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Mengintip Isi Pabrik Toyota di Kerawang pada 8 tahun lalu - byTempo Director of Production Engineering and Karawang Plant Toyota Motor Manufacturing Indonesia (TMMIN) Nandi Julyanto mengatakan, setiap tahap di seluruh pabrik Toyota di Karawang dan Sunter mengedepankan teknologi terbaru dan efisiensi. “Kami sangat memerhatikan lingkungan, setiap proses harus ramah lingkungan,” ujarnya dalam workshop media di Karawang, Kamis, 8 Desember 2016.
Teknologi dan bahan ramah lingkungan yang dipakai Toyota terlihat pada bagian pengecatan bodi yang berlokasi di
Paint Shop .
Paint Shop Setelah disatukan sampai utuh, bodi mobil dikirimkan dari Welding Shop ke Paint Shop. Proses pewarnaan bodi tak sembarangan, karena ada 12 tahapan yang harus dilewati. Mulanya, bodi dicuci dengan cairan khusus untuk menghilangkan gram sisa pengelasan. Gram harus dihilangkan agar pengecatan sempurna. Proses pencucian mobil ini memakai sistem Bazooka yang mampu menyemprotkan air sebanyak 1.500 liter per menit.
Bodi mobil dicuci ulang memakai teknologi micro bubble system. “Ini mampu menghilangkan bekas minyak di dalam pori-pori pelat mobil,” kata Nandi. Adapun dalam pengecatannya, Toyota menggunakan bahan ramah lingkungan berupa cat berbahan baku solvent 60 persen, sehingga kandungan terbesarnya adalah air. “Keuntungannya senyawa perusak ozon menjadi sangat sedikit.”
Engine Plant Bersamaan dengan proses pembuatan bodi, pabrik lain bekerja membuat mesin. Salah satu pabrik mesin baru Toyota adalah Karawang Plant 3 yang memasok mesin R-NR untuk Toyota Sienta dan produk lain. “Kami menerapkan konsep through line atau proses produksi satu atap. Ini membuat produksi lebih cepat, hemat energi, dan mengurangi jumlah stok.”
Mesin R-NR buatan Karawang ini memakai bahan dasar alumunium (ingot). Ini meningkatkan kadar komponen lokal hingga 80 persen. Penggunaan alumunium juga membuat bobot mesin jadi ringan, yakni 93 kg untuk transmisi manual, dan 83 kg untuk transmisi otomatis.
Assembly Shop Di tahap ini, mesin dan bodi disatukan. Nandi mengatakan, alat bantu perakitan menggunakan sistem karakuri, alias alat bantu gerakan tanpa energi luar. “90 persen mengandalkan gravitasi, sehingga tak butuh listrik banyak.” Sistem karakuri ini, kata Nandi, juga hasil dari inovasi karyawan TMMIN.
Untuk meningkatkan efisiensi, TMMIN menerapkan sistem perakitan tanpa pintu. Artinya, sebelum pintu mobil dipasang, operator akan melengkapi seluruh komponen di dalam mobil. “Sehingga lebih mudah.”
FERY FIRMANSYAH | PRAGA UTAMA Berita Terkait: