Sharp Indonesia Refrigerator Virtual Factory Tour 2020

Summary

This virtual tour takes viewers through the process of producing high-quality refrigerators at a factory in Karawang, West Java. The journey starts with the rollforming of metal sheets and progresses through various stages, including cabinet assembly, compressor installation, and high-frequency welding. Automated systems ensure efficiency, while rigorous quality control checks verify functionality. The final product is cleaned and packed before being shipped across Indonesia. The factory emphasizes innovation, cleanliness, and adherence to halal certification, aiming to meet the needs of Indonesian families.

Takeaways

• 😀 The factory in Karawang, West Java, produces thousands of refrigerators daily to meet the needs of Indonesian families while maintaining quality and cleanliness.
• 😀 The refrigerator production process begins with the roll forming of steel sheets, where barcodes are attached for tracking and model identification.
• 😀 The system used in production is automated, allowing barcode data to be processed by the Production Control System (PCS) for unit tracking and model changes.
• 😀 In the next step, the steel sheets are combined with condenser pipes and other supporting parts, ending with the bending process to form the U-shape of the refrigerator cabinet.
• 😀 Cabinet assembly involves joining the inner fade liner and the outer cabinet parts, followed by the installation of the top and bottom covers before the polyurethane (PU) insulation is injected.
• 😀 PU insulation is spread effectively within the cabinets by heating the cabinets before injection, and the system uses quick-change technology for faster model transitions.
• 😀 Compressors are installed into the refrigerators, which are responsible for circulating refrigerant throughout the unit to cool it.
• 😀 High-frequency welding is performed to install the evaporator, while accessories are delivered to the assembly line by Automated Guided Vehicles (AGVs), which operate autonomously to deliver parts at designated points.
• 😀 Tyvek welding is done to evacuate air from pipes and prepare them for refrigerant filling, ensuring efficient cooling performance.
• 😀 The door installation process uses automatic systems to match the door to the cabinet, minimizing errors through the PCS system.
• 😀 After all components are assembled, a comprehensive quality control process checks electrical functions, cooling efficiency, and leak tests before the refrigerator proceeds to the final finishing and packing stages.

Q & A

What is the primary purpose of the factory in Karawang?

The factory in Karawang produces thousands of refrigerators daily to meet the needs of Indonesian families, ensuring quality and environmental cleanliness.

What is the first step in the refrigerator production process?

The first step is rollforming, where sheets of metal are used to create the refrigerator cabinet, and barcode labels are added for machine scanning and production tracking.

How does the barcode label system help in production?

The barcode label is scanned by machines to automatically track data through the production control system (PCS), which facilitates unit traceability and model changes.

What is the significance of bending in the refrigerator production process?

Bending is used to shape the metal sheet into a 'U' form, which will become the refrigerator cabinet.

What happens during the cabinet assembly process?

During assembly, the interior (fade liner) and exterior (cabinet) parts of the refrigerator are joined together, followed by the installation of top and bottom cabinet covers before the injection of polyurethane (PU) material.

Why is the refrigerator cabinet heated before filling with PU material?

The cabinet is heated to ensure that the polyurethane material spreads evenly inside and fills the space properly during the injection process.

What role does the compressor play in the refrigerator?

The compressor pumps refrigerant throughout the refrigerator to enable cooling, maintaining the desired temperature inside the unit.

What happens during the high-frequency welding process?

In this step, the evaporator is attached to the refrigerator, and the internal accessories are assembled using automated guided vehicles (AGVs) that transport parts to specific points.

What is the purpose of the vacuum pump during the refrigeration process?

The vacuum pump removes air from the pipes before refrigerant is injected into the system, ensuring proper operation of the cooling mechanism.

How is quality control conducted before the refrigerator is packed for shipment?

A series of tests, including electrical checks, cooling tests, and leak detection, are performed to ensure all components are functioning correctly. If all tests pass, the refrigerator is cleaned and packed for distribution.