APPLICATION OF DYNAMIC PROGRAMMING FOR MULTIPLE CUTTER SELECTION IN OPTIMIZING MACHINING TIME OF SCULPTURED SURFACE By Jovian Agathon ID No. 004201400026 A Thesis presented to the Faculty of Engineering President University in partial fulfillment of the requirements of Bachelor Degree in Engineering Major in Industrial Engineering 2018 THESIS ADVISOR RECOMMENDATION LETTER This thesis entitled “Application of Dynamic Programming for Multiple Cutter Selection in Optimizing Machining Time of Sculptured Surface” prepared and submitted by Jovian Agathon in partial fulfillment of the requirements for the degree of Bachelor Degree in the Faculty of Engineering has been reviewed and found to have satisfied the requirements for a thesis fit to be examined. I therefore recommend this thesis for Oral Defense. Cikarang, Indonesia, February 22nd, 2018 Anastasia Lidya Maukar, ST., MSc., M.MT. i DECLARATION OF ORIGINALITY I declare that this thesis, entitled “Application of Dynamic Programming for Multiple Cutter Selection in Optimizing Machining Time of Sculptured Surface” is, to the best of my knowledge and belief, an original piece of work that has not been submitted, either in whole or in part, to another university to obtain a degree. Cikarang, Indonesia, February 22nd, 2018 Jovian Agathon ii APPLICATION OF DYNAMIC PROGRAMMING FOR MULTIPLE CUTTER SELECTION IN OPTIMIZING MACHINING TIME OF SCULPTURED SURFACE By Jovian Agathon ID No. 004201400026 Approved by Anastasia Lidya Maukar,S.T., M.Sc., M.MT. Thesis Advisor Ir. Andira Taslim, M.T. Head of Industrial Engineering Study Program iii ABSTRACT Many kinds of manufacturing companies can be found in this era of industrialization, especially the make-to-order industry such as mold maker industry in fulfilling the demand of customer. As the trend keeps changing, the sculptured surface product is introduced and has been used for object design. Optimal machining time is the main concern that will affect the production cost and customer satisfaction. Many researchers have invented methods in finding the best strategy using the Computer Numerical Control (CNC) machine in the process. Thus, this research focuses on implementing one of the research algorithm, Chen’s Dynamic Programming model using the real data. A research object is designed and asked to several respondents to simulate in particular software by their own process planning. The information from the simulation is used as the input for the calculation using Chen’s Dynamic Programming algorithm. Through the calculation, the feasible tools can be revealed, machining plane can be determined, and the optimal machining time can be obtained using the algorithm model. Chen’s model reduces the machining time to 23% in average. Lastly, the calculated time using Chen’s algorithm and simulated machining time by the respondents are compared for case study. Keywords: Mold Maker Industry, Sculptured Product, Machining Time, Computer Numerical Control (CNC) Machine, Dynamic Programming, Algorithm iv ACKNOWLEDGEMENT This thesis is hardly to be done without blessing from God and big motivation and tremendous support from the others. Therefore, I would like to express my gratefulness to: 1. Jesus Christ, as the source of inspiration and all blessing that I have gained. The only shelter to protect me from the storm 2. My beloved family, Mom, Grandma, Aunty, and Uncle. Thank you for your never ending support, prayers, and motivation to me. 3. My thesis advisor, Mrs. Anastasia Lidya Maukar, S.T., M.Sc., M.MT. and Mrs. Ineu Widaningsih, S.T., M.T. Thank you for your guidance, motivation, and advices in doing and accomplishing this thesis. 4. My academic advisor and Head of Industrial Engineering Study Program, Mrs. Ir. Andira Taslim, M.T. Thank you for your guidance, advice, and everything from the beginning until the completion of this thesis. 5. Betinsss squad: Nico, Aberson, Julius and Michael who always be a place to share the happiness and problems together in any time and many ways in rent house. 6. WW Gombel squad: Shella, Santi, Vero, Rika, Nico, Julius, Aberson, and Michael as my brother and sister in Cikarang. 7. My best closest female friend, Shofa Ramadhina, who always encourage me to keep striving finishing all that should be finished. The best place for the process to be myself. 8. My classmate, Industrial Engineering 2014 and Engineering Family. Thank you for always sharing, reminding, supporting each other, and all the memories that we had made together in the university life. 9. Others that I cannot mention one by one but keep supporting and motivating me. Thank you for make my life meaningful. v TABLE OF CONTENT THESIS ADVISOR ................................................................................................. i DECLARATION OF ORIGINALITY ................................................................... ii LETTER OF AGREEMENT ................................................................................. iii ABSTRACT ........................................................................................................... iv ACKNOWLEDGEMENT .......................................................................................v LIST OF TABLES ................................................................................................. ix LIST OF FIGURES .................................................................................................x LIST OF TERMINOLOGIES ................................................................................ xi CHAPTER I INTRODUCTION ..............................................................................1 1.1 Problem Background ......................................................................................1 1.2 Problem Statement .........................................................................................2 1.3 Objectives .......................................................................................................2 1.4 Scope ..............................................................................................................3 1.5 Assumption .....................................................................................................3 1.6 Research Outline ............................................................................................3 CHAPTER II LITERATURE STUDY ....................................................................5 2.1 Manufacturing System ...................................................................................5 2.2 Machining Process .........................................................................................6 2.2.1 Sculptured Surface ...................................................................................8 2.2.2 Computer Numerical Control (CNC) Machine .......................................9 2.2.3 Tool Selection for 3D Sculptured Cavities ............................................11 2.3 Operation Research ......................................................................................12 2.3.1 Integer Programming .............................................................................13 vi 2.3.2 Dynamic Programming ..........................................................................13 2.4 Chen’s Algorithm using Integer and Dynamic Programming .....................14 2.5 Questionnaire Design ...................................................................................17 2.4.1 Convenience Sampling ..........................................................................20 2.4.2 Purposive Sampling ...............................................................................21 2.6 State of the Art .............................................................................................22 CHAPTER III RESEARCH METHODOLOGY ..................................................25 3.1 Research Methodology .................................................................................25 3.1.1 Problem Identification ...........................................................................25 3.1.2 Literature Study .....................................................................................26 3.1.3 Data Collection ......................................................................................27 3.1.4 Data Analysis .........................................................................................28 3.1.5 Conclusion and Recommendation .........................................................28 3.2 Research Framework ....................................................................................28 3.2.1 Data Collection ......................................................................................29 3.2.2 Data Analysis .........................................................................................31 CHAPTER IV DATA COLLECTION AND ANALYSIS....................................32 4.1 Data Collection .............................................................................................32 4.1.1 Research Object .....................................................................................32 4.1.2 Questionnaire .........................................................................................34 4.2 Collecting Data Result .................................................................................35 4.3 Calculation using Chen Dynamic Programming Model ..............................36 4.3.1 Respondent A ........................................................................................39