Factory Facilities

Tanda Factory

Tanda Factory
Site area: 116,678 ㎡
(1.65 times the size of the Fukuoka Yafuoku! Dome)

In March 2005, the Tanda Factory completed conversion to an integrated production system that enabled it to produce large cylinders from materials until finished product. The foundry also improved its “clean foundry” capabilities in order to further improve the strength and quality of materials. The machine shop is using its high-precision machine tools and the processing skills it has developed over the years to improve its processing accuracy and reduce lead time through a more efficient production workflow as part of its efforts to improve its craftsmanship in order to better satisfy customers.



Tanda foundry
The Tanda Foundry Shop has been operation since October 1992

The foundry shop building is 9,894 ㎡

10-ton Hot blast air (water-cooled) cupolas: 2
20-ton Shot-blast machine: 1
20-ton Shakeout machine: 1
10-ton Casting sand processing machine: 1
10-ton Casting sand kneading equipment: 2 (other: 3)
Casting sand cooling machine: 1
Emission spectrophotometric analyzer: 1
75 KW Compressor: 2, etc. 2
20-ton Sand mold dryer: 1, etc. 2
50-ton Crane: 1, etc. 19
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Pattern shop: 1 building (1-story/2-story construction) 167 ㎡
Band saw, etc
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Pattern warehouse: 1 building (2-story construction) 1,633 ㎡
1-ton Crane: 1


Tanda machineman place
The Tanda Machining Shop (2 buildings) has been in operation since March 2005

No. 1 Machine, No. 2 Machine, No. 3 Integrated Factory
8,639 ㎡(2,618 ㎡)

NC lathe: 10
Inside Boring Machine: 7
Machining center: 7
Cooling hole processor: 4
2-axis port processor: 4
Honing processor: 3
Other processing machine tools: 9
Other equipment: 24
15-ton Crane: 5, etc. 8


4th Tanda machineman place
No. 4 Machine Shop
3,563 ㎡

NC Lathe: 10
Inside Boring Machine: 7
Other machines: 5
Annealing furnace: 4
Other machinery: 14
20-ton Crane: 1, etc. 2



Omuragata Factory

Omuragata Factory
The Omuragata Factory has been in operation since May 1986

Site area: 15,401 ㎡

In 1986 Riken Piston Ring Co., Ltd. ceased production of cylinder liners for medium-speed diesel engines. Taking on that business required a centrifugal casting production facility. Therefore, we constructed the Omuragata Factory at the Omuragata Industrial Park in Furueda, Kashima City. The new facility was also equipped with a ductile casting production system.

In 2005, we constructed a machine shop and added new equipment in order to improve our production capabilities so that we could meet the demand of our orders. This was done with the ultimate goal in mind of creating a comprehensive production system that included the entire process from basic materials to machine finishing and shipment in a single factory.

Currently we have all the equipment required for processing materials, completing, and inspecting not only cylinder liners but also cylinder covers. We therefore have achieved our goal of creating a production environment that can handle customers’ orders.



Omuragata Foundry
Foundry, 1 building
2,535 ㎡
3-ton intermediate furnace: 1
1-ton intermediate frequency furnace: 1
Vibration molding system: 1
Centrifugal casting machine: 1
8-ton shakeout machine: 1
20-ton casting sand kneading equipment: 1, etc. 2
2.5-ton monorail shot blasting machine: 1
5-ton casting sand reclaimer: 1
Sand cooler: 1
Annealing furnace: 2
Emission spectrophotometric analyzer: 1
10-ton crane: 1, etc. 11


Omuragata machineman
Machine Shop, 3 buildings
Building 1: 1,054 ㎡
Building 2: 1,143 ㎡
Building 3: 1,086 ㎡

(Building 1)
NC lathe: 4
Inside Boring Machine: 6
Turning machine: 2
Other machines: 2
10-ton crane: 1, etc. 2

(Building 2)
NC lathe: 3
Inside Boring Machine: 3
Gun drill: 2
Machining center: 2
Other machines: 8
5-ton crane: 3, etc. 1

(Building 3)
Turning center: 1
Turning machine: 2
Machining center: 2
Radial drilling machine: 1
5-ton crane: 2, etc. 3
3D coordinate measuring machine: 1

Yokota Factory

Yokota Factory
Yokota Factory
The Yokota Factory began operations in June 1944 and resumed operations in September 2008

Site area: 25,231 ㎡

After the foundry and Machining department at the Yokota Factory, the company’s original site, were consolidated and transferred to the Tanda Factory in 2004, the Yokota site ceased operations. But in September 2008 production there was resumed.

As part of our factoryo diversity production at the Yokota Factory, in December 2014 a 3-ton intermediate frequency furnace that uses the electric power source of the 8-ton furnace already at the factory was newly installed. This allowed us to restart the factory as a production center for small- to medium-sized cast components.



Yokota Foundry
Foundry shop, 1 building: 3,718 ㎡

8-ton intermediate frequency furnace: 1
3-ton intermediate frequency furnace: 1
20-ton casting sand kneading machine: 2
10-ton casting sand processing machine: 1
Casting sand cooler: 2
15-ton monorail shot blasting machine: 1
10-ton shakeout machine: 1
25-ton crane: 1, etc. 14
Emission spectrometry machine: 1


Yokota machineman place
Machining shop, 2 buildings
Building 2: 744 ㎡
Building 3: 2,742 ㎡

(Building 2)
NC turning machine: 2
Machining center: 2
Other machines: 4
7.5-ton crane: 1, etc. 2

(Building 3)
NC lathe: 6
Inside Boring Machine: 4
Machining center: 2
Boring machine: 1
Other machines: 1
15-ton crane: 1, etc. 6
Annealing furnace: 2
3D coordinate measuring machine: 1


RENAM
“Renma” Skill Up Training Center


~ Passing on Skills and Technology ~

The “Renma” Center was established in order to pass on highly-advanced individual skills and techniques required by highly-advanced numerical control Machining as this type of processing becomes increasingly automated.

At the “Renma” Center, employees not only learn by observing veteran employees demonstrate their skills and techniques, they also learn the basic techniques of casting, processing, and finishing from these veterans and participate in an aggressive educational system in which they master these skills through hands-on training.



RENMA

1.Casting

RENMA

2.Machining

RENMA

3.Hand finishing

RENMA

4.Finished work


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Research and Development Facility

Material quality

Material info

Material
TARKALLOY® for use in large liners (100x magnification)

TARKALLOY® product matrix cast using the stationary casting method

The structure is layered with graphite flakes on a pearlite base matrix with hard phase distributed evenly throughout. It is used in the manufacture of cylinder liners ranging in size from small to large.

In any product, the graphite and hard phase must be evenly distributed within the pearlite base matrix. The hard phase improves wear and abrasion resistance and the graphite improves lubricity. The strength, elasticity, hardness, and chemical composition of these structures must meet standards.


Material
Special cast iron for use in centrifugal cast cylinder liners (magnified 200x)

Since these products are manufactured using centrifugal casting, the graphite and hard phase layers are small and dense within the pearlite base matrix, which produces a high degree of strength. This method is used in the manufacture of small and medium-sized cylinder liners.


Material
TARKALLOY® cast iron ferrite base matrix (magnified 100x)

Since the graphite contained in TARKALLOY® is round, it is known as “spheroidal graphite cast iron. ” Toa Koki’s spheroidal graphite cast iron is used in many products, including ship components and cylinder covers for generators.



R&D and testing equipment

The microscopes shown below are used to determine the numerical data we require in order to provide customers with the material quality they demand.

Since inspections have become more strict over the years, we need to use these instruments to conduct detailed checks of the numerical values of our products.



Leica Microscope
Leica microscope

Mainly, we determine the size (length) of the graphite and the amount of hard phase. The instruments are able to automatically measure a specific area. When we receive a new order, we use these instruments to check the product specifications.




Digital microscope
Digital microscope  + Super depth multiple angle lens

the amount of hard phase, and therefore they are one of the most commonly used instruments at Toa Koki.




Other test equipment

System inverted metallographic microscope
3-D CAD and computer simulation system
Oil-hydraulic Brinell hardness tester
Electric muffle furnace
Sand tester
Shore hardness tester
Surface roughness tester
Ultrasonic investigation equipment


Introduction to the Technical Services Division

Testing Department, Technical Services Division
Testing Department, Technical Services Division

The universal testing machine is a testing device that measures products’ strength and elasticity. A sample of each product is always tested. Since the test pieces are stressed until they break apart, the testing room is usually very noisy.





Research & Development Department, Technical Services Division
Research & Development Department, Technical Services Division

We are conducting research into how to manufacture stronger cylinder liners with increased wear-resistance. In March 2008, we added a rotary bending fatigue testing machine and in March 2010 we added an optical x-ray analyzer to the testing department in order to allow us to conduct higher quality research.






The technical development department design department
Design Department, Technical Services Division

Technicians in the Design Department mainly create versions of customer drawings that are used for in-house production. Currently, these drawings are efficiently produced using computers.






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Technical Skill Certification Holders

July,2009 Shinichiro Ide,
person of distinguished service, overseas-related (casting cylinder liners for ship diesel engines)

Won the 3rd Prime Minister’s Award “Monozukuri Japan Grand Prize”


*Monozukuri Japan Grand Prizet (click to go to an external link)
The Prime Minister’s Award “Monozukuri Japan Grand Prize” is awarded once every two years. It was established in order to provide support to the development of Japanese industry and culture and to foster the passing on and development of the craftsmanship (“monozukuri”) that played a major role in the formation of the abundant lifestyle enjoyed by the people of Japan today. To this end, the award system was created to honor particularly outstanding people of all ages who are engaged in craftsmanship. These craftsmen range from mid-level employees who are mainly engaged in manufacturing and production to seasoned veterans who have preserved traditional and cultural technical skills as well as young employees who will be take on the traditions of craftsmanship in the future.

Minister of Health, Labour and Welfare Prize

Contemporary Master Craftsmen (outstanding technicians)
November, 2006 Shinichiro Ide[Casting]
November, 2015 Hidemi Tahara [Machining]
November, 2015 Masatoshi Ichinose [Pattern]

*About the Contemporary Master Craftsmen (outstanding technicians) Prize (click to go to an external link)

Japan Vocational Ability Development Association certification: Highly-skilled workers

Casting division (iron & steel and non-ferrous metal manufacture)
March, 2000 Shinichiro Ide
August, 2008 Shigeo Hirano

Machining (transportation machinery and equipment manufacture)
February, 2001 Hidemi Tahara


*About the Highly-Skilled Worker certification  (click to go to an external link)

Ministry of Health, Labour and Welfare, Monodzukuri Master

August, 2013 Shinichiro Ide [Casting]
August, 2013 Hidemi Tahara [Machining]
August, 2013 Masanori Fuchikami [Casting]
July, 2015  Akinari Fukuda [Machining]
September, 2015 Kazumasa Urabe [Machining]

*Information about Monodzukuri Masters (click to go to an external link)


Japan Ship Machinery & Equipment Association, Ship Master Certification

October, 2009 Masami Mine [Machining]
October, 2012 Yoshimasa Miyazaki [Machining]
October, 2012 Yasunori Yamashita [Casting]
October, 2014 Keinichi Morooka [Designing]
October, 2016 Masanori Fuchikami [Casting]

*Information about Ship Masters (click to go to an external link)


Saga Master

August, 2002 Shinichiro Ide
October, 2011 Masanori Fuchikami

*Information about Saga Masters (click to go to an external link)

Toa Koki’s “Master & Associate Master” system

Masters
No.1 March, 2006 Shinichiro Ide
No.3 January, 2016 Hidemi Tahara
No.4 January, 2016 Masatoshi Ichinose

Associate Masters
No.2 March, 2006 Shigeo Hirano
No.3 March, 2006 Yasunori Okuma
No.5 January, 2016 Masanori Fuchikami

Technical Skill Certification Holders(*Only those of Rank 1 are listed. However, Rank 1 holders who have special class certifications are listed only in the Special Class Certifications section)

Special Class Casting Technicians
Shinichiro Ide,Tetsuo Matsunaga, Yoshiaki Mikashima,Masanori Fuchikami

Special Class Machining Technicians
Hidemi Tahara, Kazumasa Urabe, Yoshimasa Miyazaki, Akinari Fukuda, Shin Tominaga

First Class Casting Technicians

Kazumasa Matsuo, Kazuharu Shimomura, Shigeo Hirano, Eiji Fujinaga, Shinichiro Hirokawa, Yasunori Yamashita, Hajime Ide, Yasuo Omagari, Takayuki Hashizume, Terumi Tsuru, Hisatsugu Yoshimura, Hirotaka Ikeda, Masayoshi Maeda, Tatsuyuki Ishibashi, Hitoshi Sakamoto, Mitsuyoshi Matsumoto, Akihiko Yamaguchi, Mitsuaki Fujii, Masanori Yasutomi, Hirokazu Fujikawa, Hirotaka Ishitaki, Tsunehiko Yoshida, Masahiro Nonaka, Yukiyoshi Ono, Koichi Matsumoto, Koichiro Sakamoto, Shigeki Tsuru, Nobuyuki Koga, Katsumi Fukuyama, Katsuhiro Tanaka, Kazutaka Nagafuchi, Yuji Ono, Shuji Fuchikami, Tatsuru Muta, Naofumi Yoshimoto, Kazuya Yamaguchi, Yuzo Taguchi, Ryo Yamaguchi, Masato Morinaga, Yusuke Imamura, Hideki Nakamura, Hiroshi Nabeshima, Kenichi Ozaki, Hitoshi Baba, Takaaki Oka, Tetsuya Yamaguchi, Yuji Tahara, Kenichi Kuroki, Shingo Yamaguchi, Yohei Haraguchi, Junya Ikeda,Takshi Ide,Kazuya Inoue,Kazutaka Yakabe,Ryota Sakamoto, Masakazu Ichinose,Mayumi Okuma,Mieko Otakara,Kentaro Yamanaka

First Class Machine Technicians

General lathe
Sakuji Nakashima, Kengo Fuchikami, Masami Mine, Akihiko Fujise, Shoji Kawasaki, Asatoshi Kusaba, Hirofumi Fujimura, Kazuhisa Nakao, Kazuaki Kobayashi, Takahiro Maeda, Yuta Kuhara, Takafumi Morita, Yusuke Koike, Yuichi Omagari, Naomichi Kugio, Kenichi Uematsu

Milling machine Technicians
Hideaki Iwashita, Kazuhisa Nakao

Machining Center Technicians
Yoshinori Tanaka, Hirofumi Urano, Yasuhiro Miyazaki, Taro Matsumoto, Mitsunobu Nakamura

First Class Finishing Technicians

Tool Finishing Technicians
Kenji Oda, Takashi Fujimoto, Yuya Mizoe, Haruki Matsuo, Shinji Ikeda

First Class Machine Maintenance Technicians

Akinari Fukuda, Yasumitsu Taguchi, Masato Kugio, Hideki Dan, Tetsutake Izaki, Junki Hirata, Taro Matsumoto

First Class fPattern Technician

Masatoshi Ichinose.

Electrical chief engineer

Yasunori Okuma,Tetsutake Izaki,Tetsuya Yamaguchi.

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