DFMA-Based Redesign of the M-Coat Tank for Plastic Sheet Coating Production at PT EA1

Abstract

Background: Plastic film sheet production at PT EA1 requires a uniform M-Coat layer to meet product quality specifications; therefore, the suitability of the coating-media container is critical to process stability and coating consistency. Objective: This study aims to redesign the M-Coat tank so that its dimensions and configuration match the coating process requirements and the machine working mechanism. Methodology: The research employed an industrial case-study design, collecting data through observation, interviews, and documentation, supported by direct dimensional measurements of the product and equipment constraints. Data were analyzed using the Design for Manufacturing and Assembly (DFMA) method to develop and evaluate the redesigned tank concept in terms of manufacturability, assemblability, and operational suitability. Findings: The proposed M-Coat tank redesign is applicable to the production line and can be operated optimally to support the plastic sheet coating process at PT EA1. Implications: The results indicate that DFMA-based redesign of process equipment can improve implementation feasibility on the shop floor while supporting consistent coating performance in coating production environments. Originality: This study extends DFMA from conventional product/component redesign to coating-line process equipment redesign by integrating manufacturability and assembly considerations with real operational constraints in plastic sheet coating production.