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Examples of proposals that give concrete form to concepts

Through application of the fully order-made metal component processing that is the specialty of SATAKE Precision Technology, we have proactively resolved the problems of our customers. Some examples of proposals that have realized “giving concrete form to concepts” are set out here.

Examples of processing proposals 1: Realization of cost reductions

Examples of processing proposals 1: Realization of cost reductions

Although the customer’s request was for cutting processing, we proposed cold forging + cutting to avoid high costs and, as a result, realized a cost reduction of approximately 30%. Processing blanks by cold forging made it possible to achieve major reductions in cutting processing costs compared to cutting processing of rods. This method of processing is suitable for components of a certain volume with shapes with swelling in the axis shape. SATAKE Precision Technology offers optimum proposals including other processing methods matched to customer needs.

Examples of processing proposals 2: Design

Examples of processing proposals 2: Design

Even in cases where manufacturing presents difficulties based on drawings provided by the customer, SATAKE Precision Technology applies its wealth of know-how to propose manufacturing designs matched to processing methods. We designed and proposed an optimum press-fit pin size for the cutting plate and press-fit pin combination and realized the finished product. We provided manufacturing design support by working hand in hand with the customer to consider quality, delivery and cost issues even from the stage of rough prototype drawings and illustrations and succeeded in realizing major reductions in the customer’s design lead time.

Examples of processing proposals 3: Processing of difficult shapes

Examples of processing proposals 3: Processing of difficult shapes

SATAKE Precision technology worked in collaboration with an affiliate company that possessed optimum welding technology to reach a solution of processing that incorporated processes difficult to realize with existing technology. In addition, by working in close liaison with the customer, we succeeded in realizing smooth management of cutting, welding and electrolytic polishing processes. Because the finished product featured a sensitive surface, we also designed and proposed packing that would not produce scratches.

Examples of processing proposals 4: Spinning lathe processing

Examples of processing proposals 4: Spinning lathe processing

We proposed spinning lathe processing for pressed product prototypes to a customer who wished to realize smooth transition from the prototype stage to mass- production. Orders can be placed for a single spinning lathe and this enables switchover to press processing whenever required. Rather than processing by craftsmen, SATAKE Precision Technology implements fully-automated NC-controlled processing using automatic spinning machines capable of simultaneous cutting processing. This approach is ideal for small-lot spot products that cause concern over the cost of dies in situations where press processing is applied.

Examples of processing proposals 5: Wire cutting processing

Examples of processing proposals 5: Wire cutting processing

SATAKE Precision Technology offered a proposal for reducing lead time by using MC for front end processing and wire cutting for final processing for processes that are time-consuming using MC only. Working in collaboration with a specialist manufacturer, SATAKE Precision Technology runs more than 12 wire cutting machines for 20 hours every day to realize major cuts in hourly costs. This approach makes it possible to handle thicknesses of 0.01 ~ 300 mm and to carry out stack processing of thin plates. Our facility is fully equipped with approximately 250 jigs including special shapes to realize cost reductions. Even when a new jig needs to be manufactured, we are able to deal with this at no charge.

Examples of processing proposals 6: Lost wax processing

Examples of processing proposals 6: Lost wax processing

SATAKE Precision Technology offers both cost reductions and quality improvements for lost wax processing. In addition to collaboration with IDSO9000-accredited overseas manufacturers, we implement double checks by companies specializing in inspections to realize a foolproof manufacturing system. Compared to domestic production, this approach enables a reduction in material costs and die costs of approximately 30% and 65% respectively. We use regular mixed-loading flights weekly and have already achieved track records with many customers.

Examples of processing proposals 7: Transfer press processing

Examples of processing proposals 7: Transfer press processing

The transfer press for thick materials is a processing method that enables labor-saving in the “cutting processing product, forging, forged product + cutting finishing” process. We offer proposals matched to customer needs for changeover from multiple single-die press + ASSY processes to technology that enables realization of an integrated press setup. A large transfer press can process stainless steel plates up to t9.0 mm thick to realize a reduction on costs of approximately 30% and reduced lead time.