Enhancing productivity by implementing unmanned automation at night and engaging in thorough process management

Headquartered in Katano, Osaka, Mukai Iron Works Co.,Ltd. manufactures stainless steel pipe fittings for use in semiconductors and space exploration. Its operations have been fully automated, with more than 40 machine tools operated unmanned at night. It continues to refine its expertise and pursue further automation.

Fitting parts for low-pressure pipes, machined from high-rigidity stainless steel

Trial and error to "get our machines operating longer"

Since its founding in 1961, Mukai Iron Works has developed a reputation as a specialist in stainless steel machining and is now involved in manufacturing pipe fittings and a wide variety of parts in areas such as high-mix, low-volume production semiconductors, healthcare, and space exploration. The company shifted its focus to automation in the pursuit of high-value-added manufacturing and underwent a lengthy period of trial and error. "Right around when I turned 20, I started to wonder how we could get our machines operating longer," explains Mukai Iron Works Chairman Hideyuki Mukai. The company took its first step toward automation with semi-automation, with the purchase of two turning centers in 1990.

"Our business relies on the initiative of our employees"
President Yasuhiro Mukai of Mukai Iron Works Co.,Ltd.

 

24-hour operation through unmanned automation at night

Mr. Mukai's next goal was to automate production at night. "A work shift lasts eight hours, but there are 24 hours in a day. I realized that we could triple productivity by implementing unmanned automation at night." The company switched to full automation in 2004 with the purchase of a multi-axis turning center. It continued to purchase additional multi-axis turning centers and standing machining centers year after year, and the company now operates more than 50 machine tools day and night. Most of the machine tools are equipped with material feeders to automatically supply materials, such as loaders, bar feeders, and palletizers. Equipment is also carefully designed and improved upon in order to allow for smooth 24-hour operation. Mr. Mukai believes that their style of automation, which combines material feeders with machine tools, makes them unique in the industry.

Enhancing productivity by engaging in thorough process management

Automation at Mukai Iron Works is supported by a process management system. The company began connecting its machine tools to the internal network and visualizing process management around the year 2000. Once programmed, data is managed on servers, where it is used to select the optimal machines based on deadlines, enhancing productivity. The company does everything it can to control quality. For example, it uses equipment such as 3D measuring instruments and air leak testers for inspections, and ensures that all machined parts pass through an ultrasonic cleaning process before being shipped.
Automation has also allowed the company to eliminate overtime work, and it has continued the practice of finishing work at 17:00 and closing up shop 15 minutes later, for more than 30 years. Mr. Mukai hopes to continue automating work. "I'm thinking of getting some cleaning robots to clean up the chips from the cutting work we do at night."

Interested in learning more? The following video covers Mukai Iron Works's automation efforts.

Note: Organization names and titles are current as of publication timing.