PERENCANAAN INDUSTRI BLOCK MESIN MOTOR

1. The Project
a. Project description
Along with technological advances in the State of Indonesia, on the mark with the
development of industrial sector, particularly the metal industry, so many products-
products that produced to meet the needs of the people of Indonesia will result-the result of
technological or industrial metal.
Product-the product of these metals in produce or inproduction with a variety of ways-
kind oflike:
1. Casting (Casting)
2. Forging (forging)
3. Welding (Welding)
One of the processes developing in Indonesia today are casting(Casting). Because
many of the metal product which is derived from the casting process, such as the one of
which is the engine block.Typecastingprocessthatis usedisLowPresureCasting.
MaterialormaterialwhichinuseisAluminumADC-12 (Aluminum DieCasting), in
accordancewith thematerialsthey use, the processusedisDieCasting(Low PresureCasting).
b. Technical Factors
- ProductSpecification
1. Dimension

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2. Technical drawing

219

17 85 33 55 23

5
81

115
22
13
23

110
9

30
R2

5
0
R2
61

62
20
138

R2
2
39

25
R7

80

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C. Raw material and resource requirements

The materialsusedtomakeengineblocksbyLowPresureCastingisan aluminumalloythat
isADC-12, inwhich thechemicalcompositionofaluminumalloysarebased
onstandardZISisasfollows:

Material ADC-12

Element Persen (%)

Cu 1,6
Si 9,6
Mg 0,3
Zn 1,0
Fe 1,3
Mn 0,5
Ni 0,5
Sn 0,3
Al residual

The materialusedisaluminumalloythat isADC-12, whichhas thepropertiesasfollows:

1. have amachinecapableofgoodcharacter.
2. havegood chemicalpropertiesand
3. havepropertiescapable ofcastingverywell.

Weight block engin : 1.1 Kg

1. Manufacturing Proses
The process will be undertaken in the manufacturing of engine block is at the start of
mold making, material selection, consolidation, compressing the liquid metal into the mold
cavity, mold disassembly, inspection, and permesinan.yang everything will be described
below:

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Raw materials Smeltingfurnace

Pattern Ladle

System
sandprocessing
Makingmold Pouring

Sand Orderprint Demolition

Cleaning

QC

Products

a. Moulding
Sand used to make products using the engine block α resin and silica sand in hardener
added.
To create a print silica sand required α resin materials:
- some weighing silica sand (depending on the needs of print).
- Resin α (alpha) of 2.5% by weight of silica sand.
- hardener as much as 25% by weight resin
Ways of making prints with Furan sand:In the silica sand mixer Continuos α + resin hardener
is mixed and then added that setup so that clotting does not occur.

b. Selection ofmaterials
In theprocess ofmakingengine blockisin the form
ofrawmaterialsandsekrapAluminiumIngotADC12.Itemsengine blockthat
producednetweight±1.1 kg.sotomakealuminumengine blockinneedofADC12±3.6kg,
becauseof thoseheavycastaluminuminaLowPreasurewillbesekrap±10%.
Here thematerialusedisaluminumADC-12, because ofits mechanical properties, the ability
ofmachines, chemical properties, and theability tocastverywell.
ThechemicalcompositionofmaterialsAluminumADC-12 areasfollows:
a.Levels ofcopper(% Cu): 1.6%
b.Levels ofsilicon(% Si): 9.6%

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c.Magnesiumcontent(% Mg): 0.3%

d.Levels ofzinc(% Zn): 1.0% Max
e.Concentrationof iron(% Fe): 1.3% Max
f.Manganese content(% Mn): 0.5%Max
g.Nickel content(% Ni): 0.5% Max
h.Tincontent(% Sn): 0.3% Max
i.The restisAluminium: residual
c. Smelting
Sekrap aluminum ingots and weighed in the light weight that has been inserted into
the furnace for melting. At low preasure casting process is aluminum metal smelting or
melting furnace which is directly on the machine, so the melting of aluminum metal is not
done in a separate furnace.
Once raw materials have been input into the furnace, the furnace in the setting with a
maximum temperature 7000 C where the temperature is already melted aluminum metal
because metal melting point of aluminum is 6600 C. while the temperature on the heating coil
or element in setting 8500 C. In the heating element is intentionally in setting 1500 C because
there is some heat is wasted because the distance between the heating element and stove far
enough (not stuck to the heating element on the stove).
The time used to heat the furnace up to temperatures of 7000 C so that the molten
aluminum metal is for ± 3 hours. After the furnace temperature has been reached and the
aluminum metal has melted, the air pressure in the stream into the furnace so that the molten
aluminum metal pressed upwards through the channels or nozzle made of stainless steel
(stainless steel), pressure on the use of 0.5 bar. The liquid metal fills the mold cavity pressure,
thus forming a product (cylinder head).
The pressure used is pressurized air generated by the compressor. The pressure that is
in use by 0.5 Barr.In order to provide stable pressure in the low preasure on a machine in use
pressure regulator from the compressor to the furnace.

d. Demolition Matter
After the entire mold cavity filled with molten aluminum metal, the pressure in the
furnace at the stop (pressure valves in the lid), until the pressure in the furnace decreases to be
± 0.2 Barr. Products on leave in the mold in the oven for ± 5 minutes is intended to freeze the
product first.Products that have been frozen in the mold, then made off from the nozzle and
the demolition of the mold to remove the product. Sand mold in destroy the manual way.
Items still hot allow to cool in free air.

e. Quality Control
Before finishing the product done, then the product in its physical appearance check
whether there are cracks, which tidat cavity filled, or disability - other casting defects. After
the examination of products and products considered to be good and do not fail, then do
further processing.

f. Machining
Productsthat have beendoneat thestateexaminationandniceanddonotfailin
themachiningprocess, wherebythemachiningprocessisintendedtocut thefin-the finoncast
products, gettingcut offsystem,orto smooththe surfaceofthe product.

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D. Environ metal and locational factors

The selectedlocationistangerang. becauseinTangerangisa locationthatisa
strategytoobtainraw materialsand easiertomarkettomajorcitiessuch
asJakartaandBandung.

E. Factorylayout

1
2
7
6
3
5

4
1 Pembuatan pola 5 Proses pemeriksaan

2 Pembuatan Cetakan 6 Proses shot blasting

Proses penuangan logam /
3 7 Proses machining
Pembongkaran cetakan

4 Proses Peleburan logam

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2. The investment
a. The cost ofpurchasingequipment
- crucible : Rp 10.000.000
- sand : Rp 3.000.000
- mold : Rp 4.000.000
- pattern : Rp 3.000.000
- fuel : Rp 15.000.000
- raw material : Rp 10.000.000
- engine : Rp 20.000.000 +
Rp 65.000.000

Opration Cost

- Services : Rp 2.000.000
- Operations : Rp 5.000.000
- Labor/month : Rp 2.000.000 +
Rp 9.000.000
Total 1 + 2 Rp 74.000.000
b. Income
Imc = Total production X Selling price
= 333 X 250.000
= Rp 83.250.000
c. Benefit
Ben = Income – Cost
= Rp 83.250.000 – Rp 74.000.000
= Rp 9.250.000

d. Break Even Point

1. BEP Price

𝑡𝑜𝑡𝑎𝑙 𝑐𝑜𝑠𝑡
𝐵𝑒𝑝 𝑝𝑟𝑖𝑐𝑒 =
𝑇𝑜𝑡𝑎𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛

Rp 74.000.000
𝐵𝑒𝑝 𝑝𝑟𝑖𝑐𝑒 =
333 𝑘𝑔

𝐵𝑒𝑝 𝑝𝑟𝑖𝑐𝑒 = 𝑅𝑝 222.222/𝑘𝑔 < Rp 250.000

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2. BEP Production

𝑡𝑜𝑡𝑎𝑙 𝑐𝑜𝑠𝑡
𝐵𝑒𝑝 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 =
𝑆𝑒𝑙𝑙𝑖𝑛𝑔 𝑝𝑟𝑖𝑐𝑒 /𝐾𝑔
74.000.000
𝐵𝑒𝑝 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 =
250.000

𝐵𝑒𝑝 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 296 𝑘𝑔< 333 kg

e. Revenue Cost Ratio

𝐼𝑛𝑐𝑜𝑚𝑒
𝑅𝑒𝑣𝑒𝑛𝑢𝑒 𝐶𝑜𝑠𝑡 𝑅𝑎𝑡𝑖𝑜 =
𝑇𝑜𝑡𝑎𝑙 𝐶𝑜𝑠𝑡
83.250.000
𝑅𝑒𝑣𝑒𝑛𝑢𝑒 𝐶𝑜𝑠𝑡 𝑅𝑎𝑡𝑖𝑜 =
74.000.000
𝑅𝑒𝑣𝑒𝑛𝑢𝑒 𝐶𝑜𝑠𝑡 𝑅𝑎𝑡𝑖𝑜 = 1.124

f. Depresiasi garis lurus

𝑇𝑜𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑎𝑠𝑖 74.000.000

= = 15.000.000
𝑈𝑚𝑢𝑟 𝑃𝑟𝑜𝑗𝑒𝑐𝑡 5

g. Biaya Oprasi

Tahun 1 = Rp 38.000.000
Tahun 2 = Rp 40.000.000
Tahun 3 = Rp 42.000.000
Tahun 4 = Rp 44.000.000
Tahun 5 = RP 46.000.000

h. Revenue

Tahun 1 = 80 % . Rp 12.000.000 . 20 = Rp 192.000.000

Tahun 2 = 100% . Rp 12.000.000 . 20 = Rp 240.000.000
Tahun 3 = 100% . Rp 12.000.000 . 20 = Rp 240.000.000
Tahun 4 = 100% . Rp 12.000.000 . 20 = Rp 240.000.000
Tahun 5 = 100% . RP 12.000.000 . 20 = Rp 240.000.000

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I. Table Cash Flow

Tahun
0 1 2 3 4 5
Investasi 74.000.000
Depresiasi 15.000.000 15.000.000 15.000.000 15.000.000 15.000.000
Operating Cost 38.000.000 40.000.000 42.000.000 44.000.000 46.000.000
Revenue 192.000.000 240.000.000 240.000.000 240.000.000 240.000.000
Pendapatan Kotor
40.000.000 60.000.000 70.000.000 80.000.000 85.000.000
Sebelum pajak
Pajak perusahaan 40 % 16.000.000 24.000.000 28.000.000 32.000.000 34.000.000

Pendapatan setelah Pajak 24.000.000 36.000.000 42.000.000 48.000.000 51.000.000

Depresiasi 15.000.000 15.000.000 15.000.000 15.000.000 15.000.000

Cash Flow 74.000.000 39.000.000 51.000.000 57.000.000 63.000.000 66.000.000

J. Present Value Cash Flow

Total Present Value Cash FlowI’ = 15 %

Tahun ke n Cash Flow XP/F Present Value
1 39.000.000 x 0.8696 33.914.400
2 51.000.000 x 0.7561 38.561.100
3 57.000.000 x 0.6575 37.477.500
4 63.000.000 x 0.5718 36.023.400
5 66.000.000 x 0.4972 32.815.200
Total Present Value 178.791.600

Total Present Value Cash Flow I’’ = 40 %

Tahun ke n Cash Flow XP/F Present Value
1 39.000.000 x 0.7143 27.857.700
2 51.000.000 x 0.5102 26.020.200
3 57.000.000 x 0.3644 20.770.800
4 63.000.000 x 0.2603 16.398.900
5 66.000.000 x 0.1859 12.269.400
Total Present Value 103.317.000

K. Net Present Value ( NPV)

NPV’ = Total Present - Total Investasi

= Rp 178.791.600 - Rp74.000.000
= Rp 104.791.600

NPV’’ = Total Present - Total Investasi

= Rp 103.317.000 - Rp 74.000.000
= Rp 29.317.000
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L. IRR
𝑵𝑷𝑽 ′
𝑰𝑹𝑹 = 𝑰 ′ + ( 𝑰′′ − 𝑰′ )
𝑵𝑷𝑽′ + 𝑵𝑷𝑽′′

𝟏𝟎𝟒. 𝟕𝟗𝟏. 𝟔𝟎𝟎

𝑰𝑹𝑹 = 𝟏𝟓 + ( 𝟒𝟎 − 𝟏𝟓)
𝟏𝟎𝟒. 𝟕𝟗𝟏. 𝟔𝟎𝟎 + 𝟐𝟗. 𝟑𝟏𝟕. 𝟎𝟎𝟎

𝟏𝟎𝟒. 𝟕𝟗𝟏. 𝟔𝟎𝟎

𝑰𝑹𝑹 = 𝟏𝟓 + ( 𝟒𝟎 − 𝟏𝟓)
𝟏𝟑𝟒. 𝟏𝟎𝟖. 𝟔𝟎𝟎
𝟏𝟎𝟒. 𝟕𝟗𝟏. 𝟔𝟎𝟎
𝑰𝑹𝑹 = 𝟏𝟓 + ( 𝟒𝟎 − 𝟏𝟓)
𝟏𝟑𝟒. 𝟏𝟎𝟖. 𝟔𝟎𝟎
𝑰𝑹𝑹 = 𝟏𝟓 + 𝟎. 𝟕𝟖𝟏 ( 𝟒𝟎 − 𝟏𝟓)

𝑰𝑹𝑹 = 𝟑𝟒. 𝟓𝟐𝟓 %

M. Pay Back
Dari Table Present Value Cash Flow dengan I = 15 % dapat di gambarkan.

Tahun ke 1 Tahun ke 2 Tahun ke 3 Tahun ke 4 Tahun ke 5

33.914.400 38.561.100 37.477.500 36.023.400 32.815.200

Tahun 1 + 2 = 72.475.500

Tahun 1 + 2 + 3 = 109.954.000

Tahun 1 + 2 + 3 + 4 = 145.977.400

- Setelah tahun ke 2 – ke 3 present value masih diperluka

Rp. 74.000.000 - Rp 72.475.500 = Rp 1.524.500
- Present Value perbulan pada tahun ke-3
Rp. 37.477.500/12 = Rp 3.123.125
- Untuk menghasilkan Rp 1.524.500 diperlukan waktu
Rp. 1.524.500 : Rp 3.123.125 = 0.5 bulan

Jadi Pay Back di capai setelah waktu 2 tahun 0.5 bulan

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Bunga 1
1. 74.000.000 X 15 % = 11.100.000
2. [74.000.000 - 15.000.000] . 15% = 8.850.000
3. [74.000.000 - (2) 15.000.000] . 15%= 6.600.000
4. [74.000.000 - (3) 15.000.000] . 15% = 4.350.000
5. [74.000.000 - (4) 15.000.000] . 15% = 2.100.000

Bunga 2
1. 74.000.000 X 40 % = 29.600.000
2. [74.000.000 - 15.000.000] . 40% = 23.600.000
3. [74.000.000 - (2) 15.000.000] . 40% = 17.600.000
4. [74.000.000 - (3) 15.000.000] . 40% = 12.000.000
5. [74.000.000 - (4) 15.000.000] . 40% = 5.600.000

Total Penjualan = Hasil penjualan

= Harga X n

Cost terbesar = Rp 66.000.000

Harga = Rp 250.000

𝑪𝒐𝒔𝒕 𝑻𝒆𝒓𝒃𝒆𝒔𝒂𝒓
𝑵 =
𝑯𝒂𝒓𝒈𝒂
𝟔𝟔. 𝟎𝟎𝟎. 𝟎𝟎𝟎
𝑵=
𝟐𝟓𝟎. 𝟎𝟎𝟎
𝑵= 𝟐𝟔𝟒 𝒃𝒖𝒂𝒉

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