Modification of the Motor Test Jig for Capacity Improvement in LE-2 Salt PCBA Production

Abstract

The Motor Test process in the PCBA Grooming Department at PT Giken Precision Indonesia was identified as the primary production bottleneck for the Salt LE-2 model due to the limited capacity of the existing motor tester. This condition resulted in the accumulation of Work in Process (WIP), increased production waiting time, and reduced operational efficiency. This study aims to improve the production capacity of the Motor Test process through the modification of the existing equipment into a Rotary Double-Type Motor Tester. The research employed the CAPD (Check–Analyze–Plan–Do) method, with the Fishbone Diagram used to identify the root causes of the problem and determine appropriate corrective actions. The proposed modification integrated a rotary mechanism, programmable logic controller (PLC), sensors, and a pneumatic system to enable simultaneous testing of two PCBA units in a single operating cycle. The implementation results showed a significant improvement in production capacity, reduced operator idle time, smoother production flow, and enhanced process stability. Furthermore, the machine performance rating increased from approximately 75% before the modification to around 95% after implementation. The results demonstrate that the proposed machine modification is an effective solution for increasing Motor Test capacity and supporting higher production requirements without requiring additional testing equipment.