GROUP

Group Introduction

5 Processing Groups

The collaboration of each group creates a commitment to high quality and technology.

Even for a single part, each group collaborates with each other as part of an integrated in-house production system. Employees responsible for their production process in each group are craftsmen who constantly pursue technology and quality improvement.

01

Process
Management Group

Our policy is to achieve low costs and meet delivery deadlines.

Group Role

Providing the overall management and support for manufacturing parts, the group requires various analytical and communication skills. Of course, cost reduction activities are also important.

Main Business Content

Material Arrangement

The specified raw materials are ordered and machining is scheduled based on the machining instructions. Since our main business is a combination of high-mix, low-volume production, the cost of materials is considered each time when deciding on a supplier and while making arrangements for heat treatment and surface treatment with outside vendors.

Process Control

A ZUIKO Machine consisting of more than 100,000 parts cannot be completed if even one part is missing.
Meticulous internal and external process control ensures that the parts delivery date is met.The Inspection Group deals with any in-house processing trouble including on-site support.

02

CAD/CAM Group

We manufacture products using cutting-edge technology.

Group Role

Creates machining programs based on production drawings. Especially for engraving processes, cutting-edge CAD/CAM solutions and experienced engineers ensure 100% processing feasibility.

Main Business Content

Machining Programming

A simple machining program can be created on the fly by a parts processor, but as the scale grows, the latest CAD/CAM solutions is essential.
In addition to creating programs, in-depth discussions with operators and select the most efficient tooling to meet short delivery deadlines.
This group requires a very high level of knowledge and experience.

VA/VE Activities

No just making parts based on the drawings, employees are always conscious of VA (Value Analysis) and VE (Value Engineering). Implementing cost reduction strategies at the machining programing stage leads to a large reduction of the load on the machining leading to efficiency of the entire factory. VA/VE proposals are done daily in cooperation with the Processing Group.

03

Turn & Mill Group

We are capable of manufacturing one-of-a-kind parts with our technology.

Group Role

A high value-added part in all ZUIKO Machines are the shaft-shaped parts which are simplified as “shafts.”
The Turn & Mill Group is in charge of extremely high-performance, custom-made shafts that provide unique features to ZUIKO Machines.
In order to adapt to increasingly complex parts, various optional tools and jigs are engineered to expand the capabilities of the machine and improve the processing technology.

Main Business Content

Lathe Processing

Shafts up to 1,500 mm in length are processed with a 5-axis simultaneous processing combination machine. Complex shapes can be finished in a short time as chucking can be done only once.

3D Engraving

Cooperating with the CAD/CAM group, fine engraving is performed on the order of 1/1000 mm. As it is invisible to the naked eye, the process is carefully done while regularly checking with a microscope camera.

Cylindrical Polishing

Cylindrical polishing is the final finish that determines the basic performance and quality of a roller’s shaft. This is an important process as it key to the high speed advantage of ZUIKO Machines.

04

Milling Group

We manufacture a wide variety of extremely high-precision parts, from small to large.
Suitable for medium volume production.

Group Role

The parts handled by the Milling Group are full of variations: iron, aluminum, resin, casting materials, and palm-sized parts to large parts exceeding Φ1,000 mm. All of the various parts make up the heart of the ZUIKO Machine.
In addition to the machine tools used, the group's commitment to processing technology is second to none. The level of craftsmanship is evident as it takes skill and judgement to differentiate the processing methods depending on the material.

Main Business Content

Milling

We actively work in collaboration with the Turn & Mill group, but our expertise is machining small, high-precision parts. Our high-precision jigs greatly reduces the labor required to make our parts. Each fastidiously manufactured part is carefully finished by hand. We can manufacture single to medium volume orders.

Processing Large Parts

The performance of ZUIKO Machines is proportional to the evolution of machining large parts. From the beginning, the Processing Technology Department has focused on in-house production of large parts exceeding Φ1,000mm which even now, is the foundation that has improved the performance of ZUIKO Machines.

05

Inspection Group

Quality assurance includes a traceability system.

Group Role

Perform quality inspection of in-house and outsourced parts including feedback for non-conforming products and follow-up on preventative action.
With thorough history management, we have a system that can take measures to prevent recurrence in the unlikely event that a non-conforming product is leaked.

Main Business Content

Quality inspection

Inspections are conducted from an objective point of view using a three-dimensional measuring machine, a surface roughness tester, and various other measuring machines.
Acceptance inspections is conducted for outsourced parts. Guidance is provided to subcontractors to standardize inspection and evaluation methods.