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Gifu Prefecture
Ogaki Seiko Co., Ltd. (Ogaki City) Manufacturing HDD-use suspension parts with precision mold
machining technology
Pacific Engineering Corporation (Ogaki City) Manufacturing automotive fuses that ensure safe and comfortable
driving
Kato Manufacturing Co., Ltd. (Kani City) Manufacturing automotive-only gas sensor covers by using metal
pressing technology without deburring
CCI Corporation (Seki City) The world's top-ranking brake fluids and engine coolants manufacture
ensures vehicle safety and reliability
Nagase Integrex Co., Ltd. (Seki City) Manufacturing precision machine tools that enable nanometer-order
super micrimachining
Nabeya Bi-tech Kaisha (Seki City) Manufacturing of a wide variety of products in very small
quantities with unique production concept and know-how
175
WAIDA MFG. Co., Ltd. (Takayama City) Manufacturing grinders, which are a must for molds that mass-produce
precision parts
Mino Ceramic Co., Ltd. (Mizunami City) Manufacturing firing kilns for fine ceramics capable of precise
temperature control
Gifu Kogyo Co., Ltd. (Motosu City) Manufacturing tunnel formwork, some of which is used in the Seikan
Tunnel
176
Manufacturing HDD-use suspension parts with
precision mold machining technology
Ogaki Seiko Co., Ltd.
3-92-1, Asanishi, Ogaki City
Gifu Prefecture
Established in 1968 TEL +81-584-89-5811
http://www.ogakiseiko.co.jp Katsuhiro Ueda
President
The suspension parts of hard disk drives (HDDs) are precision parts designed to retain the magnetic heads at intervals of 0.01 micrometers. These can be manufactured by only four manufacturers in the world.
The clearance between the magnetic head and the magnetic disk of an HDD corresponds tothe flight of a jumbo jet at a height of no more than 1 mm from ground level.
HDDs used in personal computers, HDD recorders, and other equipment have a magnetic head for reading recorded data from the magnetic disk at the tip of the suspension part. The clearance between the magnetic disk and magnetic head is required to remain 0.01 micrometers (about a dozen nanometers). This is as precise as the flight of a jumbo jet at a height of no more than 1 mm from ground level. A group of creative manufacturers centering around ultra-precise molds
HDD-use suspension parts are manufactured by using the technologies for mold machining, stamping, and production that the corporation has newly developed based on the technology for manufacturing molds for electronics parts that the corporation has been cultivating. Only a few corporations can manufacture these suspension parts: Two in Japan and four in the whole world. Dedication to creative manufacturing with a human touch
Ogaki Seiko works to enhance its expertise with the teamwork of its employees in the workplace, centering on engineers, with the world's high technology in perspective. Ogaki Seiko has thus achieved original and advanced technological development. The developed technology is designed not only to make machines and robots producing products but also to dedicate the corporation's energy to creative manufacturing with a human touch, thus producing advanced unrivaled products.
Fine clearance levitation technology for magnetic heads
(Comparison of the amounts of levitation of magnetic heads)
Magnetic head
Magnetic disk (disc)
Magnetic head
Particle of tobacco smoke
Head levitation Fingerprint
Magnetic disc
Bacterium
Hair thickness
Clearance between the magnetic head and disk
Magnetic head technology The magnetic head corresponds to the flight of a jumbo jet at a height of no more than 1 mm from ground level.
Air Magnetic head
Up to about a dozen
nanometers
Magnetic disk (disc)
Ground level
HDD suspension
177
Manufacturing automotive fuses that
ensure safe and comfortable driving
Pacific Engineering Corporation
450, Hinoki-cho, Ogaki City
Gifu Prefecture
Established in 1961 TEL +81-584-91-3131
http://www.pecj.co.jp/
Takahisa Ogawa President
The company manufactures automotive fuses that protect the increasingly complex and diversified electrical circuit systems of automobiles by using a integrated system from development to design to production. The product enjoys a share of 85% in Japan and 30%worldwide. High performance required of automotive fuses used under severe conditions
The electrical circuit systems of automobiles are becoming increasingly complex and diversified, resulting in ever-increasing demand for automotive fuses. The systems thus meet not only basic requirements for vibration resistance and durability but also for cost reduction and for various other demands such as those for down sizing, light weight, and multiple circuits. The company also develops multiple fuses compatible with multiple circuits, along with Slow Blow Fuses (which are automotive high-current fuses) and EV fuses for hybrid vehicles. The company's fuses are used in most of the vehicles produced in Japan and South Korea. Highly devoted to product quality, the company owns Japan's only certified laboratory.
The company owns its own laboratory certified under ISO/IEC 17025, a international laboratory standard. It is the only laboratory in Japan that is designed for fuses and other over current protective equipment. The test results obtained there are designed to certify the conformity of products to international standards. The acquisition of a certification for this laboratory is indispensable to the company's future expansion of sales channels leading to Western automobile manufacturers. Displaying its unique development capability in precision metal pressing as well
The company displays its unique development capability in precision metal forming, yet another pillar of the company's business. At a cost lower than precision processing of plastic resin, the company has developed a technology for precision metal forming. The company developed the technology for ultra-precision metal forming by deep drawing in an attempt to expand business in such areas such as cans for safe and precise rechargeable batteries for automotives.
Automotive fuses and related products Cans for rechargeable batteries
178
Manufacturing automotive-only gas
sensor covers by using metal pressing technology
without deburring
Kato Manufacturing
Co., Ltd.
2-6, Himegaoka, Kani City Gifu Prefecture
Established in 1949
TEL +81-574-60-0006
http://www.ksj-group.com/Kazuo Kato
President
The company's development of pressing technology that obviates the need of deburring and other downstream operations in metal pressing allows the company to enjoy a world share of 50% for its automotive gas sensor covers.
Manufacturing automotive gas sensor covers by metal pressing alone, without downstream operations
Gas sensors on automotive engines have a hole in the side of the sensor cover to detect gas concentration. These sensor covers are made by drawing a flat metal plate into a tube and then drilling a round or square hole in the side. The company has developed a technology for performing these machining operations with a single press machine. What is more, the absence of scratches and burrs in the pressed product with equal wall thicknesses allows the company to enjoy a world share of 50% in manufacturing automotive sensor covers. "Art" inherited from skilled workers to youths, then from parents to their children
The skills of skilled workers targeting a defect incidence of zero are an "art" learned through long years of experience. The company is also committed to conveying this "art." In the workplace, the importance of creative manufacturing is passed down from skilled workers to youths, and from employees to their children by building a workplace environment workers can be proud to pass on the next generation. Statistics are the compass of management
The compass of management is "A History of Japanese Economy," which the company compiled by chronologically organizing housing startups, numbers of automobiles registered, and other statistics published each year. The company's decision to shift from parts of clocks and combustion equipment (which the company had previously produced) to automobile parts was motivated by the fact that those statistics had never shown the number of automobiles registered declining from the preceding year.
Automotive gas sensor covers Pressed metal products
179
The world's top-ranking brake fluids and engine coolants manufacture
ensures vehicle safety and reliability
CCI Corporation
12, Shinhazama, Seki City
Gifu Prefecture
Established in 1949 TEL +81-575-24-4111
http://www.ccijp.co.jp
Shuji Okabe
President
CCI produces the world's top-ranking quality engine coolants and brake fluids that allow vehicles to safety "go" and "stop." CCI products enjoy a 19% world market share and a 60% domestic market share .CCI Brake Fluids and Engine Coolants are engineered to achieve high specifications, quality, and performance results
Brake fluids are required to exhibit high boiling points, low-temperature fluidity and other characteristics, including prevention of the deterioration of rubber parts to ensure safe, stable braking. On the other hand, engine coolants are required to provide excellent cooling and anti-freeze properties as well as other characteristics, including protecting the cooling system from rust and corrosion, which allow vehicle engines to achieve maximum performance. Commitment to driver safety has resulted in the world's top-ranking quality
In the postwar years when all brake fluids available in Japan were of low quality, the company conducted accident surveys and driving tests in various parts of the country in an attempt to develop excellent brake fluids that ensure driver safety. As a result, the company developed safe and smooth high-quality brake fluids along with high-performance engine coolants. The products are recognized as being among the world's best and are supplied to automakers and other corporations in the USA, enabling the company to enjoy a world share of 19%. In Japan, these products are used in new vehicles produced by all automakers thus giving the company a domestic share of 60% (including OEM products). The company's emphasis on R&D maintains high levels of technological expertise
Under the company management’s focus on research and development 40% of all employees engage in research and are committed to further improving the quality of vehicle-use chemical products and developing products in emerging cutting edge areas. The department developing soundproofing and vibration control materials is now the pillar of the company's new business. CCI continues to advance its diverse business including industrial tires and resin and is placing additional focus on biotechnology research.
Brake fluids Soundproof drain pipes
180
Manufacturing precision machine tools that enable
nanometer-order super micromachining
Nagase Integrex Co., Ltd.
1333-1, Atobe, Mugegawa-cho,
Seki City Gifu Prefecture
Established in 1950 TEL +81-575-46-2323
http://www.nagase-i.jp
Yukiyasu Nagase
President
The company manufactures the world's first machine tools which exercise control with an accuracy of one nanometer (one-billionth of a meter) and are able to produce various shapes . The machine tool with accuracy higher by one digit is needed to manufacture precision parts.
The screen of liquid crystal TV, mobile phone, and such like, is equipped with a part called light guide plate, to spread the light overall. This plate has 20 micro grooves within a span of 1mm, which requires nanoscale accuracy to be made, and the super precision mold is used to manufacture them. To manufacture the super precision mold, the super precision machine tool is necessary, which has the processing accuracy higher by one digit and the structure that controls processing of that higher accuracy. Table of the machine tool with zero friction that enables micromachining.
The positioning technology of the cutting tools attached on the machine tool is important to achieve the micromachining, and it is also influenced by the vibration of motor and such like. Therefore, Nagase has developed the ‘multi-surface holding non-contact by hydrostatic guide system’ which holds the table of machine tool in the static oil and lower the friction next to zero. It enabled super precision processing of nanoscale as it eliminated the influence such as friction resistance, vibration, and so on. The company’s perpetual quest to the precision processing machine is super miniaturization.
It is based on the management philosophy ‘Customer satisfaction is the only way that we should follow’ that the company is pushing ahead with the development of machine tool which achieves super micromachining that user required, as well as training of personnel for the technology development constantly with a step ahead of the accuracy user requires, and for the solution for the problems user has.
Super precision micromachining processor
Ultra precision form creating processor
181
Manufacturing of a wide variety of products in
very small quantities with unique production
concept and know-how
Nabeya Bi-tech Kaisha
4909-55, Kurachi Mukaiyama,
Seki City Gifu Prefecture
Established in 1940
TEL +81-575-23-1121
http://www.nbk1560.com/
Taichi Okamoto
President & CEO
Manufacturing what each customer needs in the exact quantity they need and supplying when they need. Developing machine tools specially designed for their own use, and enjoying a 70% domestic market share of cast iron Vee-pulleys. Vee-pulleys, shaft couplings and other diversified machine elements in very small quantities:
More than 30,000 items are standardized and available in stock, however quantities of each order are very small, for example 11 pieces, 1 piece, 4 pieces etc. With modern machine tools, it is easy to process those products, but setup time (preparation time for program input or tool change) would take longer with regards to processing time, in other words; machine operation rates go down and cannot cover the depreciation costs. Developing own machine tools suitable for very small-lot production at low cost:
Latest high-speed and high-accuracy machine tools are not always needed. Each machine tool should have proper accuracy and speed for products to be processed. They threw out the traditional concept of pursuing high-speed machining, and developed more than 70% of their own machine tools for their own use under the concept of having proper machining tools for optimized performance required for their products. They had been machining Vee-pulleys by 3 different process machine tools in the past, and now they have recently developed a new complex NC lathe to finish entire machining processes of Vee-pulleys, which enables them to replace 3 units of traditional lathes with 1 unit of a complex NC lathe. This minimizes setup time to 1/100, and increases accuracy 10 times more than the ISO specifications, and reduces the production cost by half. In addition, this has been awarded by “The 1st National Craftsmanship Competition of Japan “ in 2005.
Chucking the work.
The 1st process “processing the reference surface” Transfer of the work
from the 1st process to the 2nd process The 2nd process“processing
the opposite surface of the reference surface”
The 3rd and final process “turning and shaping Vee-grooves”
Finished products
182
Miniature and precision products for high-tech industries besides cast iron products Besides products manufactured by the cast iron technique, they are now manufacturing machine elements for high-tech industries such as miniature couplings for precise motion control, special screws with ventilation hole for vacuum equipment, linear motion elements, and shock absorbers for clean room application. Those products are indispensable for Japan’s cutting-edge technology industries such as LCD, PDP or semi-conductor markets.
Miniature and precision shaft couplings
183
Manufacturing grinders, which are a must for
molds that mass-produce precision parts
WAIDA MFG. Co., Ltd.
2121, Katano-cho,
Takayama City Gifu Prefecture
Established in 1946
TEL +81-577-32-0390
http://www.waida.co.jp
Hideo Waida President
As a top-ranking manufacturer of grinders, which are necessary for manufacturing precision molds, the company enjoys a share of 60% in Japan and is a leading brand in the Chinese market for CNC profile grinders Grinders are necessary not only in manufacturing molds but also in the machining of precision parts and a wide range of other applications
Manufacturers, for parts of mobile phones and other electronic devices, manufacture precision molds and use them to manufacture parts and products in mass quantities. Profile grinders are machine tools necessary for manufacturing and machining those molds. And also these machines are used for not only molds but also precision parts and cutting tools. High reciprocating technology is the key
The company developed a high reciprocating technology that increases the work efficiency of grinders (patent granted). This technology, allows the grinding wheel of a grinder to move up and down with high speed in small amounts during grinding, thus greatly increases grinding speed and improves the finishing accuracy of the ground surface. The company ranks top in Computerized Numerically Controlled (CNC) profile grinders
The CNC profile grinders, with the high reciprocating technology and diamond grinding wheels, achieve accuracy of ± 2 micrometers in the form, and can grind hard and frangible materials, such as carbides and ceramics, used for manufacturing molds, with high accuracy, quality, and efficiency. Therefore the profile grinders, are used in not only Japan but also worldwide, and greatly contribute to manufacture precision parts of electronics and other equipment.
CNC profile grinder Mold parts in grinding Mold parts after grinding
184
Manufacturing firing kilns for fine ceramics
capable of precise temperature control
Mino Ceramic Co., Ltd.
719, Terakawado-cho,
Mizunami City Gifu Prefecture
Established in 1918
TEL +81-572-68-2106
http://www.mino-ceramic.co.jpShigetoshi Ota
President
The company manufactures the world’s largest firing kilns for fine ceramics, thanks to their development of the special gas burner for firing fine ceramics as well as the precise temperature control system for inside of the firing kiln. Fine ceramics have the property of shrinking by 15 to 25% after being fired.
Fine ceramics, which are used in IC substrates and machine parts, are manufactured by firing high-purity alumina. Fine ceramics shrink by about 15 to 25% when being fired, requiring the firing kiln to be held at equal internal temperature. Any uneven temperatures in the firing kiln would result in strains and cracks in the product. For that reason, a technology is required that controls the internal temperature of the firing kiln at an equal level constantly even during heat-up of firing and cooling-off after firing. The company has developed the precise temperature control system which is capable of holding equal temperatures inside of the firing kiln and regulating heat-up of 2°C per hour
In the temperature control of the firing kiln, the company developed a gas burner designed specifically for firing kilns for fine ceramics that keep fires burning even when a flow of air is supplied at a level 30 times the theoretical flow of air required for gas combustion, along with a precise temperature control system capable of heat-up of 2°C per hour while maintaining equal inner temperatures. These developments have enabled the implementation of the world's largest firing kiln for fine ceramics (with a capacity of 20 cubic meters) which is capable of precision firing over the entire range from room temperature to 1,750°C. The company supplies the highest quality from small furnaces to the world's largest furnaces
The company's policy is "The highest quality is the best service to customers." Based on their own refractories technology, the company manufactures fire-resistance bricks suited for firing kilns for fine ceramics, precise temperature control systems and fine ceramics plants including material handling equipment which controls from input of raw materials through output of products.
Gas burner that enables equal firing The world's largest firing kiln for fine ceramics
185
Manufacturing tunnel formwork, some of which
is used in the Seikan Tunnel
Gifu Kogyo Co., Ltd.
144, Jushijo, Motosu City
Gifu Prefecture
Established in 1973 TEL +81-58-323-2000
http://www.gifukogyo.co.jp/
Tsutomu Kitagawa President
Tunnel formwork is used to build concrete walls in excavated tunnels. In such tunnel formwork, the company enjoys a share of 65% in Japan .
The challenges of tunnel construction are safety, sustainability, and cost reduction
The key to tunnel construction during the period of high economic growth in Japan was to find the way to finish a tunnel as quickly and safely as possible. After that, the challenges facing the construction industry changed dramatically to the realization of cost reduction and a comfortable tunnel internal environment. The company has then been addressing these challenges successfully by using its expertise in technical development. "GIFU Coat," which has redefined the concept of concrete formwork
"GIFU Coat," which the company developed with its unique expertise, is a technology for spraying ceramics in a plasma state in order to impregnate the surfaces of tunnel formwork with a concrete separating agent. This allows concrete to be peeled off from the formwork smoothly, resulting in a higher surface quality of concrete. Concrete walls of tunnels made by GIFU Coat irregularly reflect the light of vehicles passing by, thus reducing the strain imposed on the drivers' eyes and contributing to transport safety in the tunnels. Efforts for higher sustainability and lower cost
The company's track record of delivering its formwork to the Seikan Tunnel, along with the Tokyo Bay Aqua Line and other major tunnels in Japan, is highly evaluated by overseas entities. Thus, in recent years, the company has supplied products for to the shinkansen and subway in Taiwan and expressways and subways in Hong Kong, in addition to other facilities. The company has also achieved higher sustainability and lower cost by recycling formwork, previously scrapped in conventional practice in the construction industry.
Tunnel formwork based on GIFU Coat Equipped with an automatic cleaner that polishes tunnel formwork
