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All Journal ELPOSYS: Jurnal Sistem Kelistrikan
Dhendy Zaki Ridwan
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Control & Systems Engineering Electrical & Electronics Engineering Energy Engineering Industrial & Manufacturing Engineering

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Otomatisasi Perhitungan OEE pada Mesin Filling ILAPAK 50g Menggunakan PLC dan HMI Dhendy Zaki Ridwan; Himawan, Helmy Mukti; Kurniawan, Aditya
Elposys: Jurnal Sistem Kelistrikan Vol. 11 No. 3 (2024): ELPOSYS vol. 11 no. 3 (2024)
Publisher : Politeknik Negeri Malang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.33795/elposys.v11i3.6103

Abstract

This study addressed the limitations in calculating Overall Equipment Effectiveness (OEE) manually, which frequently led to inaccuracies and inefficiencies in industrial processes. The purpose of this research was to design an automated OEE calculation system for the ILAPAK 50g filling machine to improve data accuracy and reduce dependency on manual input. A Design Science Research (DSR) methodology was employed, involving stages of system analysis, design, implementation, and evaluation. The system utilized key components, including an Omron CP2E PLC, proximity sensors, relays, and a Human-Machine Interface (HMI) for real-time data acquisition. The findings indicated that the automated system significantly improved data accuracy, achieving reliable, continuous OEE calculations across different machine shifts. The system successfully replaced manual logbook methods, reducing human estimation errors, and displayed OEE data locally on the HMI, making it accessible for operational decisions. Furthermore, the implemented automation reduced overall downtime, enhanced machine availability, and minimized errors associated with manual record-keeping. This research has practical implications for industries aiming to optimize production efficiency. The automated OEE system demonstrated potential for scalability to other machines in manufacturing settings, highlighting its adaptability and utility in modern industrial environments. Future research could explore integration with cloud-based databases to enhance data storage and accessibility, providing a foundation for advanced predictive maintenance and performance monitoring across multiple machines.
Klasifikasi Status Idle dan Kerja Wheel Loader WA350 Berbasis Akselerometer Tunggal Dhendy Zaki Ridwan; Branjangan, Panji Peksi; Winarko, Wigo Ardi
Elposys: Jurnal Sistem Kelistrikan Vol. 12 No. 3 (2025): ELPOSYS VOL. 12 NO.3 (2025)
Publisher : Politeknik Negeri Malang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.33795/elposys.v12i3.8794

Abstract

Conventional hour meters on heavy equipment accumulate engine-ON time without distinguishing productive working from non-productive idle, which can bias preventive maintenance scheduling. This study evaluates the feasibility of separating idle and working conditions of a Komatsu WA350 wheel loader using a single tri-axial accelerometer. Vibration data were recorded at 700, 900, 1100, and 1300 rpm under two scenarios: engine-on with bucket stationary (idle) and engine-on with bucket actuation without load (working). The main indicator is the time-domain Root Mean Square (RMS) on AccX, AccY, and AccZ to represent vibration energy per axis, supported by low-frequency spectral inspection for interpretation. For paired comparison, the analysis focuses on 700–1100 rpm because the 1300 rpm dataset does not include a verified idle counterpart. The results show that AccX provides the most consistent separation, where RMS in working increases by approximately 10–13% compared to idle at 700–1100 rpm, while AccY is less stable and AccZ changes are minimal. These findings support a simple RMS-based logic as a practical basis for smart hour-metering to better reflect operational workload and improve service notification timing. Limitations include controlled test conditions (no-load bucket cycles) and a single mounting location; broader validation under varied loads, terrains, and operators is required.
Co-Authors Aditya Kurniawan Branjangan, Panji Peksi Helmy Mukti Himawan, Helmy Mukti Winarko, Wigo Ardi