MOMENT LANGKA!!! LIHAT LANGSUNG PRODUKSI TOYOTA YARIS CROSS DI PABRIKNYA!!! WAJIB TONTON! | GridOto

Summary

Join the host as they explore the production process of Toyota Yaris Cross at PT Toyota Motor Manufacturing Indonesia in Karawang, West Java. The video offers an in-depth look from the initial pressing of metal sheets to the final assembly, highlighting safety protocols, the efficient 99-second welding of a car body, and the meticulous quality control. It also showcases the assembly of hybrid batteries, the clean room powered by renewable energy, and the final touches before the vehicles undergo a rigorous inspection. Experience the impressive manufacturing efficiency where a new car is completed every 1.65 minutes.

Takeaways

• 🏭 The video provides a tour of PT Toyota Motor Manufacturing Indonesia in Karawang, West Java, showcasing the production process of the Toyota Yaris Cross.
• 🔍 Safety is emphasized at the beginning with the presenter wearing a helmet and HIV, highlighting the importance of safety gear when entering the factory.
• 🚗 The production process is divided into different plans, with Plan 2 focusing on the Yaris Cross Veloz and Yaris models, while Plan 1 is for Fortuner and Zenix models.
• 🔩 The press shop is where the car's body parts are made from steel sheets, with 55 components for the Yaris body being produced.
• 🧹 Cleanliness is crucial in the production process, especially in areas where parts are printed, to avoid defects caused by even micron-sized dust particles.
• 🤖 The welding shop is highly automated with robots, but safety remains a priority due to the sparks and flames involved in the welding process.
• ⏱️ The production line is highly efficient, with a car body completed every 99 seconds, showcasing the speed of the Toyota manufacturing process.
• 🔋 A special clean room is dedicated to the assembly of batteries for hybrid vehicles, such as the Yaris Cross Hybrid and Toyota Innova, powered by renewable energy from solar panels.
• 🔧 The assembly shop is where the car's chassis, body, and engine are combined, along with the installation of various electrical components and interior parts.
• 🛠️ The final stages of production include the installation of wheels, bumpers, and other finishing touches before the car undergoes a quality inspection, including a shower test to check for leaks.

Q & A

What is the main focus of the video?

The main focus of the video is to provide a tour of PT Toyota Motor Manufacturing Indonesia in Karawang, West Java, showcasing the production process of Toyota Yaris Cross from start to finish.

Why does the presenter wear a helmet and safety gear?

The presenter wears a helmet and safety gear because safety is prioritized, and it is a requirement to wear full personal protective equipment (PPE) when entering the factory.

What does 'Plan 2' refer to in the context of the Toyota factory?

'Plan 2' refers to the production area where the Toyota Yaris Cross Veloz and Yaris models are manufactured.

What is the purpose of the press shop in the production process?

The press shop is where the sheet metal is stamped into various body parts for the vehicles, such as side panels and other components.

How often does a part come out of the machine in the press shop?

A part comes out of the machine every 3.75 seconds.

What is the significance of the 'sample master' in the quality control process?

The 'sample master' serves as a reference to ensure that the parts produced by the machines match the quality standards and specifications.

What is the welding shop's role in the assembly of a Toyota Yaris Cross?

The welding shop is where the various components from the press shop are assembled and welded together to form a complete vehicle body.

How long does it take for a car to be assembled in the welding shop?

It takes 99 seconds, or 1.6 minutes, for a car to be assembled in the welding shop.

What is the purpose of the clean room in the battery assembly area?

The clean room is where Toyota assembles batteries for hybrid vehicles, such as the Yaris Cross Hybrid and Toyota Innova. It is kept clean to ensure the quality and safety of the battery components.

How is the clean room for battery assembly powered?

The clean room is powered by renewable energy from solar panels.

What is the difference between the batteries used in Yaris Cross and Innova Zenix Hybrid?

The Yaris Cross uses a more compact lithium-ion battery with a voltage of 175.2 volts and a weight of 20 kg, while the Innova Zenix Hybrid uses a larger nickel-based battery with a voltage of up to 201.6 volts and a weight of 40 kg.

What is the final step in the assembly process before the car is ready for inspection?

The final step in the assembly process is the installation of the bumper and filling the car with Pertamax Turbo fuel before it undergoes quality inspection.

Outlines

00:00

🏭 Introduction to Toyota Yaris Cross Production

The script begins with a visit to PT Toyota Motor Manufacturing Indonesia in Karawang, West Java, to explore the production process of the Toyota Yaris Cross. The narrator emphasizes the importance of safety by wearing a helmet and HIV (possibly a typo, should be 'PPE' for Personal Protective Equipment). The video tour covers various production stages, starting from the press shop where body panels are made, to the storage area where body parts begin to take shape. The process includes washing, centering, and quality checks to ensure precision and cleanliness, with each part being produced every 3.75 seconds.

05:02

🔧 Welding and Assembly of Toyota Yaris Cross

The script continues with the welding shop where body components are assembled into a single body. The process is highly automated with robots but still requires safety measures due to sparks and flames. The production line is efficient, with a car body completed every 99 seconds. The video also covers the roof installation process, which involves a specific sequence of attaching roof panels, reinforcement, and filler. The assembled bodies then move to the painting area before entering the assembly line, which includes a clean room for battery assembly, particularly for hybrid models like the Yaris Cross Hybrid and Toyota Innova.

10:05

🔋 Battery Assembly for Hybrid Models

The script delves into the battery assembly process for hybrid vehicles, detailing how battery cells are stacked, assembled into lower cases, and connected with cables. The process is highly automated, with robots handling delicate components. The clean room, powered by renewable energy from solar panels, ensures a clean environment for battery assembly. The video highlights the differences in battery composition between the Yaris Cross and Innova Zenix Hybrid, with the former using a more compact lithium-ion battery suited for urban use and the latter featuring a larger nickel battery for longer journeys.

15:08

🚗 Final Assembly and Quality Checks

The final part of the script covers the assembly of the vehicle's chassis, where the body, engine, and suspension are combined. The process involves multiple stages, including the installation of doors, wiring, and electrical components. The vehicles then undergo a series of quality checks, including a 'shower test' to simulate heavy rain conditions and ensure there are no leaks. The script concludes with the vehicles being filled with fuel and prepared for inspection and delivery, highlighting the mix-line production system that allows for the manufacturing of various models, including the Yaris Cross, within an impressively short timeframe of 8 hours from raw sheet metal to a finished vehicle.

20:08

🌟 Wrapping Up the Toyota Production Tour

The script concludes with a summary of the impressive production capabilities at PT Toyota Motor Manufacturing Indonesia, emphasizing the mix-line production that allows for the creation of various models, including the Yaris Cross, Yaris, Veloz, and Avanza, some of which are exported. The narrator invites viewers to like, subscribe, and follow on Instagram for more content, promising to meet again in the next video with more insights into Toyota's manufacturing process.

Keywords

💡Yaris Cross

The Yaris Cross is a compact SUV model produced by Toyota. In the video, the production process of the Yaris Cross is highlighted, showcasing its assembly from start to finish at PT Toyota Motor Manufacturing Indonesia in Karawang, Jawa Barat. The script mentions the Yaris Cross multiple times, emphasizing its production line and the various stages it undergoes, such as pressing, welding, and painting.

💡Safety

Safety is a paramount concern in the manufacturing industry, and the script emphasizes this by mentioning the use of helmets and HIV (possibly a typo for 'PPE' or Personal Protective Equipment) for safety. The video script mentions safety as the 'Number One' priority, indicating that the factory has strict protocols in place to protect workers, which is a crucial aspect of any industrial operation.

💡Press Shop

The press shop is where the metal sheets are stamped into the body panels of the car. The script describes the process in the press shop, where 'blanks' or raw materials are transformed into body parts for the Yaris Cross. This is a critical step in the manufacturing process, as it sets the foundation for the vehicle's structure.

💡Welding Shop

The welding shop is where the various body panels and components are joined together to form the complete body of the vehicle. The script mentions the welding shop as a place where components from the press shop are assembled into a single body, highlighting the use of robots and the safety measures in place due to the sparks and high temperatures involved in the welding process.

💡Assembly Line

An assembly line is a manufacturing process in which parts are added to a product in a sequential manner as it moves from station to station. The script describes the assembly line as a series of steps where the car's body, engine, and other components are assembled into a complete vehicle. This is a key part of the video, illustrating the efficiency and precision of the production process.

💡Quality Control (QC)

Quality control refers to the process of ensuring that the products manufactured meet certain quality standards. The script mentions a 'qc' area where samples are checked against master samples to ensure consistency and quality. This is vital in the production process to maintain the integrity and reliability of the final product.

💡Hybrid

A hybrid vehicle is one that uses two or more power sources, typically an internal combustion engine and an electric motor. The script discusses the assembly of hybrid batteries for the Yaris Cross Hybrid, indicating Toyota's commitment to sustainable and efficient vehicle technology. The video script provides insights into the specific components and assembly process for hybrid batteries.

💡Renewable Energy

Renewable energy refers to energy sources that are naturally replenished, such as solar power. The script mentions that the clean room where batteries are assembled is powered by renewable energy from solar panels, showcasing Toyota's efforts towards sustainability in their manufacturing processes.

💡Efficiency

Efficiency in manufacturing refers to the optimal use of resources to produce a product with minimal waste. The script highlights the efficiency of the production line, noting that a Yaris Cross is completed every 99 seconds, demonstrating the high-speed and streamlined nature of the assembly process.

💡Innova Zenix

The Innova Zenix is another vehicle model produced by Toyota, mentioned in the script alongside the Yaris Cross. It is used to illustrate the diversity of vehicle models that are manufactured in the same facility, indicating the flexibility and scale of Toyota's production capabilities.

💡Suppliers

Suppliers provide the necessary parts and components for the manufacturing process. The script mentions that 70% of the components come from suppliers, while 30% are produced in-house. This highlights the importance of supply chain management in the manufacturing process and the balance between external and internal production.

Highlights

Introduction to PT Toyota Motor Manufacturing Indonesia and the production of the Toyota Yaris Cross.

Emphasis on safety equipment (APD), including helmets and high-visibility vests, as essential for entering the factory.

Overview of Plan 2, the factory responsible for producing Yaris Cross, Veloz, and Yaris models.

Inside the press shop, where metal blanks are shaped into various body parts for the Yaris Cross, including side panels and hoods.

Discussion of the precision required in the pressing process, with quality control checking for micrometer-level defects.

Welding shop overview, where components from the press shop are welded into a full car body using automated robots.

Efficiency at the welding shop, where one car is produced every 99 seconds, with robots assembling key components like the roof.

The clean room in the assembly line specifically designed for hybrid vehicle battery assembly, highlighting the renewable energy usage.

Detailed battery production process for the Yaris Cross and Innova Zenix, noting differences between nickel and lithium batteries.

Final assembly process where body panels, engines, and interior components are fitted together, including panoramic roofs and dashboards.

The car assembly progresses through various stages, from the trim lines to the chassis, with components like brakes, exhaust, and radiators installed.

Shower testing of assembled vehicles to ensure they are waterproof, simulating extreme rain conditions.

The rectification area is where vehicles found with defects during the quality inspection are repaired.

Discussion on the mixline production system, producing various models on the same line, including Yaris Cross, Veloz, and Avanza.

Final insight into the production speed, where one Yaris Cross can be produced in 8 hours, emphasizing the factory's efficiency.

Transcripts

[Musik]

Halo teman-teman selamat datang lagi di

channel Budi Toto yes Sekarang kita lagi

mengunjungi PT Toyota Motor

Manufacturing Indonesia di Karawang Jawa

Barat untuk melihat seperti apa sih

produksi Toyota Yaris Cross seperti yang

ada di belakang saya dari awal sampai

akhir

ikuti terus videonya

[Musik]

Mungkin teman-teman ada yang nanya

kenapa saya pakai HIV sama helm ya

karena Yes safety Is Number One For You

dan ini salah satunya

jadi kita harus pakai ini APD lengkap

untuk masuk ke pabriknya yuk

[Musik]

teman-teman Sekarang kita lagi naik Buff

card ke plan 2 Jadi plan 2 itu adalah

pabriknya Yaris Cross Veloz dan Yaris

jadi di Karawang itu ada dua Plan 1 itu

untuk Fortuner sama zenix yang paling

dua ini untuk nyaris Cross sebenarnya

sih ada 3 karena satu lagi adalah plan 3

itu

dipisah ya untuk mesin NR nah destinasi

pertama kita ke press

yuk

jadi di presshop ini ngerjain

mobil-mobil ya racingan mobil-mobil yang

ada di Karawang 1 dan 2 nih

panel samping

[Musik]

teman-teman kita masuk ke presshopnya

nah ini Kelihatan nih di samping saya

itu ada

Blank jadi ini material untuk itu ya

untuk fresh-nya nah ini nanti akan

menjadi beberapa part body yang distem

di mesin mesin-mesin ini informasinya 55

komponen untuk body Yaris

[Musik]

Nah setelah di pressing nih kita masuk

ke storage teman-teman dan ini Kelihatan

nih panel-panel bodinya udah mulai

kelihatan jadi kayak pintu ya atau dari

panel samping atau bahkan ada juga itu

kap mesin sudah mulai kelihatan

ada beberapa part nanti juga di weld

tapi beda lagi tempatnya

[Musik]

nah di mesin ini teman-teman ini bisa

dibilang nih satu paket ya jadi ketika

lempengan itu datang ya masuk tuh

itu nanti dicuci dulu

Lalu setelah dicuci dia

sebelum centering dulu sebelum

pembentukan

lalu jadi trimming dan review sih dan

menariknya lagi mesin ini ngeluarin satu

part untuk

3,75 detik

[Musik]

Nah di sini tuh bener-bener harus bersih

ya karena apa Karena debu Micron

sekalipun itu bisa membuat part itu

menjadi defense Nah bisa kelihatan di

sana tuh ada lembaran biru itu bisa

menangkap debu nah setiap cetakan yang

masuk ke sini juga saat masuk itu juga

Akan dibersihkan lagi supaya make sure

banget debu itu enggak ada di

[Musik]

Nah kita masuk ke bagian qc-nya

teman-teman nah kelihatan ini adalah

sample Master jadi tujuannya Kenapa ini

adalah sebagai acuan Apakah part yang

keluar dari

mesin itu masih sama dengan yang ada di

sini nah teknis di sini itu udah

terlatih melakukan quality control

bahkan melihat di sekecil mikron

sekalipun Wow mantap sekali

[Musik]

sekarang kita pindah ke welding shop di

mana komponen-komponen yang tadi dari

press itu datang ke sini untuk dirakit

dan di Las semua jadi satu body dan

assist

[Musik]

jadi di sini itu adalah komen main body

weld Nah di sini tuh ada beberapa model

ya Ada Kalian ada Veloz dan bahkan

nyaris Cross itu mulai di kelas jadi ini

dimulainya dari sini nih teman-teman

dari lantai ya dari sasis itu di sana

itu ketemu sama side member nah semua

proses ini itu semua kompetisasi jadi

sudah memakai robot tapi tetap aja masih

harus pakai safety ya karena di sini

banyak banget Spark bunga api Nah di

welding shop ini satu unit mobil itu

keluar dalam waktu 99 detik 1,6 menit

Wow cepat banget ya

[Musik]

[Musik]

Nah setelah lantai sama sampingnya itu

di Las ya

mobil itu pindah ke sini jadi di sini

bagian atap itu dipasang

bilas Nah di sini itu enggak cuma ya

tapi ada Veloz ada Kalian juga termasuk

di sini

[Musik]

Nah jadi urutan untuk memasang roof itu

ada urutannya pertama ini panel panel

roof dipasang ke rainforce dan filler

nah dua-duanya di Spot Wheels Nah

setelah jadi di sana tuh udah kelihatan

Jadi siap untuk dipasang ke mobilnya

[Musik]

teman-teman ini adalah unit outputnya

Jadi udah di weld Habis itu langsung

masuk ke cat ya udah di voting dan dapat

warnanya ini di sana nih ada garis kos

nih warna putih ada kalinya juga di sana

warna silver wow

kita masuk ke area asembly dan ini lihat

nih ada pintu-pintu Yaris close ini baru

selesai dirakit ya termasuk sama

trainernya dalamnya

di bagian assembly line ini ada satu

clean room khusus untuk baterai xvv ini

dia

[Musik]

di dalam sini teman-teman itu di mana

Toyota merakit baterai untuk mobil

hybridnya ada Yaris Cross Hybrid dan

Toyota Innova tenis itu

[Musik]

Nah di sini nih ada komponen-komponen

baterainya nih banyak banget nah

ternyata komponen untuk baterai lithium

dan dmh itu berbeda jadi disana

perbedaannya ada

tempat loket

[Musik]

nah ini kita masuk ke clean roomnya

tempat di mana baterai Innova zenix dan

Yaris Force itu di assembly ya Nah ada

satu fakta menarik lagi clean room ini

sudah ditenagai oleh renewable energy

dari solar panel jadi

ini bener-bener

dan tentu saja area sini juga bersih

cuma ini dibuka karena kita lagi pusing

nah di asem di Line baterai ini Itu

dimulai dari mengambil sel baterai ya

dan ditumpuk

dipasang ke lower case lalu dikencangkan

lalu dipasang kabelnya di sebelahnya itu

dipasangkan dan dikencangkan juga

kabelnya nah Setelah itu pindah ke sini

nih jadi ke dipindahin oleh robot ini

kecil untuk ke pemasangan komponen

pendukung tambahan setelah itu

dipasangkan juga casenya di bagian

terakhir dan juga dicas kalian di QC

[Musik]

jadi di betreas yang beli ini itu bisa

memproduksi perharinya 260 sampai 270

unit baterai itu mix-nya teman-teman

nikel sama litium baik itu untuk teknik

ataupun nyaris Cross nah yang saat ini

itu lagi banyak nikel nih Jadi order

inovasi ini lagi gede sementara yang

reviewnya itu lebih sedikit gitu makanya

kita banyak ngelihat baterai nikel

keluar dan ini dia teman-teman baterai

Yaris Cross dan Innova zenix Hybrid itu

kalau di pretelin gimana ini Yaris cross

[Musik]

Innova zenix Hybrid nah kedua-duanya

punya karakter yang sedikit berbeda ya

Innova zenix itu dipakai untuk keluarga

ya bawa barang bawa

penumpang kadang dipakai jarak jauh

untuk mudik ya makanya dia dikasih

baterai Niko sementara untuk Yaris Cross

karena dia pakaian harian gitu ya

perkotaan eee dia dapatnya baterai

livium AEON yang lebih compact baterai

Yaris Cross itu cuma

175,2 volt voltasenya dan ukurannya

secara bobot ya itu 20 kg jadi lebih

kecil dibandingkan dengan inovasi mix

yang baterai nikel yaitu sampai

201,6 volt dan bobot yaitu 40 Kg

[Musik]

Sekarang kita mau Adventure di assembly

shop ini tempat di mana

cangkang-cangkang yang tadi udah di stem

udah di weld udah jadi body ya dan juga

udah dicat di sana tuh

di assembly di Rakit menjadi

mobil yang bisa dikemudikan nah ini

mesin komponen dari supplier nih ketemu

di sini dipasangin semua yuk

[Musik]

jadi smble itu mulai dari output dari

painting ini udah panjang nih ngantrinya

itu ke sini

ini adalah lift sejatinya lift jadi asem

itu mulai naik ke atas dulu

itu di sana pintu itu dicopot

Kenapa dicopot supaya lebih efisien

untuk

assembly pintu ya

udah diurut

[Musik]

[Musik]

tadi bodi yang udah dicopot pintunya itu

pindah ke trim satu teman-teman nah ini

dipasangkan kabel

Panoramic roof ini komponen-komponen

mulai dipasang itu jalan ke sana

itu komponennya beda-beda ya yang

dipasang ya

jadi mobil abis dari Trim 1 itu

convertnya muter ke trim 2 nanti trim 2

nih udah mulai Kelihatan nih dipasang

dasbor radiator udah dipasang terus

beberapa komponen elektrikal juga udah

dipasang Nah setelah dari trim 2 itu

naik ke atas

lewat lift lagi saya ke mezzanine turun

ke Sasi satu nah di Sasi satu itu

dipasangkan cubing buat pengereman dan

gitu di sana itu mesin dipasang dan juga

suspensinya teman-teman Oh ya nggak lupa

itu knalpot juga dipasang di sini

nah ini kita ngelihat lebih dekat ke

Sasi satu teman-teman di sana bagian

sana itu ada proses meeting antara body

sasis dengan mesinnya

dan gitu juga termasuk juga subscribe

untuk depan ya termasuk sama mesinnya

ini di dekat kita nih Ini lagi

penyempurnaan nih

dipasang-pasangin Nah dari cacing 1 itu

pindah ke chasis dua untuk diisi oil

atau radiator air radiatornya juga diisi

Nah itu pindah ke sini nih di bawah

lewat conveyor di atas sana mezzanin

turun ke final nah di final itu dipasang

kaca gitu ya dan juga komponen-komponen

lainnya seperti interior yang belum

dipasang bagian final ini udah hampir

jadi mobil kecuali pintunya karena

pintunya nanti akan dipasangkan setelah

di final ini Nah kita lihat lebih dekat

Line final teman-teman tadi udah

turunnya dari mesranin ke Line ini dia

udah mulai dipasangin tuh

karpet ini mesinnya pasti udah dipasang

ya dan juga

pelan-pelan dia maju ke depan itu

komponennya lebih banyak yang dipasang

nih kelihatan di bawah kita nih dia

pasang komponen tempat untuk Jack untuk

dongkrak Wow dan di sebelah sana nih

kursinya nih joknya udah mulai dipasang

[Musik]

nah Kita lihat final dua teman-teman di

Line final 2 Ini udah mulai dipasangkan

jok depan terus jok tengah juga udah

masuk dasbor udah kepasang dan ini di

ujung sana itu ada assembly untuk ban

dan roda jadi di finalnya final 2

assembly itu masang ban sebelum nanti

naik lagi pindah ke final 3 Nah kalau

tadi di final 2 tuh Belum dapat muka dan

belum dapat pintu Nah setelah final 2

dia naik ke atas ke mezzanin Nah itu

namanya turn itu ketika mesin itu

memasangkan pintu yang udah disembelih

ke sasis mobil yang siap untuk

disembelih nah dia turun ke final 3 nah

di Final 3 dan pasang bemper

sudah dapat bemper tadi kalian udah

dapet nih ada lagi tuh

Yaris cross yang lagi dipasangkan

bumpernya tapi dalam posisi ini engine

itu masih belum nyala nyalanya itu agak

ke depan sana

[Musik]

Nah kita ada di tahap paling akhir dari

assembly

ditemin ya di bagian sini dia udah pas

pas terakhir dan juga

mobil-mobil yang akan keluar dari sini

itu diisi dengan Pertamax Turbo sebelum

masuk ke Inspeksi ya untuk quality

checking lalu dia jalan ke sana masuk ke

Chamber ini nah Chamber ini adalah

shower test jadi dia untuk mengetes

kebocoran dengan hujan yang lebih deras

daripada hujan biasanya Nah setelah

shower test dia keluar

dan

mobil akan pindah ke storage nah sebelum

kita tutup perlu disebutkan satu lagi

tempat nih namanya rectifikasi

teman-teman jadi

ini tuh seperti workshop untuk

teman-teman di mana mobil yang ketemu di

pack itu diperbaiki di sini

[Musik]

Nah itu dia teman-teman produksi mobil

baru di PT Toyota Motor Manufacturing

Indonesia dan kita baru aja ngeliat

produksi mobil-mobilnya di sana termasuk

Toyota Yaris cross yang di belakang kita

kenapa mobil-mobil soalnya di sana Ini

diproduksi secara mixline jadi ada calya

ada Yaris yang biasa ada Veloz ada

Avanza yang untuk diekspor juga dan di

tengah-tengahnya itu pasti ada Yaris

Frost kita mulai dari

plat baja yang belum di stem lalu di

Assemble dan di weld di Las lalu di SMB

lagi dengan komponen-komponen dari

supplier yang ternyata 70% ya dari

supplier dan 30% nya itu inhouse Nah

setelah itu di inspeksi sebelum akhirnya

disimpan untuk

diekspor atau untuk konsumsi dalam

negeri Ini bener-bener pengalaman yang

ha mpir tergantikan sih teman-teman

mungkin enggak ngelihat ini setiap hari

ya dan lebih menariknya lagi dengan tag

time 1.65 menit atau 99 detik satu mobil

di atas Cross dari plat baja sampai

terakhir itu selesai dalam waktu 8 jam

itu aja Dari saya jangan lupa like

subscribe dan follow instagram

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[Musik]