Adhe Satria, Yoga Guntur Sampurno

Development of Special Service Tools Tracker Kingpin Hino Series 300 to Increase Technician Work Efficiency

Introduction

Development of special service tools tracker kingpin hino series 300 to increase technician work efficiency. Developed a Special Service Tool (SST) for Hino Series 300 kingpin maintenance, cutting service time by 88.3%. Improves technician efficiency, safety, and ergonomics. Validated with FEA.

Abstract

This study focused on the design, development, and evaluation of a Special Service Tool (SST) created explicitly for maintaining kingpin components in Hino Series 300 trucks. The research focused on the challenges and safety issues encountered by technicians stemming from the lack of specialized tools for kingpin removal. This often led to extended service times, variable repair quality, and a heightened risk of damaging components. To address these challenges, the research employed the ADDIE development model, which comprises five stages: Analysis, Design, Development, Implementation, and Evaluation. In the design phase, 3D modeling was performed using SolidWorks, and Finite Element Analysis (FEA) was conducted to verify the tool's structural integrity under various load scenarios, reaching up to 19,613 N. The SST was made from ASTM A36 steel, recognized for its mechanical strength and ease of manufacturing. The simulation results demonstrated that the structure stayed within safe limits for both stress and deformation, achieving a minimum safety factor of 1.1. The implementation took place at PT. MPM Hino Yogyakarta, where field testing showed a significant enhancement in technician efficiency. The SST cut down kingpin maintenance time from 360 minutes to only 42.08 minutes, achieving an impressive 88.3% reduction in time spent. Testing for effectiveness, based on feedback from technicians and supervisors, revealed a high level of user satisfaction, particularly in terms of safety, usability, and ergonomic design. The SST tracker kingpin provides a dependable, effective, and secure option for maintaining commercial vehicles. The successful application of it at a Hino service center highlights its practical benefits and the potential for wider implementation throughout the automotive maintenance sector. Additional improvements could involve ergonomic adjustments and the ability to accommodate various truck models, thereby facilitating broader use.

Review

This paper addresses a pertinent issue within commercial vehicle maintenance: the lack of specialized tools for kingpin removal in Hino Series 300 trucks. The authors effectively highlight how this deficiency leads to significant operational challenges, including extended service times, inconsistent repair quality, and increased safety risks for technicians, alongside a heightened potential for component damage. By focusing on these practical problems, the study lays a strong foundation for its proposed solution, underscoring the pressing need for specialized service tools to enhance technician work efficiency and overall service center productivity. The research meticulously outlines the development process of a Special Service Tool (SST) for kingpin maintenance, employing the well-established ADDIE model. A notable strength of the methodology lies in the rigorous design phase, which incorporated 3D modeling via SolidWorks and subsequent Finite Element Analysis (FEA). This allowed for a robust verification of the tool's structural integrity under substantial load scenarios (up to 19,613 N), with the material choice of ASTM A36 steel further bolstering confidence in its mechanical strength and manufacturability, achieving a minimum safety factor of 1.1. The practical effectiveness was convincingly demonstrated through field testing at PT. MPM Hino Yogyakarta, where the SST dramatically reduced maintenance time from 360 minutes to just 42.08 minutes—an impressive 88.3% efficiency gain. Furthermore, qualitative feedback from technicians and supervisors confirmed high user satisfaction concerning safety, usability, and ergonomic design. Overall, this study presents a compelling case for the practical benefits of purpose-built service tools in automotive maintenance. The successful implementation and significant time savings observed at a Hino service center underscore the immediate value of the developed SST tracker kingpin, positioning it as a dependable, effective, and secure solution. The findings offer valuable insights for the broader automotive maintenance sector, suggesting a clear path towards improving operational efficiency and technician welfare. The authors prudently acknowledge avenues for future enhancement, such as ergonomic refinements and expanding the tool's compatibility to accommodate various truck models, which would undoubtedly facilitate its wider adoption and amplify its impact across the industry.

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