Karawang –
PT Toyota Motor Manufacturing Indonesia (TMMIN) manufactures the Toyota Yaris Cross in Indonesia. The TMMIN factory in Karawang, West Java, produces the Yaris Cross for the domestic and export markets.
Not only assembling, the production process from steel plate to a complete car is carried out at Toyota Plant 2 Karawang, West Java. detikcom had the opportunity to see first hand the production process of the Toyota Yaris Cross and several other Toyota cars at the Toyota Plant 2 Karawang.
Starting from the Press Shop. From here, all the steel sheet is molded into components. Toyota demonstrated that there are three robot presses to form sheet steel into complete components. There are robots to form small, medium, and large components such as car bodies.
The process of printing sheet metal into components Photo: Rangga Rahadiansyah/detikOto
When we visited Toyota Plant 2 Karawang, we were shown how a large robot prints steel sheets into car side frames. From the Press Shop, the car has not yet been built, only the main components, such as the car’s side frame, car door, or car floor.
Sheet metal after being pressed into the shape of the side body. Photo: Rangga Rahadiansyah/detikOto
From the shape of the components that have been printed, then proceed to the welding or welding process. Several components that have been printed are put together to form a monocoque in this welding process. Starting from the side components, rear, front to the roof are welded together in the welding process.
This welding process is completely automatic. The use of robots in the welding process is carried out to determine higher precision. However, there are some welding processes that are carried out by humans for certain parts.
The welding process uses a robot. Photo: Rangga Rahadiansyah/detikOto
“When it comes to the production process, we are the advanced ones. Because I remember that in the old days we produced from the small Starlet to the big Land Cruiser. At that time, in ’95 there was no robot technology. In fact, we were very careful in determining automation. We don’t want automation to be a goal. Automation is a tool to achieve stable quality for difficult jobs,” said President Director of PT Toyota Motor Manufacturing Indonesia (TMMIN) Nandi Julyanto when met at the Toyota Karawang Plant in Karawang, West Java, Monday (7/8/2023).
After being welded into one monocoque, the next process is painting. Unfortunately, we cannot directly review the painting process.
We also saw the xEV battery assembly process at this factory. There are two types of batteries assembled here, a nickel battery for the Innova Zenix Hybrid, and a lithium battery for the Yaris Cross Hybrid.
xEV battery assembly. Photo: Rangga Rahadiansyah/detikOto
The battery in the Toyota Yaris Cross Hybrid assembled here already has 40 percent local components. Some of the components in the battery pack, such as the casing, have been assembled domestically. Meanwhile, the main components such as battery cells are still imported.
Assembly Process in Assembling. Photo: Rangga Rahadiansyah/detikOto
Furthermore, all parts of the car are assembled into one whole part in the assembling process. Starting from the interior trim, features, engine, legs, glass, seals, to form a complete car, it is processed in this assembling.
Once assembled, everything is checked. Starting from checking the features, legs, speed test, braking test, shower test or water leak test, until the electricity is checked.
Testing process after completion of assembly. Photo: Rangga Rahadiansyah/detikOto
This Toyota factory has a takt time of 99 seconds. This means that every 99 seconds a car will come out that has been produced and checked. However, not only the Yaris Cross, several other cars such as the Toyota Veloz, Avanza (export only), Calya, Yaris hatchback, and Innova Zenix were born from the same ‘womb’. The cars produced here are also a mix for the domestic and export markets.
Watch the video “Toyota Yaris Cross Hybrid GR Sport: Fast and Impressive!”
(rgr/your)
2023-08-07 13:07:01
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