JAPAN QUALITY -The Spirit of Japanese Manufacturing

Mitsubishi Materials Craftsmanship Magazine YOUR BM004E GLOBAL CRAFTSMAN STUDIO

JAPAN QUALITY The Spirit of Japanese Manufacturing VOL.4 STORIESVOL.4 Vol.4 Stories Your Global Craftsman Studio

9-14 FOCUS on PERFORMANCE 3-8 A Challenge from Japan Uniquely Evolving Japanese EYE on the MARKET Bobsleigh Network Project from the Heart of Tokyo Machining Craftsmen

15-16 17-20 21-24 HISTORY OF MITSUBISHI THE CRAFTSMAN STORY TECHNOLOGY ARCHIVE Mitsubishi DNA Passed Down to Increased abrasion resistance with the History of Grooving Tools and the Next Generation advancement of coolant-driven technology the Enthusiasm of Craftsmen THREE MITSUBISHI PRINCIPLES Jet Coolant Technology – SANKORYO – – Jet Tech Holder –

25-26 27-28 29-30 ABOUT US CUTTING EDGE WA (Japan) An Educational Base for Broad Amazing Straightness with only 0.48 mm Japanese Swords (Katana) Areas in the United States Deflection over 1km MESSAGE The term, “manufacturing,” is a simple word, but has people. How about tools? Few people are concerned a deep meaning. Almost everything we manufacture about how a tool looks. What matters is durability, supports our life in some way or another. The essence functionality and cost effectiveness. Like any product, of manufacturing, I think, is the dedication of the however, the success of a tool is the result of the manufacturer. Manufacturing starts from an idea of combined dedication and effort of everyone involved a product that we think will be useful or that might in its manufacture, the skill of the designer, the make people’s lives better. We create a design, select precision of the manufacturer, the earnestness of the materials and decide upon a method that will the service provider, the knowledge of the dealer, turn our design and materials into a finished product. and, perhaps most importantly, the feedback from The dedicated effort, experience and skill of all those the customer that ultimately uses the tool as a key involved is cumulative and the resulting product is component in the process it employs to manufacture Fumio Tsurumaki certain to exhibit qualities valued by the market, the products it develops. I am quite confident that Managing Executive Officer, qualities such as visual beauty in colour or form, Mitsubishi Materials’ journal, “Your Global Craftsman Mitsubishi Materials Corporation President, Advanced Materials & or functionality and usefulness. Some products are Studio” exhibits the combined effort, experience and Tools Company highly regarded by the public consumer in general skill of Mitsubishi Materials Corporation employees and some are highly valued by specific groups of dedicated to the manufacture of better products.

1 YOUR GLOBAL CRAFTSMAN STUDIO MESSAGE

Our goal is to help our customers succeed

First published in April of 2015, this to be a critically important aspect Mitsubishi Materials Corporation is the fourth issue of Your Global of our products. The service I mean places a priority on the manufacture Craftsman Studio. In this issue, is the smooth delivery of products of new products and technologies, we focus on the spirit of Japanese to customers, offering the most working closely with end users to manufacturing from the viewpoint reasonable prices in the industry, and find fast and effective solutions, of the manufacturers themselves our timely and appropriate response sharing the excitement of success as and we asked many experts to talk to the needs of the customer. Our we move forward together into the about their work. It is certain that desire is to maintain our position future. the common enthusiasm of these as a company that customers can specialists in their individual fields is rely on when they need help. We Toshiyuki Taniuchi to manufacture the highest quality chose the title, Global Craftsman General Manager, products that Japan has to offer, Studio, as a declaration of Mitsubishi Quality Assurance Division products that lead the pack in global Materials Corporation’s continuing Advanced Materials & competition. We often use the term commitment to providing services Tools Company Japan quality, but few link this with as a comprehensive tool studio for Mitsubishi Materials Corporation the impressive technology behind it. customers around the world. As tool Spurred to excellence by customers manufacturers and professionals, who demand and expect the highest we fully leverage our experience in quality and the uncompromising and know-how to help businesses quality-first spirit of Japanese succeed by providing individualized craftsmen, Japan produces leading- solutions to customer problems; and edge products that strive to stay while we take the lead in designing ahead of the global competition. To proposals for our customers, it is an keep pace with increasingly diverse essential part of the manufacturing customer needs, we continue process we employ to listen carefully providing highly valued products that to requests and opinions to ensure represent the best in Japan quality. the highest degree of customer satisfaction and success. Mitsubishi Materials Corporation also considers the quality of service

YOUR GLOBAL CRAFTSMAN STUDIO 2 EYE on the MARKET A Challenge from Japan Bobsleigh Network Project from the Heart of Tokyo

With maximum speeds reaching up to 140 km/hour, competitive bobsleighing is also known as Formula One on Ice. Clocking the best time for the win requires skilled bobsledders and state-of-the-art equipment. The great names in European high-performance racing, Italy’s Ferrari, Germany’s BMW and England’s McLaren put the full force of their automotive engineering talent into the development of world-class sleighs. Joining the competition, small high-precision manufacturers in the heart of Tokyo are combining their supremely honed techniques to the manufacture of world-class bobsleds. The name of the project is The Shitamachi (heart of Tokyo) Bobsleigh Network Project. In this issue, we take a look at their history as we explore the essence of Japanese manufacturing.

Cooperation from Koji Okuda and Makiko Uchida from the Ota City Industrial Promotion Organization.

Rapid Decline in Small Factories in the Heart of Tokyo made bobsleighs. Kosugi felt the fact that bobsleighs have many more parts than other “Your craftsmanship is the best!” Jamaica techniques to produce precision parts equipment used in Olympic events, and that Bobsleigh Federation President Chris Stokes such as those used in the asteroid probe most of the parts from them are metallic, came to Nagano to evaluate a bobsled Hayabusa. With major companies shifting made them the perfect undertaking for designed and manufactured by a group of their production overseas in and after the the small factories in Ota. He proposed the small factories in Tokyo, and immediately 1980s, and the aging and retirement of idea to Ota Ward officials. The proposal was decided to adopt it for the Jamaican team. small factory owners who had opened their approved, but it was determined to be too In addition to its stability, the precision businesses when the economy was booming much for the local administration to handle on processing and the capability of the project in the 1960s and 1970s, the number of small its own and suggested that Hosogai himself members to respond to the bobsledders’ factories has dropped from some 9,000 at head the project. Since Hosogai had been needs were immediately clear. The Jamaican the area’s peak in 1983 to around 3,500 now. so enthusiastic about the proposal, even bobsleigh team participated in the 1988 While small factories find it a challenge to planning to cover the budget with funds from Winter Olympic Games in Calgary, Canada, mass produce at low cost, they excel in the his own company if he couldn’t convince the the first time for a Caribbean nation to enter production of small-lot prototypes requiring Ota Ward to support the project, he accepted the bobsleigh event. Readers may have seen high skill levels and quick delivery and they the suggestion without hesitation. One day in the movie “Cool Runnings,” the story of the have confidence in their techniques. However, December of 2011, the Shitamachi Bobsleigh Jamaican team’s path to the Winter Olympics. what they needed was a way to let the world Network Project, got its start. This was a A combination of the Jamaican team’s physical know about them. Material Co., Ltd. President project that would grow to involve many, prowess and Japanese manufacturing quality Junichi Hosogai, a key figure in the Shitamachi including a former bobsleigher living in Ota marked the start of a new story at the 2018 Bobsleigh Network Project thought a good Ward, a race engine manufacturer and a Winter Olympics Games in PyeongChang, way to accomplish this would be through the university professor. Korea. However, the road that led to this Olympics. At the same time, Satoshi Kosugi, a starting point was anything but smooth. member of the Ota City Industrial Promotion Organization, had the idea of exploring the Many small factories involved in machine possibility of small factories in the Ota Ward and metal processing are based in the Ota working together to manufacture high-quality Ward, Tokyo. While 90% of these are medium bobsleds for the Olympic Games. Looking and small-sized businesses employing 19 or into this, he found that Japanese bobsleighing fewer individuals, they engage in state-of- suffered from a lack of funding, which forced the-art processing with the most advanced many bobsleighers to use old-style foreign-

3 YOUR GLOBAL CRAFTSMAN STUDIO EYE on the MARKET the on EYE

EYE on the MARKET SHITAMACHI BOBSLEIGH Cooperation among Partners – Human Bond for Manufacturing They say that “If you throw a paper plane with a design written on it through the Bobsleigh Structure Brake window of a small factory in Ota Ward, you’ll have a completed product by the next Cowl (Carbon Fiber Reinforced Plastic: CFRP) day.” This is possible because of “nakama Designed to reduce air resistance utilizing computer analysis mawashi,” literally “passing something Frame around to friends.” Taking advantage of their (made from steel, etc.) close proximity to one another, the small factories in the neighborhood are quick to Carrier ask one another to lend a hand to complete products. Hosogai felt that nakama mawashi Steering would be a great plus for this project. He Runner (made from stainless steel) talked passionately about his idea with fellow This is the part of the blade that comes into contact with the ice. It is an important part that changes the speed manufacturers, sparking their imagination Bumper and controls performance. and interest in the project. He managed to Axle (One axle is used for the front and rear.) borrow a bobsleigh from Sendai University. It was the first time he and his fellow project cooperation on the project. About 30 owners around the room, one by one, the assembled members had seen a real bobsleigh up close, attended the briefing and what Hosogai craftsmen started to sound off: “We’ll handle and they jumped at the chance to dismantle proposed to them was very simple. He laid the hull,” said one. “We’ll handle this shaft,” it piece by piece and study the parts in great out all the design drawings on the desk said another. In the end, there were no detail. They also studied the International and asked each of them to select any parts designs left on the table. By the very next Bobsleigh and Skelton Federation that they thought they could or would like day, Hosogai had already received some regulations closely before creating their to handle. There were only two conditions. parts. At the end of 10 days, all the parts had design for the Shitamachi Bobsleigh, which He told them that the project had no funding been completed. Thanks to their cooperation, was constructed of 150 parts. Hosogai to cover their costs and that they would the parts fit together perfectly on the first invited factory owners in the Ota Ward to a have only 12 days to complete the work. assembly, allowing the Shitamachi One to be briefing about the bobsleigh and ask for their Though the two conditions raised eyebrows completed within only one and a half months.

of the process, from material procurement Shitamachi One Performance is put to the Test to welding. They finished at midnight and the The Shitamachi One test run was conducted overseas. Hosogai told them that he would new parts were brought to the championship by a pair of bobsleighers who had won happily make any adjustments they would like venue on the first scheduled bullet train and two consecutive Japanese National if they were interested in using the Shitamachi on that day the Shitamachi Bobsleigh made Championships. They said they were very Bobsleigh at the Japanese National its debut in an official championship race. anxious about testing a sleigh that they had Championships scheduled to take place in Compared with the test run held 10 days prior, never worked with before. However, when the 10 days’ time. “Yes!” was their immediate the new bobsleigh bettered its time by more pair saw the serious attitude of the craftsmen, response. While rushing to make it available than one second. The Shitamachi Bobsleigh they felt reassured and their confidence in the for the championship, Hosogai found that they took first place in spite of the fact that this sleigh grew. On the first test run, they beat required some additional parts. They were was its first time running in a championship the time that took first place in the previous nearing the deadline and only had one day competition; and of course the win put the year. They said that Shitamachi One was left. In spite of the pressure, the craftsmen Shitamachi Bobsleigh and the Shitamachi much easier to handle than bobsleighs made came through. Each factory handled a part craftsmen in the spotlight. On the Way of Making a Dream Come True Shitamachi Bobsleigh development advanced team. They employed an integrated structure to a fifth version. Sadly, however, the Japan carved from solid material to increase the Bobsleigh, Luge and Skeleton Federation aerodynamics of the frame, and in October decided not to adopt it for the Sochi Olympics 2016 they achieved the lowest level of wind because of the lack of time for test runs. For resistance in history. What had started as a the PyeongChang Olympics, too, the newly dream had become a successful reality. This hired coach decided to adopt a German- success was made possible because all of the made bobsleigh. The Shitamachi Bobsleigh small factories in the Ota Ward had pursued manufacturers refused to give up, however, the same dream and in turn created a strong and they offered their bobsleigh to three new bond amongst them. The spirit and overseas teams. The Jamaican team replied techniques of the craftsmen have gradually to them first and the Shitamachi Bobsleigh been brought to every corner of the world; Project brought them to Japan for a test run. and now small factories, each with only a They decided to use the bobsleigh immediately few employees, are working together to after they tested it and the team started compete with major manufacturers such as development of a new model for the Jamaican Ferrari and BMW. The challenge continues.

Special A Challenge from Japan Feature Bobsleigh Network Project from the Heart of Tokyo

YOUR GLOBAL CRAFTSMAN STUDIO 4

EYE on the MARKET EYE on the MARKET SHITAMACHI BOBSLEIGH

Project Members Interview! Material Co., Ltd. handles all the processes of manufacturing, from material selection The Future of Shitamachi Bobsleigh and Small Factories to the sale of processed parts. We interviewed Junichi Hosogai, President of Material Co., Ltd., head of the Shitamachi Bobsleigh Network Project, to ask about Cultivating a New Breed the project and his thoughts on Japanese manufacturing. every Friday to teach. This is a comfortable of Craftsmen that Thrive and convenient learning situation for the employees, and they all try their best to in Global Competition improve their skills. When they receive their certification, their confidence and pride Junichi Hosogai, President, Material Co., Ltd. increase; and it’s a wonderful feeling for them to see the admiration in the faces of - Please tell us a little bit about Material I set out on my own and founded Material their coworkers and to hear the customers Co., Ltd. Co., Ltd. compliment them on their technique. Hosogai: Before I founded Material, I was working for a small sales company providing - Material Co., Ltd. places a priority on - Please tell us your thoughts about materials to small factories. When I visited cultivating the skills of the employees and Japanese manufacturing and international engineering companies, I often wondered because of this many Material operators competitiveness . how much the materials that I was selling have acquired a Grade 1 Technical Skill Hosogai: Because major manufacturers for 100 yen would sell for after processing. Certification. have sufficient staff, they tend to assign When I finally asked, I was surprised to Hosogai: I currently employ 11 operators specific roles to each department. The learn that the products sold for as much and I am proud to say that 9 of them have downside of this is that while, say, the person as 100,000 yen. There I was, I thought to acquired certification. Remember back in in charge of procurement is an expert in myself, working hard to sell a 100-yen school, if we were having trouble with a purchasing products, that person might product to make an 8-yen profit, when our subject, we could ask our teacher for help not know a whole lot about processing. company could be machining it ourselves or go to a tutor; but we can’t do that after That person needs to know the technical and turning that 100-yen material into a we start working. Employees have as much aspects as well as prices and delivery dates 100,000-yen product as well. I told the owner if not more to learn than students do, but for the materials he is dealing with. This of the company I was working that I would practically speaking they have neither the is why I believe that major manufacturers be happy to learn the machining techniques time nor the money to go back to school need to build cooperative relationships with so that we could handle the full range of after work. This prevents talented people medium- and small-companies that are manufacturing, from material selection from improving and realizing their full familiar with processing. Meanwhile, small through to processing and sales. However, potential. Before a manufacturer has time to factories need to improve their individual the owner rejected my offer immediately discover and nurture that talent, the young specialised techniques and proactively because he thought it wasn’t a good idea for employee has left the industry. I decided to advertise their skill in high-added-value a material supplier to handle processing too. host seminars at my company to change processing, which would allow them to get I couldn’t give up though, and finally decided this by giving employees the chance to learn involved in bidding for contracts. When I to start a new business that sold added the skills required for certification. We have started this company, I did not have any value. When I was 26, which was in 1992, an instructor that comes to the company specialist areas to offer to our customers.

5 YOUR GLOBAL CRAFTSMAN STUDIO EYE on the MARKET the on EYE

I simply tried my best to make all the work engineers, so they can’t give the craftsmen - What are you hoping to accomplish in the we got our specialty. I believe that if we have specific descriptions or exact figures. With future? a strong desire, dream, or clear purpose in this in mind, it’s a great advantage that Hosogai: I think Ota Ward has developed business, we can achieve it. the craftsmen can quickly figure out what as a manufacturing centre that offers a adjustments they need to make in response wide range of solutions for global markets. - What role did nakama mawashi in Ota to vague comments like, “It’s a bit too light,” Many of our colleagues and their families Ward play in the Shitamachi Bobsleigh or “It should be more resilient.” live here, and I hope that we can already Network Project? make this an even better place for our Hosogai: In a practical sense it is hard - The Shitamachi bobsled has improved. children. It would be great if we could all for each of the factories in Ota Ward to Tell us about the latest version. work together to realize this vison. I am also handle the entire manufacturing process. Hosogai: Our approach to bobsleigh thinking about ways of working with other Some have special plating techniques and manufacture is to try as much as possible regions in Japan to advance revitalization. others have highly advanced machining or to reduce the number of parts that require As a Japanese person, I understand unique sheet metal working techniques. Indeed, welding. The reason for this is because Japanese values, including high-quality many of these small factories have unique welded metal joints cause shrinkage, and manufacturing. If we keep seeking higher techniques that can be used in niche fields. shrinkage leads to slight distortions. What quality manufacturing, we will be able to The cost of handling everything though we did was to machine complete parts from popularize Japanese products that are would be tremendous and price them out one piece of material whenever we could. highly trusted around the world. of the market. Even if the product is well We also worked to interlock parts that manufactured and highly useful, it would be needed to be connected. In fact, we were - This is the last question. For you, what impossible to move at the price they would able to machine an eight-part combination does it mean to be a craftsman? have to charge to cover their costs. On the that had been welded on previous versions Hosogai: A craftsman, I think, is a person other hand, these small factories can share into one section. who has a consistently high level of skill. A their individual specialties to reinforce our craftsman, I think, is a goal oriented person, competitiveness against prices offered by -The Shitamachi Bobsleigh was not a person who continues doing what he or the major manufacturing companies. This adopted by Japanese teams. What was she has decided to do until it is finished. cooperation among factories is our strength. your motivation to continue working on the Beyond this, however, is the fact that while project? the spirit of craftsmanship has remained -In the processing of parts for bobsleighs, Hosogai: We started this project with the the same, new technologies have developed how do you think the small factories take goal of showing the world what our small one after another, technologies such as advantage of their capabilities? factories in Ota Ward were capable of. If we AI, Industry 4.0 and IoT. For this reason, it Hosogai: When we need to make changes had given up just because Japanese teams has become more important for craftsmen and express what we need in the abstract, decided not to adopt our model, our project to develop not only technical skill, but they can figure out what we need would have been a waste of time, energy and managerial skill as well. I want to create an immediately. It is a major advantage that the resources. If we had given up, everything environment capable of cultivating a new craftsmen at small factories can quantify that we had accomplished would have ended breed of craftsmen, craftsmen with both the abstractions and immediately make fine at that moment. The thought of giving up traditional spirit and flexible management adjustments at short notice, and it’s these before achieving our goal never occurred to skills that allow them to respond better to things that really matter when it comes to us! I also believe that continuing in spite of changing markets. improving bobsleighs. Bobsleighers are not challenges creates chances.

Special A Challenge from Japan Feature Bobsleigh Network Project from the Heart of Tokyo

YOUR GLOBAL CRAFTSMAN STUDIO 6

EYE on the MARKET EYE on the MARKET SHITAMACHI BOBSLEIGH

Project Members Interview! Sanyo Kikai Seisakusho has been machining air compressor parts for The Future of Shitamachi Bobsleigh and Small Factories 68 years. The company has 15 lathes and 4 machining centres and has built trust through expertise in machining technology. Third-generation president Small Factories Established Kotaro Kurosaka works side-by-side with his employees to pursue high value-added Stronger Bonds by Pursuing machining. Bobsleigh Network Project, I didn’t know much about people working at the factories the Same Dream in Ota Ward. The project changed that quite Kotaro Kurosaka, President, Sanyo Kikai Seisakusho a lot. Before the project, while I may have heard of a company, I really had no idea - Would you tell us about your company’s companies will combine in subsequent what they did. There were some craftsman specialty? steps in their manufacturing process, we that I heard had good skill but were hard Kurosaka: We are good at machining thin visualize the finished product to determine to get along with. Once the project started metal piping and flat plates that tend to how our part can best contribute to the though, I found that these were all great deform when gripped by machinery. We convenience and success of manufacturers people. After getting to know the individual specialize in machining extremely thin and downstream. This is, I think, a particular craftsmen at factories throughout the extremely soft materials like aluminum. strength of the Japanese manufacturer. project, I gradually became more involved With materials such as these, even the in the nakama mawashi that existed slightest impact can result is significant -Such consideration for others was during my grandfather’s time. Everyone is deformation. This requires that we ensure exhibited in the machining of parts for the in manufacturing, so it’s easy for them to the highest degree of exactness, including Shitamachi bobsleigh. It is the essence of understand what one another are thinking. the use of the correct chucks, applying nakama mawashi. How do you feel about With this mutual understanding among the correct machining parameters and this nakama mawashi culture? them, they share the same enthusiasm and selection of the right tools to finish the Kurosaka: My grandfather opened a small a sense professional pride that promotes product. factory in Ota Ward in 1948. When he cooperation. started, there were many more factories - What do you see as the strength of in the area. Currently, the number of those - What is the most memorable experience Japanese manufacturing? small factories has dropped drastically the Shitamachi Bobsleigh Network Project Kurosaka: I would say that Japanese because of the lack of people to pass them has given you? manufacturing is very considerate. on to, a declining business environment and Kurosaka: I remember one day we had Japanese manufacturers place a great deal the smaller operations moving overseas a part that required a 5-axis machining of emphasis on customer convenience; along with major manufacturers that have center. One of the project members asked that is, we think about how the customer expanded internationally. Ota Ward itself us to take care of it because we had the is planning to use the products we has undergone significant change as well. machine for it. The problem was that manufacture. These customers are Where small factories once stood, now we had used the machine for multi-face sometimes end users and sometimes apartment buildings have sprung up one machining but not for 5-axis machining, and another manufacturer who further after another; and this has weakened the we really didn’t know how to use it properly. processes the product. An example of this once close relationships that were common I hunted around for someone in Ota who is when we manufacture parts that other among factories. Before the Shitamachi could handle the machining and found a

7 YOUR GLOBAL CRAFTSMAN STUDIO EYE on the MARKET the on EYE

A small diameter radius end mill manufactured by Mitsubishi Materials was used for curved surface machining, and roughing type end mill was used for rough machining during the process of manufacturing Shitamachi bobsleighs. factory that regularly used the machine. areas have come to know about the skills overall balance, which is very important Unfortunately, the owner was too busy to and techniques that our small factories in because the weight of bobsleighers sitting handle the piece. Lucky for us, however, he Ota have. The greatest change, though, has front and rear is different. Another difficulty offered to show us how to use the machine been a significant increase in the motivation is that bobsleigh parts are generally for 5-axis work and even made a program of our employees. The pieces we and each welded, and this causes deformation. To for the machining. After we talked about a of the other craftsmen in Ota manufacture address this, we machined our bobsleigh few important points on the phone, he tailor are only individual parts that are combined parts as much as possible rather than made a program for our machine. We had to create a final product; and while people fabricating them. We are happy that never worked together before, which would don’t usually give much thought to the engineers from other countries are often normally be disconcerting; but the program individual parts that go into a product, our surprised by the smoothness and beauty of he made for our device worked perfectly. All products go into a bobsleigh that competes the sleigh structure. While we can’t know we had to do was to set up the machine and with other world-class bobsleighs. If for certain how much the machining of press the button. Shitamachi bobsleighs perform well at the parts has helped the performance of the Olympic level, we will have accomplished sleigh, as craftsmen, we give it our all if - Have you noticed any changes in your our goal of showing the world what the there is a possibility that we can improve it. company since the Shitamachi Bobsleigh factories of Ota Ward can do. Bobsleighers who have used our bobslieghs Network Project started? have told us that their high rigidity means Kurosaka: Orders have been changing. We - What were the difficulties involved less vibration on corners. did not know the specialities of individual in manufacturing parts for Shitamachi factories in Ota. Before the Shitamachi Bobsleighs? - This is the last question. What is Bobsleigh Network Project started, and Kurosaka: It was hard to machine a frame important for craftsmen? we had scant idea what the different from one block of material. We machined Kurosaka: Craftsmen should always factories in Ota could handle. As the project a block of S45C; and the middle of the do their best to turn their wisdom and advanced, however, we became more frame needed to be hollowed out to reduce technique into originality and ingenuity. and more familiar with their operations. weight. The program for this machining What we manufacture is industrial Naturally, we started asking other factories requires CAM; and even if the program products, not traditional artistic crafts. to handle jobs when our workload was works just fine in the CAM simulation, In a world moving at high speed, skilled heavy and we had short delivery dates. We we often get insufficient machining or craftsmen need to set their sights on now have very good circulation among the too much machining due to deflection or innovation. Otherwise, they will soon be left factories in Ota. People have also become deformation. Then there is weight, which behind the times. It is important not to be more familiar with the name, Shitamachi is key for bobsleds; however, weight is not satisfied with the current state, but to move Bobsleigh,” so our customers in other the only concern. We also have to look at forward.

Special A Challenge from Japan Feature Bobsleigh Network Project from the Heart of Tokyo

YOUR GLOBAL CRAFTSMAN STUDIO 8 FOCUS on PERFORMANCE

Uniquely Evolving Japanese Machining Craftsmen

PART1: Syousin Machinery Works Co., Ltd. (Kobe City, Hyogo Prefecture) Enhancing Inventiveness in Preparation for the Arrival of Machine Tools Equipped with AI Reproducing Delicate Noh Masks with a 5-Axis Machining Centre Syousin Machinery Works Co., Ltd. has advanced technological capability. It tools alone. Inventiveness is essential been engaged in machining for over 50 has manufactured completely machined in the selection of tools, choosing the years at the Kobe High-Tech Park for stainless tumblers and beer glasses, Edo machining processes and making original cutting-edge technology companies in Kiriko glasses, wine glasses, and Noh jigs. This is the spirit that underlies our Kobe. Always looking for innovation, masks, which is a traditional Japanese management policy, ʻManufacturing with a founder Shoichi Mashima implemented handicraft. The Noh masks manufactured Wealth of Inventiveness!ʼ In 5 or 10 years, 5-axis machining centres ahead of other with the 5-axis machining centre represent machine tools with artificial intelligence companies about 20 years ago and has its accumulated technology. Syousin (AI) will become common. Our work on since strived to achieve the highest quality Machinery Works President Masanobu such products is designed to improve precision machined parts by employing the Mashima said, “When I saw a carved our inventiveness to a level beyond the most advanced machine tools. Currently, wooden Noh mask at a souvenir shop during capability of AI.” Because of this Noh the company machines a wide variety of a trip, I wanted to reproduce the precision mask, manufactured in cooperation with parts for use in gas turbines at thermal utilizing a 5-axis machining centre.” The DMG Mori Co., Ltd., Syousin Machinery power plants and engines for aircraft and first process was to rough machine a block Works was selected as one of 10 Japanese submarines. of aluminum alloy measuring 180 mm × 180 representatives at the Machining Expert mm × 300 mm, and finish the horns, facial Contest, a contest for 5-axis machining Around 2010, in addition to its regular expressions and other details, including organized by the University of Hannover, work, the company started manufacturing wrinkles, without re-gripping the block. Faculty of Mechanical Engineering and products utilizing its own machining “This super-precise processing cannot be Hannover Centre for Mechatronics know-how to highlight its highly- performed by high-performance machine (Germany).

Craftsmen Talking to Tool Machines While the size and weight of the final mill. Since the material needs to be very products are being reduced, the machining thin, we need to be extremely careful and industry will also be increasingly required quick in machining to prevent bending to produce super-thin and super-fine and breaking. This is accomplished by parts. President Mashima said, “Even adjusting the cutting force.” Yusuke if machine tools are equipped with AI, Konami, Chief of Production Department, super-thin and super-fine parts are not told us about the dedication of the easy to machine. We are now perfecting craftsman, “Although it is the same as our skill in this area with the reproduction our regular work, super-fine machining of a paper plane but made of aluminum requires us to “talk to the machine.” alloy with a thickness of only 0.2 mm. Operators touch a part of the machine We machine an aluminium plate to a they use to sense the sound and vibration thickness of 0.2 mm, and provide a super- to adjust the machining parameters, the fine finish on the surface using a solid end form of jigs and method of clamping.”

9 YOUR GLOBAL CRAFTSMAN STUDIO Masanobu Mashima, President, Syousin Machinery Works Co., Ltd. Japanese products are highly regarded for their quality. Looking into the history of the industry in PART1 Syousin Machinery Works Co.,Ltd. Japan, we can find thousands of small- and medium- (Kobe City, Hyogo Prefecture) size companies that continued improving their technology amongst fierce competition to ensure PART2 Kirishima-Seiko Co., Ltd. quality. In this feature, we visited three companies (Kirishima City, Kagoshima that have established unique manufacturing methods with a small number of employees to survive in this Prefecture) industry while envisioning the future of the machining PART3 Kitami Mould Steel Co., Ltd. industry from their own viewpoint. We asked about their dedication and enthusiasm for manufacturing. (Saitama City, Saitama Prefecture)

Yusuke Konami, Chief of Production Department, Original products made by unique ideas Only 0.2 mm thickness aluminium-made “paper” plane Syousin Machinery Works Co., Ltd. Skilled Craftsmen Visualize the Entire Process, from Start to Finish President Mashima said, “Skilled craftsmen of the paper plane I made. They are good I probably can’t imitate everything he was can grasp the designer’s intention by looking craftsmen.” Konami said, “My techniques doing; but for sure I learned a lot from him.” at drawings and simple sketches, visualize are not up to this level yet. I want to be as Mashima also said, “Craftsmen exhibit the machining processes from start to finish skilled as the craftsman sent from one of our sensibility in manufacturing, and that and select the best method to produce the partnership companies. Using a centre lathe sensibility is developed through continual finished piece quickly and efficiently. This is, I and a turning tool that he made himself, effort.” He continued, “Our company gives a believe, the strength of Japanese craftsmen. this craftsman processed parts from rough brazed turning tool to newly hired employees They never separate the individual finishing to final finishing with precision in the hope that they will develop into good processes. While they concentrate on their and speed as if the parts were machined craftsmen. They grind and polish the tool by work, they keep the entire process in mind. by an NC machine tool. He also managed themselves, check the form of the edge and This aluminum paper plane was created the processes and continuously checked experience the hand feed of the centre lathe by teamwork. I just gave Konami a sample the quality until the piece was completed. to develop their sensibility.” Mitsubishi Materials Cutting Tools Suitable for Difficult-to-Cut Materials Syousin Machinery Works started using manufacturers. However, we heard via a President Mashima said, “Tools made by tools made by Mitsubishi Materials around trading company that they were looking Mitsubishi Materials are high quality and the year 2000, which is about the time for better quality tools. So we visited them long lasting. The machining of 64 titanium, Mitsubishi Materials released end mills and talked about our products. When they 55 titanium, nickel and Inconel, which with Impact Miracle coating. Suhara from tried them, everyone there was surprised are all difficult-to-cut materials, and also Mitsubishi Materials looked back to the time by the smoothness of the machined surface super alloys used for gas turbines cannot and said, “At that time, Syousin Machinery of stainless steel materials. Since then, be machined effectively without Mitsubishi Works mainly used tools made by overseas they have mainly been using our tools.” Materials tools.” Becoming the Priest that Spread the Gospel of Small- and Medium-Size Companies President Mashima pointed out that since are often afraid to include overhead costs It is time that more companies adopt globalization has taken root, manufacturers in their estimates because customers this attitude of including the real costs of have felt increasing pressure to reduce complain that prices are too high. What delivering a component and enlightening costs to remain competitive; but companies we need to do is to sell ourselves better. customers about what quality means. in the same industry are competing for We need to help the customer understand Doing this will help to raise the position work without thinking ahead seriously. what goes into production, what the real of small- and medium-size companies in “Most companies’ estimates for parts cost of the piece they have ordered is. If we the Japanese machining industry. We will processing include labour and machine can do this, customers place their orders do our part by continuing to develop new costs, but do not include rents, utility costs, with confidence that they are receiving the technology to advance the development of quality or delivery management costs. They finest quality work at reasonable prices. the industry.” (Right) Takenobu Suhara, Akashi Sales Office, Osaka Branch, Advanced Materials & Tools Company, Mitsubishi Materials Corporation

10 FOCUS on PERFORMANCE on FOCUS PART 2: Kirishima-Seiko Co., Ltd. (Kirishima City, Kagoshima Prefecture) Machining Super-Complex Forms Equivalent to or Greater than 5-Axis Machining with 3-Axis Machining Centres High Difficulty Parts Machining Kirishima City, the second largest city in August 2006. When they opened, they Kagoshima, is located in the centre of the only had 5 employees and 5 machines. prefecture. Many well-known manufacturers “We are good at machining parts with have established bases in the city, and small- complex forms. Doing so usually requires and medium-size companies that boast high-performance machining centres. advanced technology are also scattered However, because I did not have enough throughout the area. Kirishima Seiko financing to acquire machine tools at President, Tamotsu Nishishige, worked at a that time, we discussed using a 3-axis company that machined precision parts for machining centre that we already had. We the optical communication and semiconductor developed exclusive jigs and established Tamotsu Nishishige, President, Kirishima-Seiko Co., Ltd. industries, but the company went bankrupt a unique “curve cutting method” in less and precision that leads to super-fine machining due to excessive capital investment. than one year,” said President Nishishige. but increases yield ratio. Kirishima-Seiko was Supported by co-workers who expressed With this unique method capable of certified as an Innovative Management Company a desire to work with him and together machining complicated forms without re- by Kagoshima Prefecture in 2008 because of this with partner companies that were willing gripping, they could significantly reduce technology. They have since built a new plant that to provide equipment for free, Nishishige the number of processes. This single- is capable of operating 24 hours a day and moved established Kirishima-Seiko Co., Ltd. in pass machining enables higher speed the business to its current location. Producing an extremely small dice measuring 0.2 mm³ and an ultra precision “jigsaw piece” Kagoshima Industrial Support Center asked in particular were highly regarded and Recently, they made an object similar to a jigsaw Kirishima Seiko if they were interested in singled out with a Technique Award piece. The piece was a Japanese kanji character, participating in an exhibition in Tokyo. It was in the Prototype & Test Part Category takumi (craftsman). The character, takumi, and a chance for them to show products that at the Dream Contest sponsored by the base in which the piece fits were machined could highlight their technology. “I decided to a machine tool manufacturer. Their out of carbon steel, with ultra fine precision and advertise our complex super-fine machining techniques have gradually improved just 3 μ clearance. The fit was so precise that utilizing our 3-axis machining centre. I and they finally succeeded in making when laid flush, the “jigsaw piece” seems to thought it would be a good idea to exhibit a dice measuring just 0.2mm³. On disappear into the main base. The idea came from products that have a strong impact on people these stainless steel dice, they also when they were watching TV and saw a similar to attract their attention,” said Masanobu machined numbers; that are invisible product. President Nishishige asked Hotokeyama, Hotokeyama, Chief of Manufacturing Division. to the naked eye unless magnified, with if they could replicate such a thing, to which The manufacture of these items required an extremely small end mill. These Hotokeyama immediately answered, “Yes, of no welding or assembly of other parts. They extremely small dice drew interest from course.” “I was skeptical, but he brought me a used only machining to manufacture chains local newspapers and other media and finished product in a few days,” said Nishishige without joints, a bird cage that features a bird visitors to the exhibitions and their plant pleasantly. This flexibility, wisdom, and the drive and a cage as one unit as well as pyramids were very impressed by these and the to seek something new in manufacturing reflects with a decorative chain inside. The pyramids other products. the strength of the company.

Extra small workpiece measuring 0.2 mm³, Extra small products manufactured using super-fine machining which is much smaller than a grain of rice

11 YOUR GLOBAL CRAFTSMAN STUDIO FOCUS on PERFORMANCE

(Above Right) Masanobu Hotokeyama, Chief, Manufacturing Division, Kirishima Seiko Co., Ltd. Using the existing machinery creatively is the real pleasure They focused on doing as much work as beyond comparison and they deliver what they could get for three years after the we need, when we need it.” company opened its doors, accepting any and all orders, including those that came When Kirishima-Seiko receives a request in late at night or during holidays. Looking for an estimate, top management studies back on that time, President Nishishige the drawings, identifies problems and told us that he was asking himself many discusses ways to deliver the highest questions at that point in his career – “Was quality work at the lowest cost. They then this really what I wanted to do? Was this deliver a proposal to the customer, who the company I wanted to build? Did I think reviews it. Only after the customer is fully my employees were really happy?” During satisfied with the proposal does Kirishima- that time, he showed workpieces that his Seiko submit an official estimate for the company had machined at an exhibition high added-value parts machining. that received impressive comments. “That bolstered my confidence, so I decided to The question was raised whether the focus on mastering complicated precision employees prefer 3-axis or 5-axis machining, at a level that requires machining centres. “Well,” Chief techniques and skill that cannot easily Hotokeyama told us, “it’s more efficient be imitated.” With the motto, “Never in terms of work allocation to have two say we can’t. Just try hard,” they have 3-axis machines than it is to have one continued highlighting their specialty in 5-axis machine. Besides efficiency, the difficult-to-cut materials and super fine real pleasure in manufacturing is putting machining. This has led to their handling our heads together in a process of trial and of a wide range of super precision parts, error to achieve the most out of the existing including components and devices for the equipment. It is more enjoyable for us to try semiconductor, healthcare, satellite and attain the same high quality results with a other industries. Mitsubishi Materials tools 3-axis machine as with a 5-axis machine, are essential for such high-level machining because it challenges us to improve our and Chief Hotokeyama said, “The precision technique and this makes us proud as and sharpness of the Mitsubishi tools are craftsmen.” Kirishima-made products for the world In the 10 years since Kirishima-Seiko secure; this in turn enables them to fulfill opened its doors for business, its high- their potential in manufacturing. This is one quality technology has been shown by of the strengths of Japanese small- and the mass media and this has helped the medium-size companies. company to continue to grow. Their orders from companies in Kansai and Kanto have “Thanks to the employees and the increased and the number of employees has community, this company has grown so expanded from 5 to 36. President Nishishige much. To repay their kindness, I continue said, “We had an event to celebrate the to promote the advancement of machining company’s 10th anniversary in August of to highlight the advanced technology and this year. All the employees took part in skill that goes into the high-quality products the preparation and the event. Around 150 manufactured in Kirishima. I also want to people attended, including employees, family develop new machining technology that members and special guests and everyone surpasses the confidential curve cutting had a great time. At the end of the event, the method to achieve further efficiencies and employees surprised me with a present.” cost reductions.” President Nishishige This demonstrates the warm atmosphere at continues looking to the future for the Kirishima-Seiko that makes employees feel company and the community. (Left) Yoshiyuki Kanezaka, Kyushu Sales Office, Osaka Branch, Advanced Materials & Tools Company, Mitsubishi Materials Corporation

12 (Left) Kitami Mould Steel Co, Ltd. President Yuichi Kitami (Right) Kitami Mould Steel Co, Ltd. Executive Director Tomoyuki Murata

PART 3: Kitami Mould Steel Co., Ltd. (Saitama City, Saitama Prefecture) Innovating by Excluding Technical Drawings: Defying the Conventional Wisdom New Metal Moulds Vitalizing Japanese Manufacturing Metal moulds are key to the production manufacturing,” answered President Yuichi of the wide range of products being Kitami. “It doesn’t help us, though, if we manufactured around the world; and Kitami focus on experience and know-how, but Mould Steel Co, Ltd. (KMS) manufactures ultimately lose out to global competition. and sells mould bases. Established in 2002, Along with market globalization, basic KMS is a young company in an industry customer needs such as quality, delivery where experience and know-how are dates and costs have become more essential for survival and despite these demanding. With the motto, ʻEnergizing difficulties for a start-up company, it has Japanese manufacturing,ʼ we decided to thrived. We asked what made this possible. establish a production system capable of quickly responding to customer needs while “It was the skill and experience of ensuring that skill and tradition is also craftsmen that supports Japanese passed down.” Becoming Independent to Focus on Customer Satisfaction “When I started in this industry, most of the with being able to respond to customers top management of small- and medium- requests, such as changes in specifications size companies in Japan was made up of or delivery dates. Because of problems like company founders who were working hard this, KMS gradually lost customers to its to expand their businesses by establishing competitors and the company’s future was trusting relationships with individual put in jeopardy. However, instead of giving customers. The company that I was working up, this critical situation sparked a fire in for though, did not seem to care much about President Kitami’s competitive nature. He responding to customers’ needs. I felt that visited overseas manufacturers to look for was the wrong attitude, but knew that I would ways to break out of the company’s difficult have to strike out on my own if I wanted to do situation. something about it. That pushed me to start this business,” said President Yuichi Kitami, “When I saw the high productivity levels at who had been in sales and marketing before overseas manufacturers, I realized that they starting the business. At the beginning were ahead of Japanese manufacturers in in 2002, KMS did not have its own plant, using data rather than depending on the which forced it to outsource production; experience of individual craftsmen. The but in 2005, KMS finally built its own plant. difference I could see between Japanese However, even when the business seemed to and overseas manufacturers was quality. be on track, the company still had its share In other words, if we could establish an of ups and downs. One of the problems was effective system of production that could that experienced craftsmen employed at the compete with overseas manufacturers, but company often insisted on sticking with their add Japanese quality, I thought we could own manufacturing styles and this interfered break through.” Enabling Newly Recruited Employees to Work as More Experienced Staff in Just Two Weeks Kitami came up with an idea that departed background in sales and marketing helped me significantly from the conventional method of to see problems differently.” manufacturing. He started by developing unique machining “I designed a standard system, such as programmes and establishing a production the model applied to fast-food restaurants system. Yutaro Fukuhara, Head of the CAD and convenience stores that would enable System Development Department, said, employees at all levels of experience to “Developing a system and software that would machine materials at a consistently high level allow us to manufacture our own products of quality. If I had been an engineer, I might required a monumental effort, and I felt I not have come up with such an idea; but my would never get through it. However, after a lot

13 YOUR GLOBAL CRAFTSMAN STUDIO (Right) Kohei Horiuchi, Distribution Sales Section, Sales Division, Advanced Materials & Tools Company, Mitsubishi Materials Corporation FOCUS on PERFORMANCE

(Left) Kunihiko Iizuka, Chief of Iwatsuki Plant 2, Kitami Mould Steel Co., Ltd. Many young female employees are engaged in the Programming Office. (Right) Yutaro Fukuhara, Head of CAD System Development, Kitami Mould Steel Co., Ltd. of time and effort, approximately 80% of the varies and each individual looks at the piece anxious at first about not having a drawing to manufacturing processes were completely differently when they refer to a drawing. We look at, he said, “Now I feel that referring to systemised. I knew that our competition discussed the content and expressions used a drawing is an outdated method. Machining would not be able to do this easily.” in the machining instructions at great length instructions made the work more efficient to make it possible for everyone to prepare, and provide an increase in quality. We still Surprisingly, there are no drawings at machine and measure in a standardised have room to improve, but we are trying hard the factory, only machining instructions. manner to prevent operator error,” said to establish a system that allows all operators Operators do not refer to drawings when they Tomoyuki Murata, Executive Director. here to manufacture high quality products are working on a component. “Perception Although Kunihiko Iizuka, Plant Chief, felt quickly and efficiently.” Overall Optimisation Achieves a 5 to 10 Fold Increase in Speed President Kitami said, “Increasing and also divides labour into individual the manufacturing method that is unique the speed of a specific process will processes. Assigning one operator to though. KMS has a motorsport team not increase the speed of the entire each process allows each operator and many employees come to the circuit process. The key to increasing speed to learn skills more quickly and this on race days to support the team. Such is to ensure that all the processes flow leads to reduced scrap, less difficulties activities have helped to cultivate an at the same speed. Reducing the time and irregularities. Currently, KMS has atmosphere of unity among employees during which machines stop operating achieved a surprising rate of production, and increase their motivation. President leads to increased speed,” which is one that allows it to finish components Kitami said, “We will continue such the basic KMS manufacturing policy. 5 to 10 times as fast as its competitors; activities with the hope that the Therefore, KMS divides each process leading to customers having extreme manufacturing industry will become into individual operating sections, faith in KMS delivery dates. It is not only more attractive for young people.”

Continuous Search for Unique Manufacturing that Stays Ahead of the Competition President Kitami said, “We expect tools play an important role in realizing established our current system, employees durability from cutting tools. Price is less the excellent production system we have worked until late at night to deliver products important because our priority is being developed at KMS. Plant Chief Iizuka said, by the deadline; but that did not lead to able to continue operations. Any problem “The new system allows us to precisely increased profits. That was a tough time for with a tool forces the employee to focus calculate the time required for machining everyone. It’s hard to break old routines, on one machining operation, which makes each process and this has significantly but we believe that applying innovation it difficult to handle multiple operations reduced overtime work. Cutting tools are to increase the speed of production will at the same time. When this happens, the critical in our business and we completely increase our competitive advantage in the speed of the entire machining process trust and rely upon Mitsubishi Materials for global market.” Having built a new head slows, which leads to increased cost. The these tools.” office in 2015, KMS is placing a priority on MVX series from Mitsubishi Materials has a cultivating human resources as well as solid reputation among operators.” Cutting President Kitami also said, “Until we expanding business.

14 HISTORY OF MITSUBISHI OF HISTORY HISTORY OF MITSUBISHI Vol. 4 Mitsubishi DNA Passed Down to the Next Generation The location of Mitsubishi at its foundation: Nishi-Nagahori in Osaka THREE (At the beginning of the Meiji Period – around 1870) MITSUBISHI PRINCIPLES – SANKORYO – Mitsubishi Materials originated from Tsukumo Shokai (the seed of the Mitsubishi Group), the coal and mineral mining business that Yataro Iwasaki started in 1871. The Mitsubishi Group has expanded over four generations, from Yataro to his younger brother Yanosuke, to Yataro’s first son Hisaya, and on to Yanosuke’s first son Koyata. Looking back over its history, we see common principles passed down over the generations. These principles called, The Three Mitsubishi Principles, became the common management philosophy for the entire Group of Mitsubishi companies in 2011. Here we explain these three principles that provide the foundation of common management practice among the Mitsubishi Group’s approximately 650 companies. Mitsubishi Executives (Around 1880)

1. Shoki Hoko – Corporate real way, playing an extremely important 2. Shoji Komei – Integrity Social Responsibility role. The ultimate purpose of business and Fairness therefore is to contribute to the nation and Maintain principles of transparency and Strive to enrich society, both materially we exert our best effort in fulfilling this and spiritually, while contributing to the openness and conduct business with purpose (source: The Announcement at the preservation of the global environment. integrity and fairness. Mitsubishi Mining Company Extraordinary Fourth-generation President Koyata Conference Held in 1920.” Shoji komei means fairness in all things. All Iwasaki led Mitsubishi for 29 years from Mitsubishi presidents, from Yataro Iwasaki 1916, the years spanning from World War Koyata Iwasaki had a firm management to the present day have repeatedly insisted I to the end of World War II. He stated philosophy, the social contribution expected that Mitsubishi business management clearly on many occasions that “Corporate in the growth of Japanese capitalism will not prioritize profit as an end in and of management should not be conducted between the Taisho Period (1912-1926) and itself. Fourth-generation president Koyata from the perspective of profit, but from Showa Period (1926-1989). It is also a fact Iwasaki in particular, was known to prioritize the standpoint of a national project.” This that our present affluence comes at the cost sincerity and to repeatedly caution Mitsubishi Mitsubishi principle was passed down to of the global environment. This fact makes employees against focusing blindly on profits each president, from Yataro to Yanosuke, it clear that our mission must be to change and pursuing unthoughtful investment to Hisaya and Koyata Iwasaki. our way of business in ways that contribute that end. He exhorted employees to maintain to the maintenance and restoration of our a high standard of ethical behavior in all Koyata Iwasaki also said, “Production is one irreplaceable global environment, and to transactions. of the country’s most important activities. It the realization of physical and psychological is associated with national strength and has affluence throughout society. This is how “The social position of corporations has an impact on the economy and prosperity. we interpret the meaning of shoki hoko at advanced, and their growth is significantly Being engaged in production, we are, in a present. associated with the growth of the nation.

15 YOUR GLOBAL CRAFTSMAN STUDIO HISTORY OF MITSUBISHI

Mitsubishi Three Principles (Sankoryo) Written by Koyata Iwasaki Yataro Iwasaki, 1st President Yanosuke Iwasaki, 2nd President

Hisaya Iwasaki, 3rd President Koyata Iwasaki, 4th President Mitsubishi Head Office Building in Kanda-Awajicho (1888)

Mitsubishi Gosho Kaisha Main Building (Mitsubishi Maini Building: Around Tokyo Minami-Kayaba Head Office (Around 1877) Yoshioka Mine (Around 1902) 1922)

On the other hand, sadly, corporate morality 3. Ritsugyo Boeki – Global “Even if the government takes action against seems to have deteriorated. Those in Understanding through Business the businesses and assets of our British and business must serve as an ideal model for Expand business from an all-encompassing American partners, we should prevent the others in their behavior and thought. While global perspective. trust and friendship we have developed with integrity and fairness are the most important them from being damaged. Justice, humanity aspects of business, it is shameful that The biggest issue for modern Japan was and responsibility demand that we protect people try to make fortunes at a stroke or the adjustment to globalization. Since the their lives and interests using every means through means that are contrary to our ideal time of founding President Yataro Iwasaki, within the limits of the law. When peace comes of social justice. (source: An article “My Hope Mitsubishi has promoted this attitude again, we will once again cooperate together to to the Club” written by Yanosuke Iwasaki, amongst its employees. In 1941, on the day contribute to the realization of world peace and Vice-President, to the Mitsubishi Club following the outbreak of the Pacific War, the well-being of all (source: Speech made by Journal in 1915).” President Koyata made an announcement Koyata Iwasaki at Mitsubishi Council in 1941).” to the top management of all Mitsubishi Although fair competition based on free group companies, “While governments Respect for justice has been one of the ingenuity is the basic principle of the market have, unfortunately, started a war, we count basic principles of Mitsubishi Group since economy, we need to consider the sentiments many British and Americans amongst its foundation. This attitude of respecting of the general public, the customs of our partners. They have undertaken justice from a global perspective in the international society and compliance with many projects with us and so we have a midst of war embodies the Mitsubishi spirit. law. We need to exhibit high ethical standards duty to protect their lives and interests.” Mitsubishi Materials Corporation and other and conduct and promote transparency and Considering the historical background group companies keep the spirit of The Three openness in our business activities. at that time, he made a surprisingly Mitsubishi Principles (Sankoryo) in mind as courageous statement. they take further steps toward the future.

Cooperation & Photos: Archives Division, The Mitsubishi Economic Research Institute YOUR GLOBAL CRAFTSMAN STUDIO 16 CRAFTSMAN STORY CRAFTSMAN

Craftsman Story Yasuharu Imai Hiroyasu Shimizu Toshiyuki Obikawa Hidefumi Takahashi Vol.5 Development Team Staff Leader Professor, Department of Mechanical Development Team Leader Advanced R&D Group Advanced R&D Group and Biofunctional Systems, Institute of Advanced R&D Group Joined in 1991 Joined in 1993 Industrial Science, The University of Tokyo Joined in 2000 Jet Coolant Technology Jet Tech Holder Increased abrasion resistance with the advancement of coolant-driven technology

The need for high-efficiency machining for difficult-to-cut materials has been increasing in the aircraft and other industries; and now, tools capable of performing under advanced machining conditions for extended periods of time are also required. For difficult-to-cut material machining, the use of turning tool holders using high- pressure coolant has gradually increased. Although proven to be effective in controlling chips, another goal, tool longevity, has yet to become stable. Special equipment is also required for high-pressure coolant. Therefore, machine shops have longed for standard tool holders that can be used on different machine tools while they improve abrasion resistance. In this feature, we interviewed three Mitsubishi Materials employees who have developed extremely effective coolant technology in cooperation with Professor Toshiyuki Obikawa from the University of Tokyo.

17 YOUR GLOBAL CRAFTSMAN STUDIO CRAFTSMAN STORY

- First of all, would you please tell us about the characteristics of this technology? Takahashi: The significant characteristic of our new coolant-driven technology, “Jet Tech Holder,” is the placement of an L-shape nozzle that we developed at the edge of the holder to provide a powerful jet of coolant from the flank face of the insert to the cutting edge. Coolant is generally supplied from the insert rake face or to the flank face in reverse tool holder use. However, when supplied from the flank Jet Coolant Technology face, as shown in Fig. 1 (left), chips can interfere with the flow. Even when supplied Jet Tech Holder from the rake face, the coolant does not enter the narrow, high-temperature, high- pressure space where the tool’s rake introduction to the market within two to requires more effort, so it’s difficult to get face and the surface of a target material; three years. I knew commercialization people motivated. Unlike the development which is rotating at high speed, come into would be a challenge, but I felt this of milling tools, which are popular contact. The end result is that coolant coolant-driven technology had potential. projects, nobody looks forward to being does not always effectively reach the edge Besides, our group is named, “advanced involved in turning tool development. that needs to be cooled. As shown in Fig. R&D,” and I felt coolant-driven technology However, Takahashi’s description of the 1 (right), Jet Tech supplies high-pressure, was just that. basic concept of Jet Tech hooked me, so I high-speed coolant from the flank face Takahashi: The biggest turning point signed up to the project. The basic effects to the edge to prevent it from becoming during development was choosing between had been verified, so I felt that I could too hot. This makes effective edge cooling an air-assisted method to emit coolants, concentrate on commercialization. possible, which improves insert abrasion or direct acceleration of the coolant. After Takahashi: He says so now, but I still resistance. We also confirmed that a great deal of discussion, we decided remember that when I told him about the this technology can prolong tool life by to prioritize ease-of-use under a wide project, he looked disappointed and clearly approximately 30 to 50% when compared range of environments and application of less than happy about the idea. In the general external coolant supplied from the it to the different cutting tools employed end though, asking Imai to take charge of rake face. in the market. This led to our choice of design for this product was the right move. coolant rather than an air assist type. Imai: I love development and working - Would you please give us the After this decision, we set to work on on difficult-to-solve problems fits my background of development? important details such as determining personality. Shimizu: We were working to address the most effective form and size of the the significant deterioration of tool life hole that would emit the coolant and the - What difficulties did commercialization experienced during the machining of amount of flow, etc. During this phase of present? difficult-to-cut materials, but we felt we development, Professor Obikawa’s fluid Imai: The most difficult part was lacked the in-house resources we needed analysis was extremely helpful. Because the form of the port that would emit the to ensure the competitiveness of the new my knowledge of fluid analysis was rusty, coolant because it should not be produced products that were under development. I broke out my textbooks from college and by machining. For this reason, we sought outside brushed up on it. Through these efforts, cooperation. We met with Professor we were able to complete the basic design Toshiyuki Obikawa of the University of concept for Jet Tech, which allowed us Tokyo, who had been engaged in research to start full-scale development for mass on extending the life of taools used for production and commercialization. We difficult-to-cut materials. Professor put Imai in charge of the most important Obikawa was investigating the effect of a aspect of the development, design! system that directed air for cooling from Imai: I had just finished a large the flank face to the edge. Impressed with product development project. To tell the the potential of this method to extend tool truth, a turning tool holder development life, we began joint research in 2008. Takahashi: Japanese tool manufacturers were not interested in coolant-driven Flow of the coolant technology at that time. Mitsubishi Materials was also not really enthusiastic about it then either. When I learned about this joint research, I thought it looked promising; but I was also worried about whether commercialization would be practical and whether the concept would Direction Flow of the coolant Direction sell. of the work →Does not reach of the work High-speed emission Shimizu: In developing tools and around the edge of coolant from flank technology, our Advanced R&D Group face to edge looks five to ten years into the future; but specific product development focuses on Fig. 1 Principle of Jet Tech

YOUR GLOBAL CRAFTSMAN STUDIO 18 CRAFTSMAN STORY CRAFTSMAN

There were no tool holders that had a change specifications, he told me, “This industry standard that contributes to coolant port around the edge, and mass is completely different from what you reduced production costs for customers. production of such a tool holder via were talking about before!” He was Really, this technology represents an machining was not possible. In other right, but my motive was to ensure that improvement for the entire machining words, it was necessary to make an the part would satisfy customer needs. industry. I also feel that industry- independent part. Since I wanted to do Difficult as it was, Imai and I kept at it. university-government collaboration something that no one had done before, Imai: The advantage of making should be enhanced. Compared with I set to work. prototypes with a 3D printer is that activity overseas, Japan is not taking Shimizu: In fact, seeing an obstacle we can perform tests with them and advantage of this nearly as much as to manufacturing this design with the evaluate the results for improvement. it could. I want to follow this approach existing equipment, we gave up on The advancement of 3D printers has more and more. machining the port and asked Imai to reduced the development period not create the part. only in the tool industry, but in just - This is the last question. Please tell us Imai: First, we had to decide what about every area of manufacturing. what about manufacturing attracts you. material we should use for the prototype. Takahashi: After determining the final Imai: What I imagine Since a resin 3D printer was being used design, we verified the part under becomes reality. My imagination is in other product development, we went different machining conditions by commercialized and makes customers with resin. Coolant emission was fine; changing coolant type and flow. Finally, happier. This is fantastic. Being but as might easily be expected, when we were ready to make a presentation engaged in development means doing we put it to the test in actual machining, to other companies at an exhibition held something completely new. We may the heat of chips quickly damaged it. We last year. The conference room was fail and encounter difficulties but our decided to make another prototype, this filled to capacity. We were asked many ability to work on, in spite of setbacks time using metal. We found a company questions and felt a high level of interest leads to our ultimate success. That handling 3D printers for metal and among customers. Many asked us if the ability is nurtured in no small part placed the order for the prototype parts. part functioned as well under normal by our more experienced colleagues Takahashi: At the beginning of pressure. I felt that people were very who encourage us to see failure as a development, we designed the part to be interested in the fact that a Japanese learning opportunity and difficulties effective under normal water pressure. tool manufacture was working on new as a challenge. This comfortable Some customers however, use high- coolant technology. I was very pleased environment is a key to the creation of pressure coolant and under such that we had kept at this without giving something new. conditions, the nozzle would fly right up. Takahashi: I’ve been in development for off. Therefore, we needed to change the 16 years. I put plans into final shapes design to accommodate both normal - Please tell us about your future and validate theory. When the theory and high pressure conditions. We also vision. and actual product match perfectly, it’s found that the screws that fix the part to Takahashi: We first started sales with the a great thrill. Development is great fun the tool bent under high pressure, so we ISO C-type geometry, and expanded to for me because I am pursuing a goal had to improve those as well. W, D, S, T and V-geometries. We are that no one has reached yet. It may be Imai: At that time, Takahashi was planning to apply this technology to the world’s first, the world’s best or coming at me with one request after products other than turning tool holders. even the only one in the world, and I am another. We had our share of difficult Shimizu: This technology should be used very proud to be doing such work. I will discussions, usually based on, “This is more broadly, even by other companies continue working on the development not what you were asking for last time!” as an excellent way to increase service of new products to make our customers Takahashi: Every time I asked Imai to life. Indeed, it should be seen as an happier.

The photo on right shows the first prototype

19 YOUR GLOBAL CRAFTSMAN STUDIO CRAFTSMAN STOR

Y Interview with Toshiyuki Obikawa, Obikawa: First we examined the best size and form for Professor at the University of Tokyo the port. However, it is very difficult for students to freely adjust the size and form of the ports on prototypes. To University of Tokyo Professor Toshiyuki Obikawa is address this we made an adaptor with ports on the edge a leading expert in machining. He started research of the nozzle, changed the diameter of the ports and on machining when he was studying for his master’s measured both flow and speed. As the diameter becomes degree. The topic of his research was the effects of larger, the flow increases; but past a certain size, the manganese sulphide (MnS) contained in free-cutting speed drops. We discovered that approximately a 2mm2 steel. We interviewed Professor Obikawa about the cross-sectional area yielded the best flow and speed, and joint development of Jet Tech Holders with Mitsubishi we set that as the standard for design. Although I felt that Materials. emitting machining lubricant from both flank and rake faces would be ideal, I finally decided on the flank face - What were the challenges you faced in research on only to prevent a decrease in speed with the increase of difficult-to-cut materials? flow. Obikawa: Around 1980, when I became an assistant, machining targeted steel only. Difficult-to-cut materials - What impressed you most about Mitsubishi Materials? such as titanium alloys and nickel-based heat-resistant Obikawa: They helped our research immeasurably. alloys were extremely expensive and hard to obtain. The cross-sectional area of the port for the machining However, I felt that Japanese machining technology lubricant on the Jet Tech Holder was larger than the port for the aerospace industry was behind other countries, for the air employed in the AJA machining method, so so I chose difficult-to-cut materials for my research. some ports were filled with adhesive. When we emitted Machining generates heat and that heat causes the machining lubricant, the adhesives were softened significant deformation; but analyzing data to clarify by the lubricant and finally destroyed. We changed from this was very difficult. Analytical theories described in circular to L-shaped ports, which also differ depending the technical manuals at that time were not about large on the edge of each insert. I know that it must have been deformation, but about stress. It was very difficult to very difficult for Mitsubishi Materials to make and verify analyze deformation. different forms for actual use.

- What research were you engaged in after that? - How did you feel when you finally completed the Obikawa: When I became a professor, MQL machining product? was popular as an environmentally friendly method. The Obikawa: I agreed with the idea of emitting coolant use of a small amount of oil mist rather than a large from the flank face and worked together with Mitsubishi amount of lubricant was the standard at that time and it Materials through a process of trial and error to complete had spread quickly since it reduced power consumption the product. When I saw the final product, I felt it was and machining costs. In the late 1990s, an automobile simply beautiful. Tool holders are high added value manufacturer reported that replacing the coolant pump products. When roughly calculated, 1 gram of an airplane could cut energy consumption by approximately 40%. I costs about 200 yen and 1 gram of the most advanced also examined the effects of MQL machining, investigating hybrid automobile costs about 2 yen. One gram of an various points by using fluid analysis. When I was insert on the other hand, costs about 50 yen; and inserts watching MQL machining tools that emit oil mist from are disposed of after a few milligrams of wear, which both flank and rake faces, I wondered what would happen makes them extremely costly. I would like to continue if compressed air were emitted from the ports in regular research that expands the potential of cutting tools. wet cutting. My experiments yielded favorable results. This is the Air Jet Asist (AJA) method. Using air however, cost a lot more than I had expected; and this led me to the idea that we should instead use coolant and emit oil mist from a smaller port. Next came the idea that we should emit compressed air only and then follow with a coolant.

- The idea of using air is innovative, right? Obikawa: Using the AJA machining method, we thought we could push coolant by air. The flow speed of coolant is about 1 to 2 meters per second while the flow speed of compressed air is about 100 to 200 meters per second, which is quite a difference. We knew that MQL emitted air effectively, and we thought we would be able to use it. I was very lucky because the initial data in all of the research showed extremely good results. Often, unfortunately, if we obtain discouraging data at the beginning, we tend to abandon the idea.

- What were the challenges in the development of coolant technology?

YOUR GLOBAL CRAFTSMAN STUDIO 2020 TECHNOLOGY ARCHIVETECHNOLOGY TECHNOLOGY ARCHIVE History of Grooving Tools and the Enthusiasm of Craftsmen

Some say that the history of grooving tools stretches back to 1898, when the first tool bits were manufactured. History of Craftsmanship Mitsubishi Materials started producing its first grooving tool, a brazed bit, in 1956. In 1980, it developed the DG that has Always Achieved tool bit, the first bit with a replaceable cutting edge. Launched in 2008, the GY series adopted a superior clamp a Functional Beauty mechanism that dominated the market. In this feature, we trace the history of Mitsubishi Materials’ grooving tools, Ahead of its Time tools that have risen to meet the challenging needs of industry.

21 YOUR GLOBAL CRAFTSMAN STUDIO TECHNOLOGY ARCHIVE

TECHNOLOGY ARCHIVE Part1 1956 ~ bits they manufactured. Brazed tool bits adopted different carbide for each material to be machined. The tail Craftsmen competing to of each shank was colored differently to make it easy to ensure the right bit tool was show their skill with brazed being used for each material: blue shanks for steel, yellow for stainless, and red for cast iron. Some may still remember seeing tool bits these colorful tool bits on Brazed tool bits are made by jointing quality and excelled in defect resistance, shelves. a carbide cutting edge to the top of and its superior machining performance Currently, the steel shank. It was about 60 years was highly regarded by the manufacturing brazed tool ago in 1956 that Mitsubishi Materials industry during Japan’s post-war recovery. bits are less launched its first grooving tools. JIS B4105 common; stipulated strict specifications that made Craftsmen at that time generally adjusted but, they are no distinction between forms used by the form, rake angle and honing of brazed still used to different manufacturers. Performance was tool bits utilizing their grinding machines to train young determined by the quality of the carbide create conditions suitable for the materials craftsmen. used in the cutting edge. At that time, there and methods being used to improve were few Japanese manufacturers that dimensional and machined surface could manufacture carbide. Mitsubishi accuracy, and extend tool life. Their skills Materials’ carbide had outstanding abrasion could be judged by the quality of the tool

Part 1985 ~ development of high-performance inserts. These characteristics took 2 the market by storm by enabling high- speed machining that could not be matched by brazed tool bits. A chip DG tool bits with breaker was provided on the rake face of the insert for chip control during the manufacture of inserts using the press replaceable cutting edges sintering method. This chip breaker enabled lateral machining, which had When the cutting edge of a brazen bit a cam-lock type used for machining been impossible with the existing is worn or damaged, the entire bit is outer diameters, which the company brazed tool bits. Grooving tools have changed. Because this includes the launched in 1960. improved since then to become multi- shank, it is not economical; and while DG tool bits were launched in 1985 as functional tools. the cutting edge can be polished to grooving tools with replaceable edges. extend service life, highly-advanced skill is required to maintain cutting The merits of DG bits included not edge quality. This led the push for a only low cost and high quality, but high-quality, low-cost solution. That also outstanding performance. DG solution came in the form of tools with tool bit inserts could be manufactured insert-type replaceable cutting edges separately, which provided great made of carbide. The first such bit flexibility in selecting carbide introduced by Mitsubishi Materials was materials and coatings, and led to the

HISTORY History of Grooving Tools

1931 Tridia, a carbide tool, launched. 2004 New insert-type grooving tool development starts. 1956 Brazed tool bits (including grooving tools) launched. 2008 GY series, new insert-type grooving tools, launched. 1985 DG tool bit, an insert-type grooving tool, launched. 2017 New item in GY series scheduled for launched.

YOUR GLOBAL CRAFTSMAN STUDIOSTUDIO 22 TECHNOLOGY ARCHIVETECHNOLOGY TECHNOLOGY ARCHIVE

Part 2008 ~ could be distinguished from others at a 3 glance.” Nagaya continued: “The side of the modular blade was inspired by the thinning seen in racing car parts, a technique that GY series: inspired by provides both strength and light weight.” Finally, the modular-type GY series realized high rigidity equivalent to the combined type. It succeeded in reducing chattering disc brake calipers vibration for broad machining conditions and in a realizing high-quality finishing surface and long life. Since being launched for automobiles in 2008, the GY series has received an overwhelming response from the After Mitsubishi Materials launched its insert caused damage to the main body, market with sales quickly exceeding our DG tool bits in 1985, other carbide tool and this resulted in the need to replace the competitors’ products. The technological manufacturers worked to keep pace entire unit, which was not economic at all. contribution to the industry was highly by developing new multi-functional Modular type tools with replaceable inserts regarded, and Mitsubishi Materials was grooving tools. To maintain its lead against such as the DG tool bits were economic, but recognized with the 2009 Technological increasing market competitiveness that they were less rigid. Therefore, we decided Achievement Award from the Japan challenged the supremacy of DC bits, to focus on developing a new modular-type Cemented Carbide Tool Manufacturers’ Mitsubishi Materials moved quickly to grooving tool with rigidity equivalent to the Association (currently the Japan Cutting & push forward with the development of combined unit. Wear-resistant Tool Association). The GY new products. Hidehiko Nagaya, who series achieved its mission as the first new was then in the Research & Development Nagaya liked motor vehicles, especially grooving tools that Mitsubishi Materials had Department in charge of milling tools, was motorcycles, and belonged to the auto club introduced in 20 years. New items in the GY asked to head up the new-product project. at his university. He continued participating series scheduled to be launched in 2017 “I was still fairly young at that time,” said in the JAF Gymkhana, a driving competition, spring have been under development. Nagaya, “and my experience was with tools after he started working at Mitsubishi in a different area. I was surprised and Materials. “After the project started, I was happy that the company asked me to take continuously racking my brain to come up 3Lock on such a large project; but, without the new ideas. One day when I was reading a experience and knowledge I felt I should motorcycle magazine, I saw an article on have to handle the responsibility, I was also radial-mount brake calipers, which were quite nervous. I accepted the challenge, fixed vertically rather than the standard though, and set my sights on doing the best lateral placement to increase rigidity.” 2Lock job I could.” Inspired by the concept, Nagaya focused Everyone involved in the project listened on three-directional fixation to increase carefully to what customers around the durability against the force of machining: world were looking for and learned that from the front and diagonally upward as 1Lock many were dissatisfied with combined well as from the side. It was called a try- units, which were major products for lock system. “When you look at the shape, it carbide tool companies at that time due really has a simple structure. However, we to their excellent rigidity. The reason they did not have grooving tools capable of fixing were dissatisfied was that damage on the inserts from the front. I was excited and really wanted to commercialize this system before someone else came up with the idea.” Try-lock system development went very smoothly, and its high performance was verified using prototypes. However, the cost of manufacturing its modular blade, which had a complex form, had become a significant issue. “We applied complete machining to the prototypes; but this failed to meet time and cost requirements. I then decided to use press sintering technology that had been developed by Mitsubishi Materials. I think we were the first to succeed in using this technology to attach an insert to the main body of the tool. I also wanted a product that looked good and

23 YOUR GLOBAL CRAFTSMAN STUDIO TECHNOLOGY ARCHIVE

ARCHIVE TECHNOLOGY ARCHIVE

CLOSE UP Person in Charge of Intellectual Property Rights Supported the Development of the GY Series Mitsubishi Materials holds the highest number of machining tool patents among domestic tool manufacturers. It is also among the top patent holders in the world. The number of patents usually acquired for one machining tool is about 1 to 2. However, the GY series has surpassed this with an amazing 19 patents. We interviewed Koyama and Hiyama, both Managers Chief Engineers in charge of intellectual property rights about the acquisition of patents for the GY series. When- Mitsubishi Materials began cutting tool patents and the trust he had “When we were in the long, dark tunnel GY series development in 2004, the among developers made me forget my of patent conflict with our competitors, Research & Development Development worries. Before I knew it, I was standing Hiyama and Koyama lighted the way. I Department’sDivision’s Koyama with them at the cutting tests.” really appreciated them,” said Nagaya. surveyed about 500 patents that had At Mitsubishi Materials, development been acquired by other manufacturers. The GY series entailed the development staff and staff in charge of intellectual At the same time, the department also of a wide range of small parts such as property rights share information started examining the design drawings modular blades, clamp mechanisms during development. This is one of the for the new product proposed by for inserts, breakers for inserts, and company’s significant strengths in the Nagaya’s team. “I told them,” Nagaya applications for inner diameters and development of innovative products. said, “that they needed to take extra edges. “One day,” said Koyama, “we care with any modifications to avoid received notice that an the possibility of infringing patent overseas competitor had rights held by other companies; and I filed an objection to our was impressed with their attention to application for a European detail and ingenuity in moving forward patent. Although concerned, despite this restriction. I admired their we also took it as a sign that enthusiasm greatly.” the GY series was a growing force in the European In 2006, meanwhile, Hiyama, a certified market. The competitor patent solicitor on staff at the Mitsubishi claimed prior development; Materials Intellectual Property however, we argued that Department, was assigned to the Cutting the innovative form of Tool Division, which was working on the GY series delivered GY series development. “I was worried performance that had never Three staff talking about the difficulties they faced at that time. because of past patent disputes; but been achieved by other Noriko Hiyama, Manager, Intellectual Property Dept., Corporate Research & Development Nagaya’s enthusiasm about innovation products, and our patent was Dept. Chief Engineer, Intellectual Property Office, Technical Development Division (middle) Takashi Koyama, Manager, Materials & Coating Development Center, Research & coupled with Koyama’s familiarity with granted.” Development Div.Chief Engineer, Material & Coating Development, Center, Development Division (right)

Looking Back on the History of Grooving Tools “Because JIS stipulated specifications during development; but cooperation that may have potential for development for grooving tools used for brazed tool among the individuals in manufacturing, and commercialization. I’ve worked within bits, details such as form and size, sales, development and intellectual this process of development and believe performance was standardized across the property rights got us through the rough that the experience of success has a industry regardless of the carbide material patches along the path to GY series significant impact on the development of used. However, there were no standards commercialization. I can honestly say that young employees; and I hope they continue specifying the form or size of inserts the GY series came to fruition through the search for innovative cutting tools.” such as those used for DG tool bits. The the combined efforts of all employees at individuals involved in the development Mitsubishi materials, and all of us learned of DG tool bits were excited about the valuable lessons during this development opportunity to differentiate their products project. from competitors. The GY series products we developed were the first new grooving I am currently managing a cutting tools tools that Mitsubishi Materials had group, so I’m away from direct involvement produced in 20 years. Although there was in development; however, I still have lots significant pressure on us to come up with of chances to meet and talk casually with products that had great potential, we were young team members in situations that fairly free to move in our own directions. Of allow us to dispense with form. Through course, we faced a number of difficulties our talks at such times, we seek new ideas Hidehiko Nagaya, Cutting Tools Group, Indexable Tools Development Center, Research & Development Div.

YOUR GLOBAL CRAFTSMAN STUDIO 24 ABOUT US ABOUT

An Educational Base ABOUT US for Broad Areas Chicago in the United States Technical We report on the provision of total solutions and unique workshops being provided by the Center Chicago Technical Center.

Striving to provide speedy and effective in the US, outsource the testing to Interview with the solutions Mitsubishi Materials in Japan, and have Marketing Director! The Chicago Technical Center (CTC) the tests results ready for the customer was established in 2013 to enhance by the next morning. This quick response our ability to create total solutions time is a significant CTC strength. Of and provide training programs for course, they can do the same thing in My goal is to create the customers. Marketing Director Mike reverse for customers in Japan. With ideal solution for each and every customer Pace said, “We provide materials, technical centers around the world, products and services that meet and Mitsubishi Materials can provide a Mike Pace exceed individual customer needs with speedy response to all of its customers. CTC Marketing Director, the aim of maintaining our position The CTC also has the machining room, Mitsubishi Materials USA as a respected leader in the cutting located right next to the lecture room tool industry. The extensive range where specialized techniques and skills of solutions provided by us includes are taught, for demonstrations using cutting tests, technical consultation actual tools. This layout is extremely via telephone, seminars, and technical convenient for customers. Customers support designed to ensure that our can see the actual machining processes customers are able to utilize the full and results in the machining room, capability of our cutting tools.” The CTC which is equipped with the most is located near O’Hare International advanced machining center and a Airport, one of the major hub airports 4-axis lathe, which has increased the in the United States. The geographical learning effect. Each training session advantage enables Mitsubishi Materials accommodates 16 participants. This USA to provide outstanding services to makes efficient and effective class customers not only in North America, management possible for the nine but in Mexico and Canada as well. Local training sessions we provide each year. time in Chicago is 15 hours behind Because the United States is so large, Japan. Taking advantage of that time we also dispatch lecturers to customers difference allows the company to accept for which it is inconvenient to send orders for cutting tests in the evening representatives to the CTC. Pace said,

25 YOUR GLOBAL CRAFTSMAN STUDIO “We want more customers to use the conditions and environments can CTC as a means to meet their needs; and often do vary significantly from Interview with and we would like to present proposals customer to customer, and tools may be the Manager! that reduce processing costs, including used under conditions that we may not tool costs, and provide solutions for yet have encountered, we consider the high efficiency processing to improve widest variety of machining conditions the productivity for each customer.” possible in our search for more Utilizing Accumulated creative tools and machining methods.” Processing Cases to Provide Bringing to bear a tremendous amount Prompt and Effective Solutions of accumulated machining data to Seminar participants deepening Marc Kinnemann provide optimum solutions partnerships CTC Manager, Mitsubishi Materials USA Marc Kinnemann (in his 12th year at CTC places a priority on not only Mitsubishi Materials) is in charge providing customers with a place to of management at the CTC. The learn, but on facilitating interaction with CTC conducts cutting tests for other seminar participants. At the end a wide range of tools. They also of the first day, participants have dinner accumulate machining data on hard- and enjoy bowling together. Facilitating to-cut materials and a wide range of interaction on the first day deepens processed parts to provide prompt communication and understanding solutions that meet individual customer among participants, which encourages needs. Mr. Kinnemann said, “We focus greater interaction in the sessions that on the accumulation of machining follow. After lunch on the second day, data on parts for automobiles, participants go sightseeing in downtown aircraft, medical devices, and oil & Chicago and at Lake Michigan before gas equipment, and we are confident having dinner at a lakeside restaurant. and proud of our ability to provide The CTC provides customers the chance total solutions in all of these areas. not only to learn machining techniques The CTC leverages the experience and that provide solutions to their individual data it has accumulated in over 1,000 problems, but also to establish cases to provide high-quality value partnerships with others in the industry. analysis proposals. Because machining

CTC Training Program

Lecture in the classroom Machining Interactions among 123demonstration participants

YOUR GLOBAL CRAFTSMAN STUDIO 26 CUTTING EDGE CUTTING EDGE

Vol. 4 Amazing Straightness with only 0.48 mm Deflection over 1km Slot Die Useful for Liquid Coating A slot die is a tool used to apply liquid Utilizing its know-how as a cemented to develop new coatings for large liquid coating. It is often used for precision carbide tool manufacturer, the crystal panels (2,880mm×3,130mm) coating on liquid crystal panels, Mitsubishi Metals Tokyo Plant and lithium ion battery electrodes. high-function film, and lithium-ion (currently the Mitsubishi Materials rechargeable batteries. The slot die Tsukuba Plant) developed its first slot structure combines a pair of stainless die with carbide edge in 1981. This steel bodies with a cemented carbide was a die coater type slot die for film edge that forms an opening for coating manufacturers designed for use in material. The coating material is the production of audio and magnetic delivered from a storage space on the tape. Slot die production was shifted body (manifold) to the edge to ensure in 2000 to MMC Ryotec Corporation, Slot Die Structure even coating. Coating with a slot die is which entered the industry with flat [Die Coater] cleaner and more effective compared panel displays (FPD) used for liquid with other coating methods such as crystal TVs and computers. Maintaining spraying because it prevents coatings its place as a leading slot die from vaporizing or dispersing. manufacturer, MMC Ryotec continues Move

Manifold

[Role to Role]

Cemented carbide edge that forms an opening for coating material SUS Move

Manifold

Manifold

27 YOUR GLOBAL CRAFTSMANCRAFTSMAN STUDIOSTUDIO CUTTING EDGE CUTTING

(From the left) Atsushi Hayashi, Section Head Assistance, Precision Technology Group, Wear-Resistant Tools Division, MMC Ryotec Corporation Ayumu Nagaya, Section Head, Manufacturing Department Slot Die Section, Wear-Resistant Tools Division, MMC Ryotec Corporation Takahiro Isoda, Sub Leader, Precision Technology Group, Wear-Resistant Tools Division, MMC Ryotec Corporation Toshihiko Kanayama, Group Leader, Precision Technology Group, Wear-Resistant Tools Division, MMC Ryotec Corporation

Seeking Ultimate Precision to Achieve Straightness and Reduce Surface Roughness

MMC Ryotec slot dies are manufactured Furthermore, the surface roughness of is the youngest of the group, has been using highly-advanced grinding the carbide edge is approximately 0.1 developing new products that respond technology and know-how accumulated μm (Rz) and that of the stainless steel to diversified customer needs, products over 30 years to increase straightness, main body is approximately 0.2 μm (Rz), such as a three-layer coating slot reduce surface roughness and ensure giving it a shiny mirror surface. The die that is capable of handling three consistent groove width. Straightness groove width deviation of the edge that coating materials at the same time. refers to an edge that is completely discharges coating materials is reduced free of warpage. Deviation in the slot to approximately 1 to 2 μm per meter. The slot die manufactured by MMC die is limited to approximately 1 to 2 Ryotec has a leading share of the global μm per 1m, which is extremely precise. “Hayashi, Nagaya and I had been market for lithium ion rechargeable The long slot dies (for 2.5m) used designing and manufacturing slot dies batteries and liquid crystal panels. In for large crystal liquid panels were for 30 years, since the beginning of China, it has captured the top share and required to meet the same standard of development, and accumulated know- is scheduled to introduce a re-grinding straightness (1m) as regular panels, an how,” said Kanayama. “Each slot die service for edges in 2017 to establish extremely difficult standard to achieve has the same design and size with a firm position in the Chinese market, in such a large panel. They changed slightly different features. Even if we which is expected to grow further. MMC the heat treatment and machining try to process them in finish-machining Ryotec also continues to seek out new processes to reduce the residual based on drawings, we often need to customers that do not yet use slot dies. stress and warping that occur in the change grinding conditions significantly pre- and semi-finishing processes as according to differences in the History of Slot Die Manufacturing Sites much as possible. They also sought material lot and heat processing,” said installation methods and grinding Hayashi, who is with the Technology 1981: Mitsubishi Metals Tokyo Plant conditions in the finishing process with Group. Talking about the pleasure begins manufacture of slot dies the goal of limiting deviation to 1.2 μm of manufacturing slot dies, the 1989: Shifts manufacturing to the over a 2.5 m long article. This equals Manufacturing Department’s Nagaya Mitsubishi Metals Gifu Plant 0.48mm per 1km. When you consider said, “When we understand such 2000: Shifts manufacturing that 0.48mm is the width of a single differences among slot dies and achieve to Ryotec Corporation graphite refill for a mechanical pencil, the precision specified by a drawing, 2011: Ryotec Corporation is renamed this was an amazing achievement. we feel great satisfaction.” Isoda, who MMC Ryotec Corporation

*Straightness is measured at arbitrary positions in one direction and expressed as the minimum distance between two geometrically parallel flat surfaces that are vertical to the direction of straightness when holding the linear piece with the two surfaces (JIS B0621)

YOUR GLOBAL CRAFTSMAN STUDIOSTUDIO 28 Japanese Swords WA (Katana) Japanese Swords battlebl shifted hifdf from idiiindividuald combat to coordinated unit tactics, and bladed weapons were produced to meet the needs brought about by this change. Some of them are now national treasures. The Muromachi Period (1336- 1573) saw the introduction of short swords, or kozori, swords for indoor fighting, or wakizashi, and the two- sword samurai style that we are familiar with today. They were also important products in overseas trade. By the Sengoku Period (1467-1590), which saw the rise of two famous samurai, Oda Nobunaga and Toyotomi Hideyoshi, the quality of swords had improved to such a degree that they had become prized possessions and symbols of authority, taken as spoils of war and presented as honors. The introduction of firearms brought rapid change. apanese swords and their rich swordsmiths (tosho) improved their craft, Armor design shifted to emphasize ease Jindividual histories have fascinated eventually arriving at the characteristic of movement and improved protection. people for centuries. Swords were first curved blade, or wanto that distinguishes Along with this came the appearance of used as weapons in the Tumulus Period the Japanese katana from other swords the uchigatana, a sword whose weight (3rd century). Swords seen in the Asuka seen around the world. The introduction and length made it ideal for combat. The (592-710) and Nara (710-794) Periods of cavalry to Japanese warfare spurred uchigatana is what we generally think were called chokuto, or straight sword, a improvements in the length and arc of of nowadays as the Japanese sword. In name that reflects their use for thrusting the blade to allow mounted warriors to the Edo Period (1603-1868), laws were rather than slashing. The evolution of more effectively wield their swords in established to restrict sword ownership what was to become the classic Japanese battle, which is called tachi. With the by class, limiting, for example, tradesmen katana the world has come to know began emergence of samurai as the ruling class and craftsmen to short swords. As peace in the Heian Period (794-1192), which saw of the military government established spread during the Edo Period, sword use a surge in the demand for swords due in the Kamakura Period (1192-1333), declined. At the end of the period (1853), to the many internal conflicts that took skillful craftsmen cultivated under the however, sword use rose as forces within place during that period, the most famous Shogunate began to produced new types the nation again plunged into conflict. of which is perhaps the clash between of bladed weapons such as the tanto (short Although personal possession of swords the Genji and Heike Clans known as the sword), naginata and yari (pole weapons). was prohibited in 1876, they continue to Genpei Kasen. Before this time, imported Development continued as Japan faced fascinate us because we feel the proud swords were valued over domestic blades the two Mongol Invasions (1274 and 1281) history of the samurai that made them for their quality. With each successive in the late Kamakura Period. It was at famous as they built the Japan we live in conflict, however, these early Japanese this time that the prevailing method of now. History of Japanese Swords [Period] Nara Heian Kamakura Nambokucho Muromachi Sengoku Edo Meiji

[Sword Period] Jokoto Koto Shinto Shin-shinto Gendaito (Early Old Swords) (Old Swords) (Newly Swords) (Very New Swords) (Modern Swords) Former Nine Mongolian Onin War Battle of Sekigahara Haitorei Edict Years War & Invasions Gosannen War Cavalry Infantry Action

Tachi 1(Long Swords)

Tachi 2 (Swords)

Uchigatana (Swords)

Wakizashi (Short Swords)

Tanto (Short Swords)

Yari (Spears) Source: The Science of Japanese Swords Written by Masashi Daimaruya (SB Creative, 2016)

29 YOURYOUR GLOBAL GLOBAL CRAFTSMAN CRAFTSMAN STUDIO STUDIO Forging a Japanese sword requires strength and specialized skill, and swordsmiths Forging a Japanese Swords are masters at creating designs, selecting material, and finishing. The following are the major steps involved in Japanese sword making.

1. Tama-beshi 2. Tsumi-kasane 3. Shita-gitae 4. Uwa-gitae The metal used to forge the sword blade, Swordsmiths select hardest pieces, which are This stack is heated to around 1,300 degrees Imagining the intended hamon, or pattern he called the tama-hagane, is produced from suitable for the outer layer of the sword blade Celsius and hammered to remove impurities. hopes to achieve on the jigane, or blade metal, iron or black sand. It is heated and forged to called the kawagane, and stack them on a The block is folded and hammered repeatedly the swordsmith heats and hammers the iron 6-10mm thick ingots before being broken into tray. transversely and longitudinally. block to complete the kawagane. smaller pieces.

5. Tsukuri-komi 6. Wakashi-nobe & Ara-shiage 7. Tsuchi-oki 8. Yaki-ire After combining the kawagane, the hard metal The material is heated to be formed into a Imagining the hamon of the blade, blade clay, The blade is heated evenly from the top to the used for the outer layer of the blade, and bar. The bar is then formed into a blade with a mixture of clay, grinding stone powder, and bottom and quickly quenched in water to form shingane, the softer metal used for the core of a small curve using a hammer, and roughly coal dust known as yakiba-tsuchi, is placed on the curve. the blade, it is heated for forging. polished with grinding stones and other tools. the blade.

Editorial Note The publication of MMC Magazine Vol. 4 was made possible through the cooperation of many talented and dedicated people. I would like to express my deep appreciation to those who accepted our requests 9. Sorinaoshi 10. Mei-kiri 11. Completion for interviews. The major reason Any warpage produced in the yaki-ire process The signature, or mei is first written on we decided upon “Japan Quality” as is corrected by hand. the blade and then engraved with a chisel. The blade is completed and passed to other the theme of this feature was that craftsmen such as scabbard makers (saya-shi) JIMTOF 2016, one of the largest international machine tool fairs in Japan, was scheduled to be Tip of the Japanese Swords held at the same time Vol. 4 was to be published. We were able to (1) The key is that the tip does (2) Other crafts related (3) How to distinguish tachi interview a number of dedicated not to break or bend. to sword making swords from uchigatana professionals, company owners, The strength of Japanese swords is ensured by The creation of a Japanese sword requires When we look at a sword, we notice that some craftsmen and others whose stories the selection of the best material for each part. more than the swordsmith who makes the blades are exhibited with the sharp edge upward The process of realizing the ideal combination of blade. A number of other craftsmen take part and others are exhibited with the sharp edge and thoughts we are sure will be core softness and outer-layer hardness is called in the process, craftsmen such as polishers downward. This is the difference between tachi of interest to all of our readers. I tsukuri-komi. Using softer metal (shingane) (togi-shi) who add sharpness and beauty to the and uchigatana. While a Tachi is carried with the in the core helps to absorb and reduce impact, blade, scabbard makers (saya-shi) who ensure was extremely impressed by the the perfect fit for each sword, lacquer painters blade edge facing downward for easy drawing and wrapping it with a harder metal (kawagane) when riding on horseback, uchigatana is carried passion, ambition and skill these prevents the blade from bending. (nu-shi) who coat the scabbard, silversmiths (shirogane-shi) who make the metal fittings with the edge upward for easy drawing while on individuals brought to the machining placed between the blade and hilt, hilt wrappers foot. industry. I hope I can share that (tsukamaki-shi) who craft sharkskin and other materials, and handguard makers (tsuba-shi). excitement with you, the readers. I also hope this feature promotes Tachi the advancement of the machine (Haito: on the hip) processing industry in Japan and in a world that is becoming Shingane (Soft material) increasingly globalized.

Uchigatana Kawagane Yutaka Nada, Chief Editor (Hard material) (Taito: placed in a belt) Your Global Craftsman Studio Vol.4 Editing and Issuing Department: Business Strategy Department, (4) Iwaku – One of the (5) How to become a (6) Purchasing a Japanese sword? Advanced Materials & Tools attractions of Japanese swordsmith Company, Swords Mitsubishi Materials Corporation Becoming a Japanese swordsmith takes five Japanese swords are sold at sword and antique It is also interesting to learn the legends related to ten years studying under a master and stores. A Japanese sword certified as a work of to each sword. For example, a famous Japanese passing an examination given by the Japanese art can be purchased by anyone. These are for Reproduction of any of the content sword called douji-kiriyasu-tsuna is said to have Agency for Cultural Affairs. There are currently display only, however, because carrying one in in this pamphlet, including text cut the head off an ogre. Heshikiri-hasebe is approximately 350 licensed swordsmiths in a public place or removing it from its scabbard and photos is strictly prohibited. said to have been owned by famous warlord Oda Jwapan. Each licensed swordsmith is limited to are strictly prohibited. MIRACLE described in this pamphlet Nobunaga. Nikkari aoe is said to have been so producing 24 swords per year to maintain the is a registered trademark of sharp it even killed a ghost. high standard of quality. Mitsubishi Materials Corporation.

Photos are provided by the All Japan Swordsmith Association/ TV-Setouchi Create, Co., Ltd./ Bizen Osafune Japanese YOURYOUR GLOBAL GLOBAL CRAFTSMAN CRAFTSMAN STUDIO STUDIO 30 Sword Museum YOUR GLOBAL CRAFTSMAN STUDIO 004 Mitsubishi Materials | Advanced Materials & Tools Company

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EXP-16-E012 31 YOUR GLOBAL CRAFTSMAN STUDIO 2017.4DS Printed in Japan EK(1.1C)