Second Production Dept. (Finishing Section)

Second Production Dept. (Finishing Section)

Mold parts machined are precisely finished and assembled at Second Production Dept. and ready for delivery to customers.

This Dept. assemble all the parts finished by the first Production Dept. before shipping to customer. The solid design of mold is created by Engineering Dept. which incorporate ideal elements and the newest technology, and then based on the design, the First Production Dept. manufacture component parts, transfer all the parts to the Second Production Dept. for assembly. After assembly, check finally the quality and accuracy, all of which hone and polish the mold to perfection in dept.-by-dept. process. Yamaguchi-Seiki uphold the slogan as “the concept of ‘back to basics’ is underlying in manufacturing.” and have been “sticking to satisfay needs of customers through our solid mold production”. It is the Second Production Dept. that symbolized the slogan and attitude of the company , who is finally responsible for completing the mold. Before end, plastic parts are prototyped by using the finished mold and our own Injection molding machine in-house, then measured the dimensions to feed back the variations for repairing and building the higher-precisione mold.

Finishing Section

A realm of artisanship – where we continue to take up the challenges of pursuing ever higher quality in the 1/1,000-millimeter region.

In our prototyping and our operations to correct errors in detailed areas, we sometimes tackle the punishing challenges of working at a thousandth of a millimeter, makes for product-making processes that crystallize the total strengths of people, skills, and equipment to perform grinding at the micron level. The attention that leverages every area of expertise in this way to improve each and every mold with precision and care is connected to our commitment to the basics and fidelity, and bears fruit in the form of the high-quality, high-precision molds we make.

The finishing work for molds is done by hand, and lies within a realm of artisanship that hinges upon intuition and many years of experience. Notwithstanding this, it is also important to transform these skills into data and put them to good use not in the form of individual ability, but as an organization. How to pass down these skills and transmit the skills of artisanship to later generations – we intend to continue devoting effort to creating an organization to take up the next generation of molds.

Second Production Dept.

Production flow

  1. 1

    Finishing process

  2. 2

    Assembly process

  3. 3

    Spotting process

  4. 4

    Trial process at the final equipment

Only the quality manufactured at “each process responsible to deliver after passing the requirements” can produce molds that customers can satisfy.

The plant is dedicating to check and assemble the many mold parts machined at prior processes, in a high accuracy at 0.01mm.

Assembled mold with moving core

Die spotting presses

Validating mold by assembling fixed (Cavity side) mold and mobing (core side) mold up to 28 tonnage and try out plastic injection molding.

Assembly line teams

This Second Manufacturing Dept. is composed of 6 teams, who set and match position of molds ranging 80 to 3500 tonnage class, assemble and maintain under the direction of team leaders ;

The first team handle 1 to 2.8 tonnage

The second team do 2.8 to 15 tonnage

The third team do 2.8 to 15 tonnage

The fourth team do 2.8 to 15 tonnage

The fifth team do 10 to 30 tonnage

The sixth team do 10 to 30 tonnage

Polishing team

Polishing are required keen five senses to produce 0.001mm accuracy.
Finishing quality ranging 0.001mm can only provide customer satisfaction and expectation at five senses level over requirements.

Cranes and hoist

Overhead travelling cranes

Double cranes

Jib crane

30t／15t 4
20t／10t 1
15t／10t 2
10t／5t 3
10t 2
5t 1
2.8t 4
1t 2

We have been focused on improving crane efficiency by reducing job suspension time.

Die spotting presses

Equipment Manufacturer mold clamping pressure Unit
Die spotting Press machine Amino 500t 2
Amino 400t 1
Ogihara 300t 1
Asai 200t 1

Plastic Injection molding machine

Equipment Manufacturer mold clamping pressure Unit
Injection Molding Machine Mitsubishi 3500t 1
Mitsubishi 1600t 1
Mitsubishi 850t 1
Mitsubishi 290t 1

The Second manufacturing Dept. Major operations

Preventing sag at parting line of the cavity is main job by applying 3D induction hardening

Induction hardening is applied in need to prevent sag at PL area of the cavity.

Electrical furnace

Welding the cavity surface requires severe temperature control, we conduct welding with utmost attention to the conditions as follows;

①Welding conditions
  1. When heating or cooling furnace, 20℃ per hour must be controlled.
  2. Keeping the temperature after heating, over 280℃ for 5 hours is must.
  3. The welded portion must be held over 350℃ for z5 hours.
  4. When cooling, the part must be kept in the furnace till 150℃.
②Inspection
  1. Inspect the depth of flaw by penetration flaw detection test
  2. Inspect the harness at the welded and peripheral regions of the welded part
  3. Inspect gloss after polishing at the welded portion

The carriage type Furnace has 1500 wide,1500 high and 2500 long, which can heat the larger mold for bumper and elevate temperature up to 550℃能

Visualization of PL opening and pressure in the mold at molding

When trying out injection molding, we recommend to attach displacement censer to monitor the distance of the mold opening. Depending on the customer request, we can also measure the inside pressure of the mold at injection. All of these will support customer to get the best molding conditions at actual mass production.

Strengthen the detailed portion of welding

Since 2015, we started efforts to introduce precise welding mahine in earnest, which enable us to weld at low temperature as well as at the portion that Tig welding machine cannot. We have been launching a full-scale developing and applying new technologies into our line of technology that other companies do not have or apply, to provide new solutions for customers’ requirement and expectation.

We have 4 units of Precise welding machine, one is SW-V02, 2 are SW-V01 and 1 is SW-9800 by Sanwa Shoukou manufacturing Co.,Ltd.

Reason of the introduction

Before 2015, mainly depending on the outside suppliers, it took longer lead time and much cost. After introducing precision welding machine in house, we can reduce great lead time and cost.

Qualification system

Since welding requires experience and skills, qualification system are set for team members to eliminate the dispersion in quality and to stabilize the welded quality.

Advantages
  • Reducing the lead time by limiting the welding portion.
  • By limiting the heat impact to the mold, it becomes easy to weld and repair at the texture and design surface.
  • On site repairing enables us to reduce workload for carrying in and out the mold and to shorten the restoring time for the production.
  • The equipment can enable us to repair cracks and pinholes as well as pin breakage of ‘speaker’ inner core easily, which were difficult to fix before.