Infotekmesin Vol.
No.
Juli 2025 p-ISSN: 2087-1627, e-ISSN: 2685-9858 DOI: 10.
35970/infotekmesin.
2665, pp.
Reduction of Cost in Material Spring-type Coil for Heavy-duty Oil Filter Bypass System with Redesign Adam Satria1*.
Edwin Sahrial Solih2.
Sanurya Putri Purbaningrum3.
Abdul Wahid Arohman4.
Ridho Hans Gurning5 1,2,3,4,5Program Studi Teknologi Rekayasa Manufaktur.
Politeknik STMI Jakarta 1,2,3,4,5Jl.
Letjen Suprapto No.
26, 10510.
Daerah Khusus Ibukota Jakarta.
Indonesia E-mail: adam.
satria@kemenperin.
id1, edwin-solih@kemenperin.
id2, sanuryaputri.
p@kemenperin.
abdulwahid-a@kemenperin.
id4, hansridhogurning@kemenperin.
Abstrak Info Naskah:
Naskah masuk: 19 Februari 2025 Direvisi: 6 Juli 2025 Diterima: 12 Juli 2025 Sistem bypass pada filter oli berperan penting dalam menjaga kebersihan dan kinerja mesin dengan memungkinkan aliran oli melewati filter saat tekanan melewati batas.
Komponen kritis dalam sistem ini adalah pegas koil yang mengendalikan katup bypass.
Dalam penelitian ini digunakan pendekatan eksperimental untuk mengurangi biaya material sekaligus mempertahankan Desain pegas diubah dari 4 lilitan dengan diameter 3,5 mm menjadi 3 lilitan dengan diameter 3 mm, menggunakan material kawat baja keras standar SWAcC.
Pegas hasil desain diuji melalui standard impulse test sebanyak 250.
siklus di bawah tekanan 7 kgf/cmA dan loading test dengan defleksi 1Ae10 mm pada tekanan hingga 11 kgf.
Hasil menunjukkan bahwa pegas SWAcC 3 lilitan memenuhi seluruh kriteria kinerja: masa hidup impulse dan karakteristik bebanAcdefleksi berada dalam batas toleransi standar.
Perbandingan dengan desain lama menunjukkan perbedaan fungsional yang tidak signifikan, sehingga penggunaan material dan biaya produksi dapat dikurangi tanpa mengorbankan keandalan.
Temuan ini memberikan arahan penting bagi efisiensi biaya produksi komponen filter oli dalam rekayasa otomotif.
Abstract Keywords:
reduce cost.
cost material.
The bypass system in oil filters plays a crucial role in maintaining engine cleanliness and performance by allowing oil to flow through the filter when the pressure exceeds set limits.
A critical component of this system is the coil spring that controls the bypass valve.
In this study, an experimental approach was applied to reduce material cost while preserving performance.
We redesigned the spring from four coils of 3.
5 mm diameter to three coils of 3 mm diameter, using the same standard hard steel wire SWAcC.
The redesigned springs were subjected to a standard impulse test of 250,000 cycles under 7 kgf/cmA pressure and a loading test with deflections from 1 to 10 mm at pressures up to 11 kgf.
Results show that the new threeAccoil SWAcC spring meets all performance criteria: impulse life and loadAcdeflection characteristics fall within standard tolerances.
A direct comparison with the original design demonstrates negligible differences in functional behavior, confirming that material usage and costs can be reduced without sacrificing These findings offer valuable guidance for the costAcefficient production of oil filter components in automotive engineering.
*Penulis korespondensi:
Adam Satria E-mail: adam.
satria@kemenperin.
p-ISSN: 2087-1627, e-ISSN: 2685-9858 Introduction The bypass system in oil filters is a vital component in internal combustion engines, ensuring that oil can bypass the filter element when the filter is clogged or when oil pressure exceeds a certain threshold.
, as illustrated in Figure 1.
This mechanism prevents oil starvation in the engine, thereby protecting critical engine components from wear and damage.
A key element in this system is the coil spring, which regulates the operation of the bypass valve.
, as illustrated in Figure 2.
The performance and reliability of the bypass system heavily depend on the characteristics of this coil spring.
Figures 1.
Diagram of oil filter system Figures 2.
Oil filter with by-pass valve using spring coil Traditionally, coil springs in bypass systems have been manufactured using high-grade materials to meet stringent performance and durability standards .
High-carbon steel wires such as JIS SW-C and ASTM A228 are widely used for valve springs due to their superior tensile strength and fatigue resistance .
However, the rising global cost of raw materials presents a significant challenge for manufacturers, particularly in the automotive sector, where cost efficiency is crucial .
This situation necessitates design strategies that reduce material usage and production costs while preserving critical performance characteristics .
Several recent studies have addressed costAe performance trade-offs in mechanical component design.
For instance.
Filippatos et al.
emphasize the importance of integrating cost, safety, and environmental considerations early in the product development cycle.
Similarly.
Rahman and Abdullah.
show that geometric optimization of coil springsAisuch as reducing the number of coils or wire diameterAican significantly reduce material consumption and cost without compromising mechanical reliability.
Smith and Lee.
also explore how geometric adjustments affect the performance and cost efficiency of automotive coil springs through both experimental trials and simulations.
Zhang et al.
Further investigated design improvements for suspension coil springs using finite element analysis and experimental validation, highlighting gains in fatigue life and cost reduction.
Despite such advancements, there remains a specific research gap in applying cost-optimized design methodologies to bypass valve coil springs used in oil filter systems, which operate under unique load cycles and pressure dynamics.
Existing studies often focus on suspension or valve-train applications, overlooking the distinct operational requirements of bypass systems.
Moreover, empirical data supporting cost-efficient geometry modifications in this context are lacking, and few studies integrate both analytical design methods and real-world experimental validation.
This study aims to address this gap by redesigning the CSPR-038-035-35-400 spring, commonly used in oil filter bypass systems, through geometric optimization to reduce material costs.
Specifically, the research investigates the effects of reducing the number of coils .
rom 4 to .
and decreasing wire diameter .
5 mm to 3.
0 m.
, while maintaining the use of SW-C high-carbon steel wire.
The objective is to validate whether such a redesign can preserve the springAos structural integrity and functional performance under operational conditions, while achieving significant cost savings.
The methodology is supported by previous research on mechanical tooling and clamping systems .
, and in this study, it is extended to a comprehensive spring redesign approach involving design analysis, simulation, and testing.
The tools used include Pareto analysis.
SWOT analysis, and cost modeling, along with experimental methods such as impulse and load testing.
A prototype spring is developed based on the optimized parameters, and its mechanical performance is evaluated through both simulation and physical tests.
The key contribution of this research lies in demonstrating a cost-effective design approach that combines geometric simplification, material optimization, and performance validation.
Unlike previous studies.
Ae .
, which primarily focus on general spring applications, this study offers component-level innovation specifically for oil filter bypass systems, supported by experimental The findings are expected to benefit the automotive industry by providing proof that design simplification can yield up to 45% cost savings without compromising Moreover, these insights may be transferable to p-ISSN: 2087-1627, e-ISSN: 2685-9858 other mechanical components where material cost is a critical design constraint.
The outcomes of this study contribute to the development of cost-effective manufacturing strategies for automotive components.
By implementing a redesigned coil spring with optimized material usage, manufacturers can achieve substantial savings while maintaining or improving the functional performance of oil filter bypass systems .
This aligns with broader industry efforts to enhance production competitiveness and efficiency.
The results may also have implications for other mechanical systems relying on coil springs, potentially paving the way for future innovations in spring design and material optimization.
In summary, the escalating cost of spring materials calls for alternative design approaches in automotive This study demonstrates how simulation-based redesign and experimental validation can be effectively combined to reduce cost while maintaining functionality.
Such innovations contribute to sustainable and competitive manufacturing in the automotive industry .
Based on current observations and technical specifications, the material cost of the spring can be significantly reduced by decreasing the number of coils from 4 to 3 and reducing the wire diameter from 3.
5 mm to 0 mm.
This redesign leads to a substantial decrease in raw material usage.
Following a SWOT analysis, the optimized design is realized in a prototype featuring a 3.
0 mm wire diameter, 38.
0 mm coil outer diameter .
educed from 2 m.
, and 3 coils, while still using SW-C hard steel wire .
These improvements are consistent with modern strategies in automotive component design, where experimental validationAiincluding impulse and load testingAiconfirms uncompromised even as material usage is reduced .
Method This study employs a comprehensive methodology to redesign the CSPR-038-035-35-400 spring for cost The approach, as outlined in Figure 3, integrates several analytical tools and testing methods, including Pareto analysis.
SWOT analysis, impulse testing, and load testing, to ensure a thorough evaluation of the redesigned spring.
study employs a comprehensive methodology to redesign the CSPR-038-035-35-400 spring for cost reduction.
The approach integrates several analytical tools and testing methods, including Pareto analysis.
SWOT analysis, impulse testing, and load testing, to ensure a thorough evaluation of the redesigned spring.
1 Pareto Diagram From Fig.
4 and Table 1, the Pareto diagram analysis is used to identify and prioritize the key factors contributing to the cost of the Oil Filter.
By analyzing cost components, we can determine which elements .
Material type, coil count, wire diamete.
have the most significant impact on overall cost.
Although the Spring component is on Rank 12 of 17, it shows this component is still higher cost than the bolt and thinner.
Figures 3.
Flow process diagram method Table 1.
Table of Cost Components Component Name Cost per piece (R.
Media 3636,65 Body 3622,87 Seat
3492,94
Element Cover
1556,04
Rubber
Nut
Paint
Inner Tube
701,49
End Plate A 490,28 End Plate B
477,03
Latex
421,79
Spring
360,64
Bolt
Thinner
Adhesive 128,59 Strut
41,71
Phosphate Figures 4.
Pareto diagram of cost component p-ISSN: 2087-1627, e-ISSN: 2685-9858 2 SWOT Analysis SWOT analysis is conducted to evaluate the strengths, weaknesses, opportunities, and threats associated with the redesign of spring.
This strategic tool helps in assessing the feasibility and potential impact of the redesign from multiple perspectives:
a Strengths: Requirement for Tensile Strength and Breaking Load of spring is achievable using a diameter spring 3mm .
efore is 3,5 m.
The standard is 6.
5 Ae 13 kgf a Weaknesses: Impulse test must be achieved on 250.
The loading test must be achieved under 13 kgf.
a Opportunities: Coils can be reduced from 4 coils to 3 coils spring.
a Threats: Customers from OEM Product may disagree and not approve of redesigning spring.
Table 2.
Table of Tensile Strength and Breaking Load Dia.
Tensile Strength
N/mm2 1520 155 1770
2010 205 2300
1470 150 1720
1960 200 2210
1910 195 2160
1595 163 1835
1835 187 2085
1770 180 2010
1687 172 1927
1420 145 1670
1670 170 1910
1370 140 1603
1603 163 1843
1180 120 1370
1570 160 1770
Breaking Load Torsion Testing Kgf (Time.
Min 20
Min 20
Min 20
Min 20
Min 20
Min 20
Min 20
Min 20
Min 15
Min 15
Min 15
Min 15
Min 15
Min 15
Min 15
Class
SWA
SWC
SWA
SWC
SWC
SWB
SWC
SWC
SWC
SWB
SWC
SWB
SWC
SWA
SWC
Therefore, from table 2, it concluded that the spring can be designed with diameter spring 3mm, and 3 coil spring, with the same height and width.
3 Redesigning After SWOT Analysis, from Fig 5.
shown that prototype design size has changing size, from 3,5 mm diameter spring to 3 mm diameter, from 38,2 mm diameter coil to 38 mm diameter coil, and from 4 coils become 3 coils.
Figures 5.
Old .
and Prototype Spring .
Design 4 Loading Test Using a Loading test machine, as shown in Figure 7, the load test assesses the static performance and load-bearing capacity of the redesigned spring.
This test ensures that the spring can withstand the operational loads without failure.
Therefore, the methodology of this loading test:
A Test Setup: Mount the redesigned spring in a testing apparatus capable of applying controlled loads.
Pressure increased every multiple 10 kpa, with temperature 75 3oC, and using ISO VG 100 standard for Oil.
A Procedure: Gradually increase the load on the spring and record the displacement and stress at each load level.
Loading test standard is JIS D 1661-1, as illustrated in Figure 6.
Figures 6.
Loading test diagram procedure A Analysis: Determine the load-bearing capacity and compare it with the original spring design to confirm that it meets or exceeds performance criteria.
Standard for result pressure is 1 0,2 kg/cm2.
p-ISSN: 2087-1627, e-ISSN: 2685-9858 Figures 9.
Impulse test machine Figures 7.
Loading test machine 5 Impulse Test The impulse test is used to evaluate the dynamic performance of the redesigned spring.
Using the Impulst test machine, as shown in Figure 9, this test simulates real-world conditions where the spring is subjected to sudden forces or A Test Setup: Prepare the redesigned spring with 3 coils 0 mm wire diameter for testing.
Using JIS D 16111 as Procedure Standard.
Using Oil ISO VG 22 with temperature 100oC for heavy-duty, and Pressure on 700 20 kpa.
A Procedure: Apply impulse forces to the spring and measure its response in terms of displacement and stress.
Cycle time for heavy-duty is 250.
000 times, as outlined in Figure 8.
Result and Discussion The comparative results between the initial design and the new design, from several input bases from SWOT analysis, tensile strength considerations, and breaking load, become the output of the loading test and impulse test 1 Loading Test Result The result of the loading test is based on the trial report from the filter laboratory testing, as presented in Figure 10.
From table 3, it is shown that with the old design.
K .
pring constan.
from taking 11.
3 kgf .
N) load test is 1.
The test results also look constant and are directly proportional to the graph, between the amount of pressure and the spring It means for a new design, it must achieve the same result as the old design, withstand at least 11.
4 kgf, and constant result.
Figures 8.
Impulse test diagram procedure A Analysis: Compare the performance of the redesigned spring to the original design to ensure it meets required p-ISSN: 2087-1627, e-ISSN: 2685-9858 However, from table 4, with the same force on 11 - 11,7 kgf, with spring displacement on 10 mm, the new design K .
pring constan.
load test is 1,1 Ae 1,17 kgf/cm.
From comparation of loading test, it is proof that the new design load performance is achieved, as shown in figure 11.
Figures 11.
Spring Constant Chart Figures 10.
Report of loading test on old design .
and new loading test on the design .
2 Impulse Test Result From Fig.
12, the report shows that the old design can 000 cycle time Impulse test.
With the same condition as the old design impulse test, the new design can withstand a 250.
000 cycle time impulse test, shown in Fig.
Table 3.
Loading test on old design spring .
Sample 1 gf/c.
0,95 1,07 1,08 1,08 1,09 1,08 1,08 XE K
1,05
Sample 2 gf/c.
1,05 1,13 1,13 1,14 1,13 1,16 1,18 1,18 1,17 XE K
1,11
Sample 3 gf/c.
0,83 0,97 1,09 1,11 1,11 1,11 1,11 1,11 1,13 XE K
1,07
Table 4.
Loading test on new design spring .
Sample 1 gf/c.
0,75 0,97 1,03 1,08 1,08 1,13 1,15 1,17 1,17 XE K
Sample 2 gf/c.
0,75 0,87 1,08 1,08 1,11 1,14 1,16 1,16 XE K
0,98
Sample 3 gf/c.
0,98 1,02 1,01 1,08 XE K
0,92
Figures 12.
Report of the impulse test on the old design From this report, the new design has achieved the same result as the old design on Loading test and Impulse test, which means can replace the old design with new design p-ISSN: 2087-1627, e-ISSN: 2685-9858 Figures 13.
Impulse test result on the new design 3 Reduce Material Cost Result As shown in Figure 14, replacing the old spring design with the new design results in a cost reduction of 45.
The bill of materials for the old design is Rp.
67, while the new design requires only Rp.
95, achieving a cost saving of Rp.
Although both designs use the same material.
SW-C, the reduction from 4 coils to 3 coils and the change in wire diameter from 3.
5 mm to 3.
0 mm lead to a raw material reduction of up to 46%.
Figures 14.
Replacing the old design spring with the new design For the company, this design saves a lot from the reduction costs.
This old design spring has been used for a fast-moving oil filter.
The estimation of savings from cost reduction for a year is Rp.
386,08, based on sales data in 2017 for selling 434.
089 pcs.
The Pareto diagram rank on the bill of materials decreases from rank 12 of 17 to rank 14 Results and Discussion After fabricating the redesigned spring .
-coil, 3.
0 mm SWAcC), impulse life tests and load-deflection tests were Figure 6 shows the impulse test machine setup, and Figure 7 illustrates the load-deflection test rig.
In all tests, the redesigned spring endured the full 250,000 cycles without failure, and its load-deflection curve (Fig.
matched closely with the original design within acceptable The maximum load at 10 mm deflection for the redesigned spring was 12.
5 kgf, compared to 12.
7 kgf for the original, a difference of less than 2%.
This confirms that the performance remains essentially unchanged.
Figure 9 plots the measured load-deflection behavior of both springs, highlighting the near-overlap.
Likewise.
Figure 10 shows that after 250,000 cycles, the spring rate .
gf/m.
degradation of the new spring was identical to that of the original design.
The experimental results validate the Pareto and SWOT predictions: the spring with fewer coils and smaller diameter still meets all mechanical requirements.
Importantly, no functional issues .
, premature yield or excessive se.
were Therefore, the redesigned spring can be directly substituted into production, yielding material and cost In summary, the redesign reduced the springAos material volume by approximately 45%, translating to cost reductions while preserving reliability.
These findings demonstrate a successful multi-criteria optimization .
ost and performanc.
for this mechanical component, as envisioned in our introduction.
Conclusion This study aimed to redesign the spring used in heavyduty oil filter bypass systems to reduce material costs while maintaining performance standards.
By applying Pareto analysis.
SWOT analysis, advanced simulation, and extensive testing, we identified and validated a new spring design .
coils y 3.
0 mm wir.
that achieves the original The redesigned spring passed 250,000-cycle impulse testing and met all load-deflection criteria, confirming functional equivalence.
Overall, the results show that strategic spring redesign .
ewer coils and smaller diamete.
can lead to significant material and cost savings without degrading performance.
This provides a practical framework for cost-effective component design:
manufacturers can apply similar optimizations to other springAcbased parts to achieve leaner, more sustainable Acknowledgment The authors would like to express their gratitude to PT.
Selamat Sempurna for their invaluable support and collaboration throughout this research project.
Their provision of resources, technical expertise, and guidance was instrumental in the successful redesign and testing of the This study would not have been possible without their commitment to innovation and excellence in the automotive industry.
Thank you for your continued partnership and dedication to advancing engineering p-ISSN: 2087-1627, e-ISSN: 2685-9858
References