OPERATE THE OTOMATIC FLUX CORED ARC WELDING ( FCAW ) MACHINE

CHAPTER II

OPERATE THE OTOMATIC FLUX CORED ARC WELDING ( FCAW )

MACHINE

 

2.1. Definition of FCAW automatic machine

Flux Cored Arc Welding (FCAW) is frequently referred to as flux cored welding.  Flux cored welding is a commonly used high deposition rate welding process that adds the benefits of flux to the welding simplicity of MIG welding.  As in MIG welding wire is continuously fed from a spool.  Flux cored welding is therefore referred to as a semiautomatic welding process. Self shielding flux cored arc welding wires are available or gas shielded welding wires may be used.  Flux cored welding is generally more forgiving than MIG welding.  Less pre cleaning may be necessary than MIG welding.  However, the condition of the base metal can affect weld quality. Excessive contamination must be eliminated.Flux cored welding produces a flux that must be removed.  Flux cored welding has good weld appearance (smooth, uniform welds having good contour).  

One type of FCAW requires no shielding gas. This is made possible by the flux core in the tubular consumable electrode. However, this core contains more than just flux, it also contains various ingredients that when exposed to the high temperatures of welding generate a shielding gas for protecting the arc. This type of FCAW is attractive because it is portable and generally has good penetration into the base metal. Also, windy conditions need not be considered. Some disadvantages are that this process can produce excessive, noxious smoke (making it difficult to see the weld pool); under some conditions it can produce welds with inferior mechanical properties; the slag is often difficult and time-consuming to remove; and operator skill can be a major factor.

 

Picture 2.1 FCAW manual process

A drawing of FCAW at the weld point, Another type of FCAW uses a shielding gas that must be supplied by an external supply. This is known informally as “dual shield” welding. This type of FCAW was developed primarily for welding structural steels. In fact, since it uses both a flux-cored electrode and an external shielding gas, one might say that it is a combination of gas metal (GMAW) and flux-cored arc welding (FCAW). This particular style of FCAW is preferable for welding thicker and out-of-position metals. The slag created by the flux is also easy to remove. The main advantages of this process is that in a closed shop environment, it generally produces welds of better and more consistent mechanical properties, with fewer weld defects than either the SMAW or GMAW processes. In practice it also allows a higher production rate, since the operator does not need to stop periodically to fetch a new electrode, as is the case in SMAW. However, like GMAW, it cannot be used in a windy environment as the loss of the shielding gas from air flow will produce visible porosity (small craters) on the surface of the weld.

Next match manual FCAW turn to the automatic FCAW because if welder have weld process with the long project welder need to rest so the welding process is stop and make some defect to the result of weld. If welder use automatical FCAW machine that wil make welding process will continue and not be stop and if welder weld the material with manual process that will make some defect but if welder use the automatic FCAW machine will not make many defect. And then, the machine more stabill since do welding process. And this machine will make welder more easy to doing welding process

 

Picture 2.2 Automatic FCAW machine

2.2. Komponen mesin FCAW otomatis

Sebelum melakukan proses pengelasan, seorang welder harus memahami komponen-komponen dari mesin FCAW otomatis yaitu :

 

 

  1. Tabung gas co2

Tabung gas CO2 adalah tabung yang digunakan sebagai tempat gas pelindung wire yang menggunakan gas karbon dioksida (CO2) .

 

Picture 2.3 Co2 gas tube

 

 

  1. Regulator

Regulator pada gas CO2 berbeda dengan tabung gas pada umumnya karena pada bagian belakang regulator terdapat oven untuk memanaskan gas CO2  karena gas CO2 bersifat dingin, jika tidak dipanaskan maka akan terjadi penyumbatan pada saluran gas buang.

 

  Picture 2.4 CO2 gas regulator

 

 

  1. Selang  gas CO2

Selang gas CO2 adalah alat penyalur gas CO2 ke mesin.

 

Picture 2.5  Hose CO2 Gas

 

  1. Torch/ Gun

Gun berfungsi sebagai alat penyalur gas buang dan kawat wire pada benda kerja.Serta sebagai penghantar massa.

 

                        Picture 2.6 FCAW automatic gun/torch

  1. Control box

Digunakan untuk mengatur posis, kecepatan, besar kecil ayunan, laju mesini Gun/Torch pada saat pengerjaan.

 

Picture 2.7 control box

 

  1. Welding wire

Wire pada mesin FCAW berbeda dengan wire pada umumnya karena wire pada FCAW memiliki selaput pelindung yang melindungi hasil pengelasan dari kontaminasi udara luar.

 

Picture 2.8 welding wire

  1. Control system

Kontrol system adalah mesin yang digunakan untuk mengatur arus pada mesin FCAW otomatis.

 

Picture 2.9 control machine

  1. Kabel power

Kabel power adalah kabel yang menghubungkan antara mesin dan supply tenaga.       

 

                    Picture 2.10 power cable                                   

  1. Trafo

 

Picture 2.11 Travo

 

Digunakan untuk mengubah arus voltase pada supply tenaga untuk menggerakkan motor pada control box.

  1. Rail  :

 

Picture 2.12 rail

 

Digunakan sebagai dudukan control box agar dapat melakukan pengelasan dengan jarak yang panjang.

2.3 cara mengoperasikan mesin FCAW otomatis

2.3.1 Hal yang diperhatikan sebelum melakukan proses pengelasan

Sebelum melakukan welder melakukan proses pengelasan dengan menggunakan mesin FCAW otomatis seorang welder harus menggunakan alat keselamatan kerja karena mesin FCAW otomatis memiliki dampak negative yang besar jiga tidak menggunakan alat pelindung diri maka seorang welder perlu menggunakan alat keselamatan kerja seperti gambar dibawah

 

Picture 2.13 savety equipmen

2.3.2 Alat-alat pendukung yang digunakan

1. Palu Terak

               

Picture 2.14 welding hammer

Digunakan untuk mempersihkan hasil pengelasan dari selaput pelindung

 

2. Sikat baja

 

Picture 2.15 welding brus

Untuk membersihkan benda kerja dari kotoran yg dapat mengakibatkan cacat pada hasil pengelasan

3. Shild to spater

 

Picture 2.16 shild to spater

 

Digunakan untuk melindungi torch/gun dari spatter yg dapat mengakibatkan penyumbatan

4. Tang jepit

 

Picture 2.17 smit tang

Tang digunakan untuk melepas torch pada gun serta memotong welding wire

2.3.3 Komponen mesin yang perlu diperhatikan sebelum melakukan

         pengelasan

  1. Pastikan regulator telah terpasang dengan baik pada tabung

 

                Picture 2.18 regulator join

 

  1. Perhatikan sambungan selang gas pada mesin dan regulator agar tidak terjadi kebocoran,

                                       i.      

                       Picture 2.19 regulator hose join

  1. Perhatikan sambungan kabel travo pada control box telah terpasang karena jika tidak maka motor pada control box akan terbakar
  2. Perhatikan sambungan kabel power telah terpasang dengan baik pada supply tenaga.
  3. Perhatikan pemasangan torch/gun telah terpasang pada tempatnya dan gunakan anti spatter pada torch/gun untuk melindungi gun dari spatter
  4. Perhatikan rel control box agar terhindar dari hal-hal yang dapat menghambat    laju control box
  5. Perhatikan pengaturan arus pada mesin control
  6. Perhatikan pemasangan wire telah terpasang pada tempatnya.

2.4.      pengoperasian mesin FCAW otomatis                     

Pengoperasian pada mesin FCAW otomatis meliputi dari dua komponen yaitu yang pertama ialah pengaturan pada mesin control dan control box danpengaturan pada controlMesin

2.4.1       Pengertian pada mesin control

pada mesin FCAW otomatis menggunakan system digital dan program kerja yang canggih. Pengaturan arus pada mesin control ada 2 sistem yaitu terprogram dengan otomatis jadi, apabila welder mengatur arus voltase pada mesin maka secara otomatis mesin akan memprogram pengaturan ampere yang sesuai pada angka voltase yang diatur oleh welder juga sebaliknya apabila welder mengatur angka ampere maka secara otomatis mesin akan menyesuaikan voltase yang sesuai dengan angka ampere yang dicantumkan oleh welder selain mampu mengatur pasangan voltase maupun ampere dengan otomatis mesin juga dapat menyesuaikan kecepatan wire dengan otomatis sesuai dengan pengaturan voltase ataupun ampere meter yg di cantumkan welder. Selain itu mesin juga mampu menyimpan data yang teladigunakan welder pada saat melakukan proses pengelasan jika mesin hendak di gunakan oleh welder lain dan mengubah \arus yg telah ditentukanpada control system.pengturan gas , untuk mengatur gas buang apakah berfungsi dengan baik atau tidak digunakan tombol gas chek , pengaturan welding wire padasaat pemasangan , mengulur welding wire tanpa harus mengeluarkan gas buang, juga control pada wire diameter dapat menyesuaikan diamaerer wire yang digunakan

      AMPERE MENU    VOLTAGE MENU     ARC CONTROL   A/V CONTROL

LOAD

SAVE

ENTER

GAS CHECK

ROLLING WIRE

SPOT TIME

WIRE DIAMETER

WELDING MENTOD

Picture 2.20 control machine

2.4.2        pengaturan pada control box

 

Left interlude gun speed control

Right interlude gun speed control

Pada mesin control box ada beberapa pengaturan yaitu,

 

On/of  power up control box

 

 

 

 

Off  all, speed, gas. Wire

Off gas/wire

Wide move gun control

 

Center interlude gun speed control

Speedometer cm/min

Speed control

Go Strigh and retreat machine control

On/of center control boxpower

Right,left,up,down, gun  control

On welding wire

On gas co2

Gun move speed control

 

Picture 19 control box ruls

 

Komponen komponen diatas di gerakkan oleh motor pada control bok agar dapat beroprasi control bok memerlukan travo yg berfungsi untuk mengubah arus 220v menjadi 110v karena jika suplay tenaga control box diberi arus 220v maka motor pengerak pada mesin control box akan retbakar

 

Picture 20-21 travo and engine control box

 

 

 

 

g

 

 

2.4.3        pengoprasian mesin FCAW otomatis

  Yang pertama seorang welder perlu mengatur arus pada control mesin menyesuaikan jenis pengelasan dengan program kerja mesin Setelah welder paham dan mengerti langkah-langkah sebelum mengoprasikan mesin FCAW otomatis selanjutnya cara mengoprasikan mesin FCAW otomatis , pada saat mesin FCAW otomatis sedang beroprasi seorang welder harus menyesuaikan titik center welding wire yang berada pada tengah FCAW welding gun dengan benda kerja , setelah sesuai dengan benda kerja pertama welder harus mengaktifkan gas buang lalu mengaktifkan welding wire                                                                                                                                                                                           

 

On welding wire FCAW machine

 

On gas co2 FCAW machine

Picture 22 control box seting

 

            Setelah mesin beroprasi welder hanya perlu mengatur tingi rendah dan center kiri dan kanan welding gun karena benda kerja tidk selalu lurus dan kadang memiliki tinggi yg berbeda jadi untuk menyesuaikan dengan benda kerja welder hanya perlu melakukan pengaturan tinggi renda serta center kiri dan kanan

 

Down button

Right button

Left button

Up button

Picture 23 FCAW gun control

 

2.5 Types of Defects

To achieve a good quality join it is essential that the fusion zone extends the full thickness of the sheets being joined. Thin sheet material can be joined with a single pass and a clean square edge will be a satisfactory basis for a join. However thicker material will normally need edges cut at a V angle and may need several passes to fill the V with weld metal. Where both sides are accessible one or more passes may be made along the reverse side to ensure the joint extends the full thickness of the metal.

Lack of fusion results from too little heat input and / or too rapid traverse of the welding torch (gas or electric).

Excess penetration arises from to high a heat input and / or too slow transverse of the welding torch (gas or electric). Excess penetration – burning through – is more of a problem with thin sheet as a higher level of skill is needed to balance heat input and torch traverse when welding thin metal.

 

2.5.1. Retak Las ( crack )

  1. 1.     Cacat las yang sering sekali terjadi pada saat proses pengelasan adalah retak las yang dapat dibagi menjadi dua kategori yakni : retak dingin dan retak panas. Retak dingin adalah retak yang terjadi pada daerah las pada suhu kurang lebih 300 0C. Sedangkan retak panas adalah retak yang terjadi pada suhu diatas 500 0C. Retak dingin tidak hanya terjadi pada daerah HAZ (Heat Affected Zone) atau sering disebut dengan daerah pergaruh panas tetapi biasanya terjadi pada logam las. Retak dingin ini dapat terjadi pada daerah panas yang sering terjadi. Dan retakan ini dapat dilihat dibawah anic Ias, retak akar dan kaki, serta retak melintang. Penyebab umum pada semua jenis keretakan las ini adalah:
    1. Pilihan jenis elektroda yang salah atau tidak tepat.
    2.  Benda kerja terbuat dari baja karbon tinggi.
    3.  Pendinginan setelah pengelasan yang terlalu cepat.
    4. Benda kerja yang dilas terlalu kaku.
    5. Penyebaran panas pada bagian-bagian yang di las tidak

seimbang.

 

Picture 24 crack

Penanggulangan Retak Las

Dalarn menghindari terjadinya retakan las pada daerah panas, atau usaha penaggulanganya supaya tidak terjadi retak pada las antara lain :

a.  Menggunakan elektroda yang betul, dalam hal ini sedapat mungkin menggunakan

elektroda dengan fluk yang mempunyai kadar hydrogen rendah.

  1. Sebelum mengelas, pada daerah sekitar kampuh harus dibersihkan dari air, karat, debu, minyak dan zat organik yang dapat menjadi sunrber hidrogen.
  2.  Mendinginkan perlahan-lahan setelah dilas  Membebaskan kampuh dari kekakuan.
  3. Mengadakan pemanasan pendahuluan sebelum memulai pengelasan, denga cara ini retak las dapat terhindarkan.

 

2.5.2       Solid Inclusion

 

Picture 24 solid inclusionion

Inclusion/ Inklusi adalah partikel kontaminan yang terperangkap dalam weld metal. Partikel slag yang terperangkap adalah jenis yang paling umum dari inklusi.Permukaan tidak benar dibersihkan juga dapat berkontribusi inklusi.Inklusi tungsten bisa dihasilkan dari potongan-potongan kecil tungsten yang putus dari ujung elektroda di FCAW

Beberapa factor penyebab slag:

  1. Terkontaminasi weld preparation
  2. Salah kecepatan pengelasan
  3. Arc lenght terlalu panjang

Cara menagulangi

  1. bersihkan permukaan yang akan di las
  2. perhatikan kecepatan pengelasan
  3. jika terjadi slag bersihkan baagian yg terkontaminasi slag dengan grida lalu weld kembali hinga rertutup

 

2.5.3  Lack of Fusion

 

Picture 26 lack of fusion

Defect ini menggambarkan kondisi ketika weld metal tidak sepenuhnya mengis isambungan weld, ada ruang antara weld metal dan parrent material atau antara weld bead  dimana ada lack.

lack of fusion bisa dikelompokkan :

  1. Lack of sidewall fusion
  2. Lack of inter-run fusion

Factor penyebab lack of fusion antara lain

-Contaminated weld preparation

-Poor welding technique

-Amperage too low

-Amperage too high (high travel speed)

-Large root face, small root gap

Cara menangulagi

-perhatikan kebersihan sebelum melakukan welding proses

-perhatikan kecepatan pada saat pengelasan

-perhatikan pengaturan arus

-perhatikan lebar root gap jgan terlalu lebar

 

2.6  perawatan mesin

 Ketika  seorang welder telah selesai mengunakan mesin FCAW otomatis , maka seorang welder harus melakukan beberapa perawatan pada mesin FCAW otomatis yaiu dengan cara

  1. Matikan keseluruhan mesin control maupun control box
  2. Membersihkan mesin dan peralatan yg perlu di bersihkan dari debu dan kotoran dengan kuas
  3. Melepas semua peralatan yang terpasang dan menyimpannya pada tempat yang baik
  4. Meminyaki rel serta motor pada mesin control agar tidak macet dan mencegah korosi
  5. Menutup mesin dengan terpal agar tidak rusak dan kotor

Begitulah tata cara sebelum maupun sesudah pengoprasian mesin FCAW yang baik

 

CHAPTER III

CLOSING

3.1       Conclusion

            Authors conclude that the process of OPERATED OF FLUCX CORED ARC WELDING OTOMATIC MACHINE that should be known by each welder, because knowledge is very important in the welding process, we can know how to operate machine with a right ruls and we can know what preperation before operating the FCAW otomatic machine because without preparation (preheat) conducted the initial results of the welding will cause weld defects

3.2       Suggestion

            As for suggestions that the author wanted to convey in this report for smooth Industry Practice (PRAKERIND) for the foreseeable future. advice authors are as follows

            3.2.1    School

We recommend that the school add a lesson about the fate initial (preheat) operated FCAW otomatic machine, so that the student/students can better understand haw to operated FCAW machine at the welding process because it can help welder for welding process that will more easy to doing if welder have knowlage . As well as providing tools operated FCAW otomatic machine so that students/students can quickly grasp the challenge to operated the FCAW otomatic machine

3.2.2    Company

It is expected that the company can establish a relationship of close cooperation with vocational schools in Batam to provide more places for students who will implement the Industrial Employment Practices (PRAKERIND) to stay abreast of company rules and regulations, so that students who perform (PRAKERIND ) can learn to work well.

 

            3.2.3    Student

For students who perform PRAKERIND should always ask and consult the supervisor if experiencing difficulty in the process of Industrial Work Practices. And comply with all regulations of the Company, so that cooperation between the school and the company could run well.

 

 

  

 

CHAPTER I

                   INTRODUCTION

1.1       Background

            To enhance the human resource community Batam, Batam City Government continues to strive to provide and prepare a quality workforce, in order to be competent and competitive industry in the world both in cities and even in other countries. One of the government’s efforts in creating a quality workforce and competent, the Batam city government to make an educational program in which students / vocational high school students can learn directly with the working world directly to the field, this program called the Industrial Employment Practices.

            Industrial Internship is a comparison between theory which can be in school with work procedures used in the workplace (Field), Industrial Practice aims to enable students / vocational high school students can understand the world of work, prepare to become a mature workforce and competent, and ready to use immediately after finishing school.

            Batam is an industrial city that has a direct border with other countries of Singapore and Malaysia for example, and this provides a significant opportunity for the welfare and walk forward Batam. One company that is developing the company in the field of Steel Construction. While in the field of Steel Construction’s own job is a job most major types of welding in which the welder in the compulsory to pay attention to all matters relating to the welding process that will take place. One of the important in the welding preheat the materials (Base Metal) and the electrode to be used, because if there is discrepancy between the material (Base Metal) and the welding electrodes will greatly affect the outcome it will be welding.

Definition of welding according to DIN (Deutsche Industrie Normen) is a metallurgical bond at the junction of metal or metal alloy is carried out in a molten or liquid state. In other words, welding is the local connection of a metal rod by using thermal energy. The switching process is sometimes accompanied by pressure and additional material. And there are many types of welding are in use in the workplace, including:

 

  1. Shielded Metal Arc Welding (SMAW)
  2. Submerged Arc Welding (SAW)
  3. Gas Tungsten Arc Welding (GTAW)
  4. Gas Metal Arc Welding (GMAW)
  5. 5.     Flux Cored Arc Welding (FCAW)

But in the discussion of this report, the authors will only discuss the handling requirements and the type of electrode baking and holding weld Shielded Metal Arc Welding (SMAW).

Then, before performing the welding thing to note is the initial treatment of the electrode to be used, and in this case the electrode baking and holding a very important role and the welding must be performed in progress but must be in accordance with the Welding Procedure Specification (WPS) or in accordance with Baking Atmospheric conditions and permissible use Exposure Time. After baking the electrode made ​​the next step is a process in which Holding the electrode in the baking was finished at the intersection of (holding) in places that have been provided with a temperature regulation in accordance with the standards used.

 

 

 

1.1.1    Industrial Internship (Prakerind)

            In implementing the Industrial Practice in PT. Toyo Kanetsu Indonesia, Batam Plant writer has the objective to be achieved, as for its main purpose is to explain and reveal all the observations and knowledge gained during the three-month writers in carrying out the practice of Industrial Work in PT. Toyo Kanetsu Indonesia, Batam Plant. In addition to the above-mentioned goals, the author also aims to:

In order to be a proof in which the author actually conducting Industrial Practice (PRAKERIND) in Warehouse Welding Electrode in PT. Toyo Kanetsu Indonesia, Batam Plant.

  1. To learn and prepare the selves to enter the workforce.
  2. To gain insight into the jobs that  exist in the auto weld Welding Electrode in PT. Toyo Kanetsu Indonesia.

1.1.2    limitations

In the discussion of this report, the authors will only discuss about:

1. OPERATE THE OTOMATIC FLUX CORED ARC WELDING MACHINE

1.1.3    Methods of Writing

            In the preparation of a report required data related to the report. To prepare this report, the authors use data collection methods as follows:

 

  1. Research directly

Is the data collection methods or techniques or practices to jump directly to the field

  1. Interview

Held a question and answer with a supervisor or a person associated with the discussion materials.

  1. documentation

Methods of data collection by collecting data related to the agency.

1.1.4    Report Structure

            In order for a report or paper can be more easily understood and to understand of society or the reader, the writer needs to make a systematic statement or a limitation of reports / papers on the subject Prakerind which is actually the same as the table of contents.

            And thus, I will explain briefly about the contents of the report are as follows:

TABLE OF CONTENTS

MOTTO…………………………………………………………………………………………….. i

COMPANY CERTIFICATION PAGE………………………………………………..  ii

SCHOOL CERTIFICATION PAGE…………………………………………………..  iii

 FOREWORD……………………………………………………………………………………. iv

TABLE OF CONTENTS……………………………………………………………………   v

CHAPTER I    1.1 INTRODUCTION

                        1.1.      Background………………………………………………………. 1         

                        1.1.1    Industrial Internship……………………………………………            3

                        1.1.2    Limitation………………………………………………………….            3

                        1.1.3    Method Of Writing……………………………………………..            3

                        1.1.4    Report Structure…………………………………………………            4

1.2  OVERVIEW

                        1.2.      Background PT. Toyo Kanetsu Indonesia………………            7

                        1.2.1    Corporate Organization Structure…………………………            9

                        1.2.2    Organizational structure Elucidation…………………….            10

                        1.2.3    Procedure work…………………………………………………. 14

                        1.2.4    Field Of Work Activities……………………………………..            18

CHAPTER II              OPETATE THE OTOMATIC FLUCX CORED ARC WELDING (FCAW) OTOMATIC MACHINE

2.1       definition of  flucx cored arc welding otomatic machine……………………………………………………….      20

                        2.2       the component ofFCAW otomatic machine ……..     21

                        2.3       cara mengoprasikan mesin FCAW otomatis……..     22

2.3.1    komponen mesin ygang perlu di perhatikan  22

                        2.4       operating FCAW otomatical machine…………………  36

                                    2.4.1    definition of  FCAW control machine……..   37

                                    2.4.2    definition of FCAW control box…………    38

                                    2.4.3    operating FCAW machinE…………………….    39

                        2.5       type of devec and prevention………………………….    39

                                    2.5.1    crack……………………………………………….    40

                                    2.5.2    solid inclusion……………………..……..    41

                                    2.5.3    lack of fusion………………….…………     42

CHAPTER III             CLOSING

                        3.1       Conclusion…………………………………………………….     43       

                        3.2       Suggestion……………………………………………………..    43

                                    3.2.1    School…………………………………………………    44

                                    3.2.2    Company…………………………………………….     44

                                    3.2.3    Student……………………………………………….     44

References……………………………………………………………………………………..    ix        

Curiculum Vitae………………………………………………………………………………   x

Appendix………………………………………………………………………………………..   xi

Charge of controlling the activities of maintenance and control all material deficiencies and problems that occur when working on a project.

2.1       Background PT. Toyo Kanetsu Indonesia, Batam Plant

   On 9 September 1974 made ​​cooperation between the mining company’s Oil and Gas (Pertamina Joint Venture Company), which is one of the fabrication of construction of oil storage tanks in the world famous, and is one of the fabrication of well-known construction of oil tanks in Japan.

       Then to expand his business, PT. Japan’s Toyo Kanetsu (TKJ) opened a branch of another :

  1. Toyo Kanetsu K.K Chiba, Japan ( Chiba Plant)
  2. Toyo Kanetsu Indonesia (TKI), (Batam Plant)
  3. Toyo Kanetsu Malaysia (Sales Office)
  4. Toyo Kanetsu Dubai, UAE (Sales Office)

   PT. Toyo Kanetsu Indonesia, Batam Plant (TKI) is engaged in the manufacture of oil tanks. PT headquarters. Toyo Kanetsu Indonesia in Jakarta, while in Batam is a center of manufacture of the tank itself (Center for Production Process).

 

Data PT. Toyo Kanetsu Indonesia, Batam Plant as follows:

Company name                       : PT. TOYO KANETSU INDONESIA

founded in                               : 9 September 1974

The division of Capital          : Toyo Kanetsu  K.K  86%  Nissho Iwai Co       14%

address Batam                        : Jl. Tenggiri, Batu Ampar Kota Batam 29432

phone                                      : ( 0778 ) 412158 / 412159

Fax                                          : ( 0778 ) 412157

e-mail                                     : tkibatam@pttki.co.id

Central Office Address           : Mid Plaza Building 1, 8th. Floor

 Jl. Jend. Sudirman Kav.10-11

Telephone                               : (021) 5707739 / 5707805

Fax                                          : (021) 5703950

e-mail                                     : tkijktho@cbn.net.id

 

2.2.      Corporate Organization Structure

            Organizational structure of the company is a form of a framework

arrangement that shows the relationship between subordinates by superiors, so it can clearly be seen standing/position and authority of the person and the

responsibilities of each part in a regular employment determination and

responsibility.

In general, every company whether large or small company has an organizational structure, because the structure of this organization and the leader of each staff employee will know his position with in the company and to whom they have responsibility.

A good organizational structure has the following requirements:

  1. The separation of responsibilities
  2. The separation of field workers
  3. The separation of functions
  4. The separation of powers

Organizers in the PT. Toyo Kanetsu Indonesia, Batam Plant (TKI) to use the organizational structure of a line, in which a command line that connects directly between the leaders with subordinates.

In PT. Toyo Kanetsu Indonesia, Batam Plant (TKI), Plant Manager, Quality Control Section Manager, Fabrication Section Manager, PPC Section Manager and Administration Manager, is a series of tasks to form a partnership in that you want to accomplish together.

 

2.3       Organizational Structure Elucidation.

            Each leader in PT. Toyo Kanetsu Indonesia, Batam Plant has the duty and authority as follows:

  1. Plant Manager

Charge of controlling all activities in the enterprise, from initial activities until the end of the activity to quality products that work.

  1. Document Controller

Assigned to assist the implementation of tasks and Plant Manager controls all incoming documents and task manager gives sole responsibility to Document Controller.

  1. Quality Control Section Manager

Charge of controlling the activities of maintenance and control all material deficiencies and problems that occur when working on a project.

  1. PPC Manager

Charge of controlling each of the recording of documents in and view the budget spent.

  1. Fabrication Section Manager

Controlling the duty of all the activities have been running That the production section, of checking all the processes related to ordering and parts production to the delivery of goods have been completed and That in production.

 

  1. Administration Section Manager

Charge of controlling the purchase of goods required the production, control the material that goes on each reservation, providing educational system for employees who excel, and selecting employees who apply for work at the company.

  1. Quality Control Staff

Helping Quality Control Section Manager in carrying out their duties carefully and responsibly.

  1. Welding Engineer

Responsible for assisting the Quality Control in the task of doing / making spack for use in completing a project worker.

  1. Fabrication Engineer Staff

Assigned to assist the take-over of material fabrication, create bill of material in the production, control the production process, making the layout fabrication in accordance with the drawing, and the latter has the task to control the fabrication document.

  1. Fabrication Staff

Help Fabrication Section Manager in carrying out their duties carefully and responsibly.

 

 

  1. Transportation Staff

Served as the agency responsible for the delivery of goods that have been in production.

  1. Material Controller

The person responsible for controlling all materials, whether purchased or used.

  1. Procurement Staff

Parts that make the purchase of goods needed in the production process.

  1. Accounting Staff

Responsible for the acts and expenses of making time out.

  1. General Affairs Staff

Section in charge of holding all the supplies needed in the production process or other purposes needed in the company.

  1. Maintenance Staff

The person responsible for the maintenance and care of the equipment items used in the production process is assisted by several people in the field.

  1. Plant Quality Control Group

A check on the drawing, determine the appropriate inspection checking with Speck on a particular project, and the dimention and visual checks.

 

  1. General Foreman

Responsible for overseeing the production process in the field and is responsible for General Production

  1. Packing or Shipping Group

Helps Transportation Group Leader in the delivery of goods that have been produced in the field.

  1. Warehouse Clerk

Provide working tools consumable data needs related to production workers.

  1. Welding Foreman

Welding served as production manager.

  1. Fitting Foreman

Served as a regulator of production Fitting.

  1. Welding Group

Welding or splicing process in the production process that requires assembling.

  1. Fitting Group

Fit Up process in the production process that requires assembling.

 

2.4       Procedures and Work

Disciplines of a company is to consider, because if labor does not meet the regulations made ​​by the leader then it will not produce as expected. The regulations shall contain the rights and obligations of workers that must be fulfilled, which aims to maintain the relationship between leaders and subordinates is more harmonious.

            The following regulations apply to workers in PT. Toyo Kanetsu Indonesia, Batam Plant (TKI) is as follows::

  1. For workforce tailored to the needs company and labor have to be able to meet and comply with regulations that have been made ​​by the company.
  2. Candidate must pass a new labor recruitment exam conducted by the company.
  3. Candidates who received a trial of at least 3 (three) months.
  4. During the trial each party may terminate unconditionally.
  5. Workforce who graduated with the best value can be appointed as labor in accordance with the classification.
  6. Workforce PT. Toyo Kanetsu Indonesia, Batam Plant (TKI) must comply with all applicable regulations at the company..

Company procedures are held to create a good working atmosphere and raises morale. With the expected rules of rights and obligations of employees in the company becomes more apparent.

This rule applies to permanent employees and contract workers with the conditions stipulated by the agreement.

  1. Weekday working hours and the company are set as follows:
    Working hours is the time at which employees in the workplace as required to be determined to do the job.
    1. Working day is a day where employees are required to attend for work at a place specified company.
    2. Rest time is not counted as working hours.
    3. Days and hours worked is calculated as follows: :

Monday to Thursday              : 07.30 s.d 16.30

Friday                                     : 07.00 s.d 17.00

Saturday                                  : 07.30 s.d 15.00

Coffee time     morning          : 09.00 s.d 09.15

Coffee time     afternoon        : 16.00 s.d 16.15

Break Monday to Thursday    : 11.45 s.d 13.00

rest Friday                              : 11.15 s.d 13.30

 

  1. Attendance recording

a.   At the time comes and go home, employees are required to scan the card is present / absence as proof of attendance

b.   Employees are not allowed to scan the cards of other employees

c.   Employees who are exempt from the provisions of the above is the manager of each division..

  1. Not Attend Work
    1. Worker absenteeism due to illness or other cause, shall be notified in writing to the employer no later than the next day.
    2. Preliminary Notification can be done by telephone and then followed with written notification.
    3. In the case of employees who did not attend because of illness:

1)     2 (two) consecutive days or more, shall be substantiated by a doctor.

2)     10 (ten) consecutive days or more must be proven by an authorized treating physician and the medical institutions like hospitals.

  1. Employees for 6 (six) days in a row does not work without the written statement accompanied by valid evidence, then the employee is considered to resign

 

1)     The act of discipline

Disciplinary action carried out by stages :

a)     verbal warning

Conducted by their immediate supervisor or other staff who are responsible in the event the employee commits an offense that is lightweight and can still be improved.

b)     The written warning

Made a written warning if a verbal warning is ignored, it can be by mail.

c)     Exemption temporary duty (suspended)

d)     Termination of employment (FLE)

2)     Uniform and badge

a)     Employees are provided with work uniforms and work wear is required at the time of doing the job.

b)     Employees are required to use traditional identification (ID Card) as proof that the company provides employees of PT. Toyo Kanetsu Indonesia, Batam plant for a company located in the environment.

3)     Safety

PT. Toyo Kanetsu Indonesia, Batam Plant in performing his job to safety first of its workers, workplace safety regulations in the PT. Toyo Kanetsu Indonesia, among others:

a)     Each employee PT. Toyo Kanetsu Indonesia entered the company’s work area must wear a safety hat (helmet) and other safeguards in accordance with the work performed.

b)     Any employee entering in the area are required to wear safety shoes during his stay in the field.

This is done to maintain the safety of the employees of PT. Toyo Kanetsu Indonesia (TKI) in order to avoid accidents or other matters that are not desirable.

2.5       Field of Work Activities      

      Field of activity being engaged by PT. Toyo Kanetsu Indonesia today is a fabrication, which is a manufacturer of oil tanks for oil and gas industry needs.

PT. Toyo Kanetsu Indonesia, Batam Plant to ensure the success of any contracts awarded to the company, by providing high quality and reliable accountability, with production, such as LNG (Liquid Natural Gas), LPG​​, SGH.

      Today employs about 500 workers employees, consisting of 80 (twenty eight) permanent employees and 420 (four hundred twenty) contract employees from various levels. Field work done by each company is different, PT. Toyo Kanetsu Indonesia, Batam Plant (TKI) especially engaged in the tank maker which serves as a storage and oil production resulting gas. Types are as follows:

            a. Spherical Tank

            b. Floating Tank

            c. Dome Roof Tank

            d. Cone Roof Tank

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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