However, to achieve this, a system is needed that does not affect or halt the production process and does not require replacing the existing system during the upgrade process. Therefore, a system that can adapt to the existing one is necessary. This research aims to implement an IoT-based SCADA system in an existing plant by integrating the system with ctrlX Automation to address this issue. The implementation is carried out in several stages. The first stage involves integrating the plant controlled by the Omron CP1L PLC with ctrlX Automation. The second stage is creating tags for the SCADA system using tools installed on ctrlX Automation. The third stage involves developing the user interface. The fourth stage is the remote access communication process for the IoT system using the OpenVPN Cloud tool. The test results show that the integration between the Omron CP1L PLC and ctrlX Automation was successful, with a 100% tag retrieval rate from the Omron CP1L PLC, and the data could be visualized. The user interface can be accessed, and remote access can be performed on different networks and locations using the OpenVPN Cloud tool. During testing, the average data transfer write-read delay with one address/tag during remote access was 61.3ms, and for the write-read test with three addresses simultaneously, the average was 78.1ms. Based on these results, the data transfer process using ctrlX Automation integrated with the Omron CP1L PLC can be categorized as very good.

SMART ANDON SYSTEM BASED ON INDUSTRIAL INTERNET OF THINGS (IIOT) Purnomo , Wahyudi; Maulana, Gun Gun; Suryatini, Fitria; Sunarya, Adhitya Sumardi
Jurnal Rekayasa Mesin Vol. 15 No. 2 (2024)
Publisher : Jurusan Teknik Mesin, Fakultas Teknik, Universitas Brawijaya

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/jrm.v15i2.1532

In many industrial settings, there are several problems that can arise during the production process. These include machine breakdowns, quality issues, and unexpected delays, which can impact productivity, reduce overall efficiency, and result in lower quality output. In addition, without an effective monitoring system, it can be difficult to identify the root causes of these problems and take appropriate corrective actions.To address these challenges, the implementation of a smart andon system can be highly beneficial. This system enables real-time monitoring of the production process, allowing operators and management to quickly identify and respond to any issues as they arise. By providing instant notifications and alerts, the smart andon system can help reduce downtime, increase productivity, and improve product quality. It also enables more accurate and comprehensive data collection, facilitating better analysis and decision-making by management. Overall, the smart andon system can play a critical role in improving operational efficiency, reducing costs, and enhancing overall competitiveness in today's highly competitive industrial landscape.the implementation of a smart andon system has been shown to improve production efficiency, reduce downtime, and increase overall equipment effectiveness (OEE). The system allows for real-time monitoring of the production process, early detection of problems, and quick resolution of issues through timely alerts and notifications. This can result in significant cost savings for the industry, improved product quality, and increased customer satisfaction.

Implementation of an automatic monitoring system using electromagnetic induction parameters to enhance hot forging quality Maulana, Gun Gun; Martawireja, Abdurrahman Harits; Suryatini, Fitria
Jurnal Polimesin Vol 23, No 4 (2025): August
Publisher : Politeknik Negeri Lhokseumawe

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.30811/jpl.v23i4.3313

This research presents the implementation of an automatic monitoring system using electromagnetic induction parameters to enhance the quality of heating processes in hot forging industries. Efficient heating is essential in industrial applications, particularly during the production stage of hot forging. To ensure consistent product quality and optimize energy efficiency, accurate and responsive monitoring is required. The proposed system integrates electromagnetic induction sensors to capture, in real time, the physical characteristics of heated AISI 4140 Bolt M24 × 100 mm (±0.35 kg). Sensor data are processed using intelligent algorithms to identify critical parameters such as temperature, heat distribution, and optimal heating time. Based on these results, the system automatically adjusts heating parameters, thereby ensuring consistent product quality and improved energy efficiency. The results indicate that the system, supported by a Human–Machine Interface (HMI), Programmable Logic Controller (PLC), and infrared temperature sensors, was effectively implemented. It demonstrated real-time monitoring of process parameters with no detected errors, smooth data transfer between components, and reliable temperature display on the HMI with an average delay of only 1.1 seconds. This research provides an integrated solution to improve hot forging quality, reduce energy waste, and accelerate production cycles, contributing to more intelligent heating control systems for industrial applications.

Decision Support System Untuk Mengukur Kinerja Mesin Stamping Berbasis Key Performance Indicator Maulana, Gun Gun; Suhada, Muhammad Giri; Purnomo , Wahyudi
CESS (Journal of Computer Engineering, System and Science) Vol. 10 No. 2 (2025): Juli 2025
Publisher : Universitas Negeri Medan

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.24114/cess.v10i2.67836

Dalam industri manufaktur, mesin stamping memegang peran penting dalam menentukan kualitas dan kapasitas produksi. Namun, penilaian kinerja mesin yang masih dilakukan secara manual seringkali menimbulkan keterlambatan informasi dan kurang akurat, sehingga menghambat proses pengambilan keputusan. Penelitian ini bertujuan merancang dan mengembangkan Decision Support System (DSS) untuk mengukur kinerja mesin stamping berbasis Key Performance Indicator (KPI). Sistem ini dirancang untuk mengintegrasikan data operasional mesin secara otomatis melalui sensor dan perangkat monitoring yang terhubung ke basis data terpusat. KPI yang digunakan mencakup efektivitas waktu operasi, frekuensi downtime, rasio produk cacat, serta volume produksi harian. Data yang terkumpul dianalisis dan divisualisasikan dalam bentuk laporan grafik dan dashboard interaktif, sehingga memudahkan manajer produksi dalam memantau performa mesin secara real-time. Selain itu, DSS ini dilengkapi modul peringatan dini (early warning system) untuk mendeteksi potensi penurunan kinerja mesin. Hasil pengujian menunjukkan bahwa aplikasi memiliki tingkat akurasi yang sangat tinggi. Pada parameter Real-time dan Raw Material KPIs, rata-rata error tercatat 0%, menunjukkan kesesuaian penuh antara server dan perhitungan manual. Parameter Percentage Time memiliki rata-rata error sebesar 0,297%, sedangkan Real Cycle Time sebesar 1,977%, yang disebabkan oleh tampilan antarmuka yang hanya menampilkan angka tanpa desimal meskipun data backend menyimpan angka lebih detail. Pada parameter Energy KPIs, rata-rata error tercatat sebesar 7,57%, disebabkan oleh pembulatan angka desimal yang memengaruhi hasil perhitungan biaya ketika data awal (KWH) relatif kecil. Meskipun demikian, aplikasi tetap mampu menampilkan data secara real-time dan historis dengan tingkat keandalan yang memadai. Secara keseluruhan, aplikasi DSS yang dikembangkan berhasil mendukung pengambilan keputusan dengan menyediakan data kinerja mesin yang akurat dan informatif, serta membantu memantau penggunaan energi dan biaya bahan baku secara lebih efektif.

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