p–ISSN: 2723 - 6609 e-ISSN: 2745-5254
Vol. 5, No. 10, October 2024 http://jist.publikasiindonesia.id/
Indonesian Journal of Social Technology, Vol. 5, No. 10, October 2024 4551
Optimization of Industrial Machine Balancing Processes for
Fastening Precision and Efficiency
Muhammad Ando Prasetyo
1*
, Yasinta Sindy Pramesti
2
Universitas Nusantara PGRI Kediri, Indonesia
Email: [email protected]
1*
, [email protected]
2
*Correspondence
ABSTRACT
Keywords: balancing;
balancing machine;
hofman hl-28;
screw conveyor.
The industrial sector in Indonesia is experiencing rapid
development, which encourages the need for optimal and
efficient production processes. This research focuses on
optimizing the screw conveyor balancing process using the
HOFMAN HL-28 balancing machine at PT Petrokimia
Gresik. The main goal of this research is to improve
precision and efficiency in machine operation, as well as
reduce unwanted vibrations in mechanical equipment such
as screw conveyors. The research method involves tool
preparation, balancing testing, and data collection related to
parameters such as weight, dimensions, and tolerances. The
test results show that proper balancing can significantly
reduce vibration, improve machine operation stability, and
extend the service life of the equipment. Thus, this study
concludes that optimizing the balancing process on screw
conveyors not only improves operational efficiency but also
plays a role in reducing downtime and improving production
quality. This optimization is very important to support the
performance of the industry in order to compete globally.
Introduction
The development of the industrial sector in Indonesia has progressed rapidly. Fierce
competition in the industrial world requires companies to further improve their
performance to be able to compete with competitors (Anaam et al., 2022). Companies
need to adjust the level of consumer needs to the available production capacity to be able
to produce optimal production levels. Problems The development of the modern era is in
line with the rapid development of science and technology, forcing companies to produce
a high level of productivity (Manurung, 2010). High productivity can be achieved if the
production process runs effectively and efficiently (Sultan et al., 2018). Line balancing is
part of the production process where the material moves through the workstation and aims
to process the material into a sub-assembly to then become a finished product. The time
to complete a product is determined by the speed of the processing path (Harbintoro,
2019).
Muhammad Ando Prasetyo, Yasinta Sindy Pramesti
Indonesian Journal of Social Technology, Vol. 5, No. 10, October 2024 4552
Manufacturing is an industry that deals with the use of advanced equipment such
as industrial machinery, a regular and measurable management program to convert raw
materials into finished goods and marketable products (Harahap, 2024). Examples of
manufacturing industries include textile companies, garment industries, handicraft
industries, electronics industries, and automotive industries (Aldimiyyathi et al., 2023).
The fabrication process is defined as part of the activities of a company that is oriented
towards fulfilling material aspects with the final stage in the form of the production of
finished goods as part of several materials (Julian et al., 2022).
PT Petrokimia Gresik is one of the parts of Pupuk Indonesia Holding Company
(PIHC) which is a State-Owned Enterprise (BUMN) that was formerly known as PT
Pupuk Sriwidjaja (persero) or PUSRI (persero). 9 other companies are members of PIHC,
namely PT Pupuk Iskandar Muda, PT Pupuk Sriwidjaja Palembang, PT Pupuk
Kalimantan Timur and PT Pupuk Kujang Cikampek, PT Pupuk Indonesia Energi, PT
Pupuk Indonesia Pangan, PT Pupuk Indonesia Logistik, PT Mega Eltra and PT Rekayasa
Industri (Salim et al., 2016). PT Petrokimia Gresik is engaged in the production of
fertilizers, chemicals, and other services such as construction or design services,
equipment, engineering, and engineering which occupies an area of 450 hectares in
Gresik Regency, East Java. The government designed the existence of PT Petrokimia
Gresik in 1956 through the State Planning Bureau (BPN). Initially, the fertilizer factory
to be built in East Java was called the Surabaya Petrochemical Project. The name
Petrokimia itself comes from "Petroleum Chemical" which is abbreviated as
Petrochemical, which is chemicals derived from oil and natural gas (Ahyan, 2020).
The service and fabrication department of Balancing is a very important part of the
process used to adjust or balance equipment or mechanical components to operate stably
and efficiently. The main goal of the balancing process is to reduce or eliminate unwanted
vibrations that may occur on mechanical equipment such as shafts, wheels, fans, or other
components (Hapid & Supriyadi, 2021).
Manufacturing companies generally have an assortment of products with different
designs and functions. To realize the goal of forming a product that is by the design
standard, the raw materials will first go through the fabrication process. Raw materials
that are generally used as raw materials are plates, pipes, steel, stainless steel, aluminum,
and other metals. Later, this raw material will be formed by a fabrication machine
according to the desired function of the manufacturing plant (Suharman et al., 2018). The
fabrication process at PT Petrokimia Gresik, especially the fabrication department,
produces screw conveyors. A screw conveyor is a mechanical device used to transport
materials in the form of powders, granules, or masses over relatively short distances. This
conveyor consists of a rotating spiral called a flighting or auger that is attached along the
axis in a closed pipe or channel.
The stages in the work of the screw conveyor are marking, cutting, drilling,
assembling, welding, checking, finishing, blasting, and painting. To distribute the mass
of the rotating system so that the center of mass is at the same time as the axis of rotation,
the Balancing Screw Conveyor is balanced. This helps to minimize vibration and improve
Optimization of Industrial Machine Balancing Processes for Fastening Precision and Efficiency
Indonesian Journal of Social Technology, Vol. 5, No. 10, October 2024 4553
the overall performance and life of the equipment which is one of the reasons for balncing
on the Screw Conveyor. The balancing machine of the fabrication department uses
HOFMAN HL-28, the balancing machine is very important to maintain the optimal
performance of the screw conveyor, and reduce the noise or vibration of the screw
conveyor which can interfere with the quality of machine performance.
Several previous studies have discussed balancing processes in industrial
equipment to improve efficiency and reduce adverse vibrations. Kalmegh and Bhaskar
(2012) examined balancing impellers in centrifugal pumps to improve engine service life
and operating efficiency. The results of the study show that proper balancing can reduce
vibration and extend the service life of engine components. In addition, research by Kholil
(2014) at PT LG Electronics Indonesia also focuses on line balancing in the production
process to improve time efficiency and productivity. These studies show the importance
of balancing in the operation of industrial machinery, but most studies only highlight
specific equipment, without highlighting the use of modern balancing machines such as
the HOFMAN HL-28.
This research offers a new contribution by applying the HOFMAN HL-28
balancing machine specifically to the screw conveyor at PT Petrokimia Gresik. There are
not many studies that use this type of balancing machine, especially in the context of the
industry in Indonesia. By optimizing balancing using the latest technology, this research
not only improves efficiency, but also extends the life of equipment and lowers
maintenance costs.
Previous research has focused more on more general machines or processes such as
balancing on impellers or line balancing processes in mass production. In this study, the
main focus is on optimizing the balancing screw conveyor using HOFMAN HL-28 which
has not been studied in depth. The study also emphasizes on vibration reduction and
increased operational stability, which is new in the context of Indonesian industry,
especially in the fertilizer industry which relies heavily on screw conveyors for the
production process.
Based on the background of these problems, the research conducted by the
researcher is to optimize the screw conveyor balancing process using a HOFMAN HL-
28 type balancing machine to determine the balance of rotation and mass distribution.
The purpose of this study is to find out the results of the balancing process, including
balancing parameters and initial unbalance.
Method
Stages and processes in machine optimization research to obtain results with
maximum precision and efficiency. The following is a flow chart of the research carried
out:
Muhammad Ando Prasetyo, Yasinta Sindy Pramesti
Indonesian Journal of Social Technology, Vol. 5, No. 10, October 2024 4554
Mulai
Observasi
Perumusan Masalah
Melaksanakan Penelitian
Mengambil Data Penelitian
Apakah Pengambilan
Data Sesuai?
Selesai
Studi Literatur
Hasil Penelitian
Tidak
Ya
Kesimpulan
Figure 1. Experimental flowchart
This research was carried out at PT Petrokimia Gresik in the period from October
2024 to January 2024. The machine used for the testing process is a HOFMAN HL-28
type balancing machine. The following are the tools and materials used to support the
research:
Table 1
Tools and Materials
No
Tools and materials
1
Dynamometer
2
Welding machine
3
Grindstone
4
Digital Scales
5
Screw Conveyor
The following are the research procedures that will be carried out:
a. Prepare the tools and materials that will be needed.
Optimization of Industrial Machine Balancing Processes for Fastening Precision and Efficiency
Indonesian Journal of Social Technology, Vol. 5, No. 10, October 2024 4555
At this stage, the author prepares tools and materials such as dynamometers,
welding machines, rulers, digital scales, and screw conveyors.
b. Testing and data retrieval
At the stage of testing and data collection using a balancing machine, the following
things must be considered:
a) Setting Up the Balancing Machine
b) Setting the screw conveyor to be balanced on the HOFMAN HL-28 machine
c) Data input on the monitor
d) The last step is to turn on the balancing machine
Results and Discussion
Balancing Screw Conveyor Testing
Figure 2. Screw Conveyor Balancing Testing Tools
Previously, testing the data of the equipment to be balanced such as name,
dimension (mm), Radius (mm), and Tolerance (g), In the process of working the machine
itself by analyzing the vibration that occurs in the machine, during the testing of the unit
to be tested previously weighing is carried out to obtain the data required by the balancing
machine, then placed on the platform or bearing, after which the unit will be rotated
through a belt or end drive, During the process of playing the unit, it will produce
vibrations, the vibration is detected by the sensor on the machine, the sensor produces
data from the vibration that occurs in the unit and will appear on the digital display screen
of the machine, from the results which part of the unit is not balanced with the engine,
and later there will be an addition or reduction of mass in that part so that the unit can be
balanced again. Parts or components that are often balanced in the fabrication department
include screw conveyors from factory II using horizontal balancing machines with
balancing grade 2.50G with Std ISO 1940 in the workshop and fabrication department.
Parameter Balancing
Before balancing, several data are needed by the balancing machine regarding the
unit such as Weight, Dimension, Radius, Tolerance, etc. The Screw Conveyor itself has
the following specifications:
Muhammad Ando Prasetyo, Yasinta Sindy Pramesti
Indonesian Journal of Social Technology, Vol. 5, No. 10, October 2024 4556
Table 2
Balancing Parameter
Balancing Parameter
Rotor Weight: 1000.00 Kg
Balancing Test Speed: 149
RPM
Tolerance Plane 1: 125.517 g
Label 08
Input Data
This monitor is used to input data before and after finishing the balance, this CAMB
balance also stores balancing data that has been done, after the balance data is by the
predetermined size, the CAMB balance monitor will store the data and the final finishing,
namely the print out of the final balancing data. At the beginning of the balancing screw
conveyor process, data input is first to find out the information data before carrying out
the next process which is then saved for the preprocessing balancing stage.
Figure 3
CAMB Balancing Monitor (input data balance)
Balancing Screw Conveyor
Screw balancing is carried out by adding or subtracting mass or plates on the side
of the degree that is not balanced, on the monitor screen it detects that the screw is added
to the mass load with an iron plate on the part that has been detected in the CAMB Balance
monitor screen system. Before adding mass, measure the mass using a digital scale.
Optimization of Industrial Machine Balancing Processes for Fastening Precision and Efficiency
Indonesian Journal of Social Technology, Vol. 5, No. 10, October 2024 4557
Gambar 4
Timbangan Digital
Welding
After the mass or iron plate is weighed/measured according to the weight that has
been displayed on the CAMB balancing monitor screen, the welding process is carried
out on the side of the screw conveyor that has been detected at the level, but in the initial
welding, it is only done by dropping on the iron plate/mass.
Figure 5
Welding process
In the initial 58 weldings, it was only done by dripping on the iron plate/mass. The
result is that after adding mass/load, the screw conveyor is rotated with a belt or and drive
with 2 rotations/gears 2 ratios on the spindle, with a speed of 140rpm, in the process of
playing the unit, on the CAMB Balance screen, press the start button which will later
produce data on mass unbalance and degree of unbalance. Furthermore, the mass/load
reduction of the screw conveyor was carried out because the results displayed on the
monitor screen were still not sufficiently balanced, then the mass/load reduction was
carried out by cutting iron plates using welding with a voltage of 120 volts and using the
Muhammad Ando Prasetyo, Yasinta Sindy Pramesti
Indonesian Journal of Social Technology, Vol. 5, No. 10, October 2024 4558
NS 8945 electrode type. After adding the load/mass by welding the iron plate on a certain
shaft part of the screw, cool it so that the object does not know the expansion, by using a
fan that is high enough speed and spraying water on the mass addition part. This is so that
during the testing of the object by rotating the balance the data obtained will be accurate
with the addition/subtraction of the mass.
Finishing
The finishing or finishing stage after the balancing screw conveyor process involves
several important steps to ensure that the balancing process runs smoothly and that the
appropriate size can achieve the desired balance. Here are some of the steps that are
usually involved in the finishing stage of a screw conveyor. Once the desired balance has
been achieved, a final inspection is carried out to ensure that all components are in good
condition and that the equipment meets the specified balance tolerances. Also the
certificate attached from the CAMB balancing monitor data. Assembly and Testing
Components that have been balanced are reassembled, and the entire system is tested to
ensure smooth operation without excessive vibration. Detailed records of the balancing
process, including before and after measurements, correction methods, and final results,
are quupmentated for reference and quality control in subsequent improvements. This
documentation is essential for effective maintenance and to meet regulatory requirements
or industry standards.
Figure 6
Balancing Certificate
Optimization of Industrial Machine Balancing Processes for Fastening Precision and Efficiency
Indonesian Journal of Social Technology, Vol. 5, No. 10, October 2024 4559
Conclusion
The working efficiency of the Screw Conveyor unit, in the area of Production
Department 3B of PT Petrokimia Gresik (coal carrier) has been maximized and with the
addition of the balancing indication on the Screw can extend the lifetime of the Screw
itself because if there is a disturbance in the Screw motor it will be easily detected by the
system and operator, and it will be easy to carry out preventive maintenance. The work
efficiency of unit D.5 in the area of the Fabrication Department 11B of PT Petrokimia
Gresik has been maximized and with the addition of the balancing indication on the screw
can extend the lifetime of the screw itself because if there is a fault in the screw motor, it
will be easily detected by the system and operator, and it will be easy to carry out
preventive maintenance.
Muhammad Ando Prasetyo, Yasinta Sindy Pramesti
Indonesian Journal of Social Technology, Vol. 5, No. 10, October 2024 4560
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