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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