ITO FOUNDRY & MACHINERY CO., LTD.

This is a certain kind of casting that only we can do.

〝Tradition × Innovation 〞

Company NameRepresentative

Address

EmployeesProduction Capacity

Materials

Company Overview

I T O F O U N D R Y A N D M A C H I N E R Y C O . , L T D .

I M S C o . , L t d .

Scale (units: ㎡ )

Scale (units: ㎡ )

http://www.itofound.co.jp

With a constant focus on innovation related to processes such as unframed and sand mold casting, as well as partially reinforced cast iron, we provide variant variable production to meet the needs of our customers.

Construction machinery components, hoist components, electric car motor components, pipe materials

Site Area: 10,250 ㎡Building Interior: 4,656 ㎡

Manufactured Products

Scale

Construction machinery components

Site Area: 30,097 ㎡Facility Interior: 5,230 ㎡

Manufactured Products

Scale

IMS Co., Ltd.

Koji Ito, Representative Director

3129-13 Muramatsu, Tokai-mura, Naka-gun, Ibaraki(inside Hiraharananbu Industrial Park) Tel: 81-29-270-5201 (Representative)

19 (as of March 2017)

Machining, foundry technology services

Company Name

Representative

Address

Employees

Work Content

The Group achieves a comprehensive manufacturing framework for processes ranging from provision of materials to machining, inspection, and shipment. The cutting-edge machining center features a flexible production line based around NC lathes that delivers high-quality products to customers in a timely fashion. In addition, the Company also conducts technical support functions such as raw material planning and consideration (CAE analysis).

Conducting cast metal product machining with a combination of processing and equipment technical prowess. Aiming for improved customer satisfaction by providing comprehensive services from model production to machining for completed products all within the Group.

IKI CAST VIETNAM Co., Ltd.

ITO TEKKO CO., LTD., ITO FOUNDRY AND MACHINERY CO., LTD.

Noi Bai Industrial Pak, Hanoi, Vietnam

500 tons (monthly, two shifts)

FC150 – FC300, FCD450 – FCD600

96 (as of March 2019)

Company Name

Investors

Address

Production Capacity

Materials

Employees

Founded in 2007 in Vietnam with joint investment from ITO TEKKO CO., LTD. with the goal of providing a stable supply of products for customers expanding overseas that wouldn’ t be as affected by exchange rate fluctuations. In order to make sure proper casting manufacturing takes root in the broad market of Vietnam as well, the company is putting the technology and knowledge of ITO FOUNDRY AND MACHINERY CO., LTD. (its mother company) to use and has adopted a production framework that uses the same technology as Japanese companies in order to provide products with a level of quality identical to this mother company.

Manufacturing and selling medium and large casting items using self-hardening furan resin and green sand casting methods.

VINA ITO Co., Ltd.

ITO FOUNDRY AND MACHINERY CO., LTD

Dong Van III Industrial Zone, Ha Nam, Vietnam

300 tons (monthly)→ Future estimate: 1,000 tons

FC150 – FC300, FCD450 – FCD700

50 (as of April 2019)

Company Name

Investors

Address

Production Capacity

Materials

Employees

Founded in April 2018. Operations started in May 2019.In order to handle environmental problems which could occur in Vietnam as well in the future, we will introduce a large dust collector and Mg processing unit, improving the operating environment.As a plan for the second period, we will introduce large processing machinery and build a framework which can provide completed products to our customers' overseas factories.

Manufacturing and selling medium and large casting items using a self-hardening alkaline phenol casting method.

I K I C A S T V I E T N A M C o . , L t d .

ITO FOUNDRY AND MACHINERY CO., LTD.Koji Ito, Representative Director3129-43 Muramatsu, Tokai-mura, Naka-gun, Ibaraki(inside Hiraharananbu Industrial Park)Tel: 81-29-306-0030 (Representative)99 (as of March 2017)First Factory: 800 tonsSecond Factory: 300 tons (monthly production, two shifts)Total 1,100 tonsFC150 – FC300, FCD450 – FCD700, heat-resistant vanadium-enhanced cast iron

ＶＩＮＡ　ＩＴＯ　Ｃｏ．，Ｌｔｄ

First Factory Second Factory Total

13,553.76

5,728.20

327.35

515.87

1,797.00

327.35

515.87

1,797.00

2,313.78

1,391.95

11,239.98

4,336.25

Site Area

Factory

Warehouse

Office Building

Employee Parking Lot

First Factory Second Factory Total

6,610.856,610.85

1,308.69 1,118.93

Site Area

278.90

(including office space)Factory

Warehouse 278.90

2,427.62

表4 表1

208210

Since the Company ’s founding in 1946, we have ca st various

c o m p o n e n t s f o r l a r g e m a c h i n e s u s e d i n c o n s t r u c t i o n a n d

industrial applications.

By incorporating our proprietar y cutting-edge technolog y into

th e c a s t i n g m e th o d o f ma nu f a c t ur i n g , w h i c h ha s a h i s t o r y

spanning mil lennia , we carr y out manufacturing in a way that

no other company can.

Since the Company ’s founding in 1946, we have ca st various

c o m p o n e n t s f o r l a r g e m a c h i n e s u s e d i n c o n s t r u c t i o n a n d

industrial applications.

By incorporating our proprietar y cutting-edge technolog y into

th e c a s t i n g m e th o d o f ma nu f a c t ur i n g , w h i c h ha s a h i s t o r y

spanning mil lennia , we carr y out manufacturing in a way that

no other company can.

Casting has contributed to human development since ancient times. This technique is important even now, and it ’s essential to society. With passing this technology on to the next generation and surviving as a casting factory in the modern era as our themes, we devote ourselves to diligent study day by day, putting efforts into developing technical innovations to improve our operating environments and increase both quality and productivity as well. All our employees join together as one, and with constant passion for our corporate ideals of I (idea), T (technique), and O (opinion), put sincerity into the manufacturing processes of all of our metal casting products, which are the fuel of industry. We hope for your continuing patronage and consideration.

K o j i I t o , R e p r e s e n t a t i v e D i r e c t o r

●Single-heating system for partially-reinforced cast iron●3D CAD casting simulation●MKS-160 briquette machine●CHT-970 horizontal split automatic　molding machine●BUYMASTER heavy item handling robot●Workflow management system●WMW20 teaching mixer

●Safety and Health Competition●Pointing and Calling Competition●Company President safety patrols●Opening a shaved ice stand in the summer●Evacuation drills●AED training course

●Company quality control presentations●Excellent Improvement Proposal Competition●Participating in the All-Komatsu Skills Competition●Participating in the Katsuta National Marathon●In-house study meetings

TechnologicalInnovation

Education andInheritance

Safety

Environment

Attention to detail supported by over 70 years of history.

●Regular environmental measurement●Radiation measurement (once every two weeks)●Odor measurement (once every two weeks)●Cleaning the area around the Company (once per week)

We have the knowledge for improving our capabilities.

Taking pride in our achievements.

Frameworks for achieving habitual safety.

Innovation always accompanies history.

There’s a kind of manufacturing that’s essential to society.

ITO FOUNDRY& MACHINERY

p2 p3

AXLE HOUSING AXLE HOUSING AXLE HOUSING

AXLE HOUSING SWING SUPPORT STATOR FRAME

STATOR FRAME BACK HEAD HUB

BOOM BRACKET MISSION CASE REAR HUB

Taking pride in manufacturing products no one else can.

Motor frame for railroad use

Construction machinery components

Major Products

Ship deck machinery components

ITO FOUNDRY& MACHINERY

208 208

4 9

The process of carrying out the various planning and design elements related to casting. Important for ensuring that no defects arise from the solidification and shrinking within the casting mold.

The process of creating a model for copying the product shape to a sand mold. We usually use wooden models for this process.

Sand and self-hardening alkali phenol resin are kneaded together, inserted into the blank, and hardened.

Scraps, the main materials used, are melted in an electric furnace. Through this dissolving process, the material components are measured, and adjustments are made as necessary.

Melted materials are poured into the mold. When the iron has cooled and hardened, this is the process of breaking down sand mold and removing the product. The sand on the product surface is also carefully removed.

After frame removal, a shot blast machine is used on the product to remove sand, sprues, and burrs.

Machining is carried out as necessary in accordance with the product specifications.

Inspections are performed using both the coordinate measurement machine and the human eye, and the product accuracy is confirmed down to the micro level.

Pouring Quality inspection

Flow of manufacturing

We implemented robotics and IoT in our sand mold creation processes with automation as our goal. By saving operations for different casting products and playing them back through the mixer arm (teaching and playback), variation in the operations performed has been eliminated. At the same time, wasted material has been reduced, stable quality has been maintained, and equipment operation ratios have improved. In addition, we are organizing the accumulated data based on various conditions and analyzing it to pursue further optimization.

BUYMASTER heavy item handling robotSand reuse equipment

■Emission analyzer

■Chip briquettes

Molding

Material melting

Frame removal Casting finishing Machining

Coordinate measuring machineTeaching MixerNew business of in-house model creation

Machinery Manufacturer Number of units2-ton high-frequency induction furnace KITASHIBA ELECTRIC ３ Hitachi 35 Nipponhoist 4 SINTOKOGIO １ TAIYO MACHINERY １Pneumatic transport plant SINTOKOGIO １7 ton Shakeout machine SINTOKOGIO １5 ton Shakeout machine TAIYO MACHINERY １Mold drying furnace Aoki Seikan Kogyo １20/10 ton Teaching mixer SINTOKOGIO １20 ton long-arm mixer SINTOKOGIO １20 ton long-arm mixer TAIYO MACHINERY １10 ton mixer SINTOKOGIO ２5 ton mixer SINTOKOGIO １5 ton mixer TAIYO MACHINERY １Crane type shot blast SINTOKOGIO 4Annealing furnace Aoki Seikan Kogyo ２Dipping and paint drying equipment Aoki Seikan Kogyo １BUYMASTER TAGAMI EX １Barinder KOYAMA １Cold box molding machine FOUNDRY １

Machinery Manufacturer Number of units Shimadzu Corporation １ OBLF １30 ton Amsler testing equipment Maekawa Testing Machine Mfg. １Charpy impact testing equipment ITANI KOKI MFG. １Various Brinell hardness testers TOKYO KOKI ４Ultrasonic and magnetic inspection equipment TEITSU DENSHI KENKYUSHO, Taiyo Pro. ３CE meter Nakayama ３Metal microscope, endoscope Olympus 1 eachCoordinate measuring machine (CMM) Mitutoyo 2Gate-type coordinate measuring machine (CMM) Mitutoyo １3D scanner CREAFORM １Automatic grinding machine IMT １

Equipment information

■Master arm ■Main unit arm

Follow-up

Feedback

Plan design Model creation

ITO FOUNDRY & MACHINERY Factory

IMS■Main production equipment

■Main inspection equipmentEtc.

Etc.

Optical emission spectrometer

Sand collection and reuse equipment (3Ｓ = 7.5 ton) (2Ｓ = 3 ton)

Overhead movement crane■IMS Co., Ltd. processing equipment specifications list

Frameless casting equipment (line) SINTOKOGIO １Roll-over machine for trimming die SINTOKOGIO １Roll-over machine for facing SINTOKOGIO １Roll-over machine for die matching SINTOKOGIO １Ito Molding equipment (line) Aoki Seikan Kogyo １ Kao-Quaker TOCHU Band saw machine (large/small) DAITO SEIKI 2Screw compressor (3 (37kw), 2 (22kw)) Hitachi 5

Main painting equipment ４Type Manufacturer Model

numberTable size (pallet size)

ATC units

APC units

Makino Milling MachineMitsubishi Heavy IndustriesDMG MORIOkumaMitsubishi Heavy IndustriesMakino Milling MachineOkumaO-MDMG MORIO-MNIIGATA MACHINE TECHNOOkuma

A100ESC100CNCNH6300VTM-100GB100CNC-5MCB1210-A602SP-V920EXVTL915NHX8000VTL1600HN80-DV100R

□1000φ1400□630φ1000φ770□1000φ710φ915□800φ1600□800φ900

90-6036-60241660166212

2-22-2-2522-

Horizontal Machining CenterGear Shaping MachineHorizontal Machining CenterNC Vertical LatheNC Hobbing MachineHorizontal Machining CenterNC Vertical LatheNC Vertical LatheHorizontal Machining CenterNC Vertical LatheHorizontal Machining CenterNC Vertical Lathe

Yamazaki Mazak e-1060V 8/II φ1250 80

2

2

2

5-Axis Multitasking Machine (turning: 20, milling: 40)

(turning: 20, milling: 40)

Turning Center

Turning Center

TOSHIBA MACHINE

TOSHIBA MACHINE TMD-13S

TMD-13S

φ1600

φ1600

60

60Briquette machineIn the machining process, approximately10% of the material is ground away (as shavings). A briquette machine (pressure device) pressurizes these shavings, forming them into solid masses which can be reused for casting. Approximately120 tons of these metal shaving scrap materials are reused per year. This machine is a major contributor to both quality improvement and cost cutting.

ITO FOUNDRY& MACHINERY

P5 206mm 208mm208mm 206mm P8

2003

Colleagues pass on techniques, mutually improving each other’s skills.

The development of casting techniques is our history.

February 1946ITO TEKKO CO., LTD. founded solely by Kohei Ito

April 1961Kohei Ito appointed as Executive Chairman,Shoichiro I to appointed as Company President

October 1995Koji Ito appointed as Representative Director

June 1999Patent application for spheroidalgraphite cast iron product manufacturingmethod submitted

May: ISO9001 certification acquiredJuly: Second manufacturing factory added on

2005

February: Painting factory added onJune: ITO Co., Ltd. founded as an affiliated company

2006

May: IKI CAST VIETNAM Co., Ltd. (Hanoi) established, production startedJuly: Recognized as one of the “300 Energetic Small to Mid-Sized Manufacturing Companies of 2008” by the Minister of Economy, Trade and Industry

2008

October: IMS Co., Ltd. founded as an affiliated company

2012May: Operations started at IMS Co., Ltd.

2013

April: DNV GL ship classification factory certification acquiredDecember: ITO Co., Ltd. merged with ITO FOUNDRY & MACHINERY CO., LTD.

2016

When I learned about casting in a class,

that was what drove me to work here, and

this is the only company I applied for when

jobhunting. It’s a tough job, but the work is

really worthwhile, too, and although I was

unsure of myself at first, gradually learning

how to do more and more makes me happy

every day. I’m also overjoyed at the way I

keep getting better as I learn how to do

more and more.

The more I can do, the happier I feel

Hayao Ikeda

I get a real sense of trust every day in my face-to-face meetings with customers. In the same way, communication with the people work ing on the factory f loor manufacturing products is something I always want to pay close attention to. I hope to continue carrying out my duties with good footwork and a fast pace.

Building relationships of trust through speedy handling

Daiki Fujita

I joined this company partly because one of

my college professors introduced me to it,

and... my introduction to the world of working

adults was a tough one. After starting here, I

worked on all aspects of the manufacturing

process from product inspections to shipping,

and now I’m already in my 9th year. Precisely

because I’m used to the job now, I sometimes

change my point of view and discover new

things, and I continue to learn every day.

Precisely because I’m used to the job, I change my perspective

Takumi Kikuchi

During the factory tour before I joined the company, I was overwhelmed by the sight of the melting furnace at work, and to be honest, I found it a bit scary. But now, I'm working in a managerial role. I focus on moving forward toward achieving our goals every day as a matter of course, and I focus most of all maintaining a "safety first" policy with all of our staff looking out for each other so nobody gets hurt.

Never forgetting our original intentions

Hiromasa Ishiyama

When I decided to start working in Japan, I

discovered the world of casting while

attending classes at a Japanese language

school. It was different from my initial

impression, and I feel a sense of happiness

from applying advanced knowledge and

techniques to manufacturing. Right now, I’m

hoping to produce results in the collaborative

research I’m conducting with a university.

The joy of knowledge transforming into results

Ngo Nhu Hoang

When I first joined the company, I learned a lot from watching the craftsmen at work. Even now, as I learn all kinds of things from various training sessions, I hope the younger employees will watch me and learn a lot from that. Work is 80% planning, and I ’m doing my best to make sure I’m thoroughly prepared in advance.

Work is 80% planning

Yoshimi Kanazawa

When I had a meeting and stated honestly

what we could and couldn't do, the client

was pleased and said, "I appreciate your

sincere attitude." That's stuck with me ever

since. I've continued to be honest and do

my best since then, and I always want to

make this company into one that wil l

continue on with the next generation.

Quietly and Honestly

Tomohito Kataoka

I moved from the Manufacturing Department to my current position, which mainly involves handling complaints. To be honest, I was unhappy about the change at first, but when my colleagues and I discover a method for resolving an issue or improving something, that reduces mistakes in the field as well. Nothing makes me happier than hearing words of appreciation and praise from customers.

When it rains, the ground hardens

Hiroshi Hida

2015 fiscal year hire

2010 fiscal year hire

2008 fiscal year hire

2007 fiscal year hire

2005 fiscal year hire

2002 fiscal year hire

2004 fiscal year hire

2004 fiscal year hire

January: Awarded the Ibaraki Industry Grand Prize 　　　　Award for the 2008 fiscal year

2009

March: Operations started at ITO Co., Ltd.April: ISO14001 certification acquired

2007

April: New factory operations started in Tokai-mura

March: Solar power generation business (300 kW) launched

2014

February: IMS Second Factory establishedJune: Model creation in-house operations started

2017

May: VINA ITO operations started June: Selected as one of the "Vibrant HABATAKU Small and Medium Enterprises 300 Program" by the Minister of Economy, Trade and Industry

2019

April: VINA ITO founded (Dong Van III Industrial Zone, Ha Nam, Vietnam)

2018

ITO FOUNDRY& MACHINERY

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