Technology and product certification system "Toyota Monozukuri Brand" owned by SMEs and small businesses in Toyota City --Toyota Keizai Shimbun

Provided by: Toyota Manufacturing Brand Promotion Council Produced by: Toyota Keizai Shimbun

Focusing on the excellent technologies and products of small and medium-sized enterprises and small businesses that support this region, which is an "industrial city with advanced technology and production methods cultivated in the automobile industry," those that meet certain standards are " Certified as "Toyoda Manufacturing Brand", we will promote corporate development and employment, improve the manufacturing level and improve the image of the region.

The Chokoji Factory, which is the base of our headquarters, designs and manufactures automobile production equipment. About 20 people belong to the Technical Headquarters. We are working on technological development for the development of new fields by utilizing the technologies cultivated in automobiles by engineers in various fields such as mechanical, electronic, control, and AI.

In the aircraft industry, we are promoting the introduction of lighter aircraft from metal aircraft with carbon-free and ecology in mind, and many aircraft using carbon fiber composite materials (CFRP) are playing an active role. Shinmei Kogyo is working on the utilization of technology in the aviation business, taking on the challenge of new manufacturing based on customer requests and research with universities, and developing the automatic composite material restoration processing device "OMNI-3". I am working on.

Aircraft can be damaged by lightning strikes, hail, stepping stones, and equipment collisions. CFRP is a material that is difficult to process, although it has the characteristics of being lightweight and having high strength. To repair a damaged CFRP machine, after removing the damaged part, it is necessary to process it into a mortar shape so that the contact surface with the repair material becomes large. ) And a lot of time is required.

In order to solve such problems, we have developed "OMNI-3, an automatic composite material restoration processing device" that automates CFRP scarf sanding processing technology that can only be realized by skilled workers with the concept of "anyone, easily and accurately". Start on. We have realized a technology to automatically and quickly process CFRP scratches with high quality (scarf sanding). We are brushing up for practical use.

It is not necessary to prepare the machine shape data (drawings, shape scan) before the copy processing repair work by "Karakuri structure".Achieves automatic machining that follows the shape of the machine

"Pneumatic" device design A safe device design that realizes no electricity in the processing section and does not cause fuel ignition accidents.

Realizing "skilled skill" in a short time After installing the device, anyone can complete the scarf sanding process in a short time by inputting damage information (scratch depth, diameter).

Founded in 1960 with the metal recycling business as a pillar. With the management philosophy of "Challenging recycling and the environment and becoming a company that is well received by society," waste including medical waste is centered on resource recycling such as proper disposal of iron and non-ferrous metals and used automobiles. We are engaged in a wide range of businesses such as incineration and intermediate treatment, rental and maintenance of aerial work platforms and forklifts.

We have established a system to process, sort and manage metal resources of various shapes, properties and components generated from the life cycle of the automobile industry according to recycling applications using our unique technology. In a vacuum dezincification plant, pressed scrap of galvanized steel sheets used in automobiles is heated in a vacuum furnace to sublimate only zinc and separate and recover it. Iron becomes a high-quality cast iron raw material, and the recovered zinc is also circulated in the automobile industry as pure zinc crystals.

Used automobile engine cooling water (LLC) collected from car dealers is detoxified by the action of microorganisms. Treated water is discharged into the Yahagi River system using an environmentally friendly treatment method.

We have a rigid stalker type incinerator (vertical incinerator) for proper incineration of waste, which is the only one in Toyota City. This incinerator can also incinerate infectious industrial waste generated from medical sites that are indispensable to our daily lives. We will contribute to society by properly disposing of medical waste, which is expected to increase due to the aging of the future.

We collect precious metals and rare earths by processing and sorting used small household appliances called "urban mines" on our own line. In Japan, where resources are scarce and most of them are imported from overseas, we are working on the domestic circulation of resources. In the automobile industry, which is undergoing a major transformation such as EV, we will also work on new resource recycling while the materials and raw materials used are changing.

Incineration of industrial waste Installed a solid stalker type incineration that properly incinerates waste discharged from each company and medical infectious industrial waste.

Waste LLC Microbial Decomposition Treatment Plant The engine cooling water (LLC) of used automobiles collected from car dealers is detoxified with the help of microorganisms. The treated water is discharged into the Yahagi River system by an environmentally friendly treatment method.

Used small household appliances, which are also called non-iron recycling urban mines that recover resources from small household appliances, are processed by our own processing and sorting line. We are promoting optimal material recycling for the domestic circulation of resources.

Our company was founded in 1963 and is located in the northern part of Toyota city area, and is one of the few companies in Japan that consistently manufactures silica gel used as a desiccant from raw materials. Approximately 50 employees manufacture safe, secure, and high-performance "Made, In, TOYOTA" silica gel.

Silica gel has a wide range of adsorption properties due to scientific adsorption (adsorption by silanol groups) and physical adsorption (adsorption by capillarity). The structure is a collection of silicon dioxide particles that continuously form fine pores like a mesh.

It acts as a desiccant by adsorbing moisture (water vapor) in these fine pores. It is possible to change the hygroscopicity by changing the pores and particle size of the silica gel. In addition to desiccants for foods and dehumidifying sheets for clothing and bedding, musical instruments such as pianos and trumpets, and metal-based automobiles. It is used for various purposes such as rust prevention of parts.

The newly developed chromatographic silica gel is a material used for liquid chromatography that analyzes and separates chemical substances. In the field of biochemicals such as pharmaceuticals, electronic materials such as component separation / purification materials in liquids Developed for use in fields such as cosmetics, food industry, and precision organic chemistry.

Grafcil, which has been commercialized in response to user requests, is 100 μm (0.1 mm) and 50 μm (0.05 mm) spherical silica gel, and is supported by business partners and the government, regardless of conventional production methods. We have achieved high quality and low cost by developing our own production technology. Furthermore, we have succeeded in producing silica gel for crushing type chromatography, not limited to spherical ones.

Pursuing the possibilities of new silica gel, we will work to create high-value-added products to meet the demand in new fields through the research results so far and joint research in collaboration with industry and academia in Aichi Prefecture.

Although the supply chain is frequently disturbed due to the Korona-ka, our company, which has our own technology, does not need to import from overseas and can provide a stable supply.

We can produce according to the silica gel characteristics required by our customers, and we can also provide samples.

By utilizing ISO9001 and JIS (Japanese Industrial Standards), we are promoting the stability and improvement of quality.

We are engaged in the production and maintenance of Andon, which displays information on line work in automobile factories, the design of avionics control equipment, board manufacturing, and the business of utilizing drones by applying aviation technology. In particular, the drone-related business started development about 10 years ago. We have been working on various technological developments using unmanned aerial vehicles = drones capable of vertical takeoff and landing.

At the time of development, the battery performance was poor and it was not possible to fly for a long time, so we focused on and developed the "wired power supply system for drones" that won the Toyota Monozukuri brand product category this time for long-term flight tests.

By installing our wired power supply system on a commercially available battery-powered drone, it can be converted into a wired drone and enable long-term flight. It is possible to fly the drone for a long time by passing electricity through the electric wire, and the biggest feature is that you can continue to fly the drone while sending electricity, so for example, you can shoot for a long time in sports broadcasts such as marathons and golf, wind power generation and It is used for inspection of large-scale facilities such as bridges and temporary base stations of telecommunications companies. You don't have to have a lot of expensive batteries or spend a lot of charging time.

In addition, by using a composite cable that includes optical fibers, images and control signals can be wired, and if the range is 30 meters or less, it can be flown outside the scope of the Aviation Law, so we are able to develop and sell wired drones. We would like to contribute to society by pouring.

Ideal for long flight at fixed points such as inspection of high places. It does not require charging and can operate even during a power outage. Outdoors, power is supplied by an engine generator or the like.

When mounting heavy equipment or when you want to extend the cable, you can expand the power supply unit for large drones.

It is possible to fly by communicating with a composite cable even in the field where there is radio interference and it is not possible to control with a radio.

We are a company that collects, processes, and reuses metal scrap. It has been 51 years since the company was founded, but even before the terms "SDGs" and "carbon neutral" were used, we have been engaged in the business of recycling resources in consideration of the global environment under the concept of effectively utilizing limited resources. I'm out.

Our main business is to put molten aluminum (melted aluminum) melted at the factory into a pot (AL serve) like a thermos bottle and transport it to automobile makers and parts makers while keeping it warm. It is mainly used in the manufacture of missions and engines. We also manufacture 2.5 kg and 200 grams of aluminum ingots. Aluminum contributes to the weight reduction of automobiles, has the advantages of low melting temperature, easy molding, and easy recycling (90% is recycled).

The award-winning "suspended aluminum ingot charging device" moves an ingot (aluminum bar) molded into a suspended shape from a special box in a suspended state and directly immerses it in the existing hand-held furnace. It is a device to enter.

In many foundry plants, molten aluminum melted in a centralized melting furnace is transported to a holding furnace at hand, but when the production volume fluctuates, the holding time in the melting furnace becomes longer and energy efficiency deteriorates. I have a problem. The solution is to install a melting furnace at hand for each casting machine, but it is difficult to introduce it due to space and cost issues. The "suspended aluminum ingot charging device" developed by our company can convert a hand-held furnace into a hand-melting furnace at low cost and in a small space. By slowly immersing the ingot, dirt entrainment is reduced and molten metal contamination is prevented, and at the same time, the ingot preheating device is not required. Optimal molten metal management and efficient processes can reduce CO2 emissions and provide the required amount of materials at the required time without waste according to the subsequent process. We will contribute to carbon-free manufacturing in Japan through this product.

By adopting a hanging ingot and a special box for vertical insertion, it is possible to insert an ingot with a simple one-finger hand, reducing man-hours for step disassembly and waste products.

A heat source can be installed even in the narrow hot water receiving room of the holding furnace, which saves space and realizes the melting of existing holding furnaces at low cost.

It is easier to respond to fluctuations in production volume and is more energy efficient than holding molten metal in a centralized melting furnace, reducing energy consumption and CO2 emissions.

Our company is a company that originated from Mitsui & Co., Ltd., which was founded by volunteers from the Nagoya branch of Mitsui & Co., Ltd. at the time after the dismantling of the conglomerate after the war. We have been working on making materials used in automobile manufacturing with the origin of "whether hemp bags used for product transportation can be recycled", and have been walking as a manufacturing industry with the origin of recycling and recycling.

"MPS", which won the award in the technical category, is named after the acronym "Mitsuiya Material Pelletize System". Technology that enables recycling into sheet materials. The feature is that it is possible to recycle not only the offcuts generated in our own production process but also the offcuts generated by other companies. The material sheet made by MPS has been well received as a technology that has the same feel and appearance as the conventional ones, and also leads to the increase of added value of environmental protection, and is used in many car models as deck side parts and battery covers. increase.

In addition, as a challenge to seek new value, we are also working on foaming technology, which is not only "low cost" but also "lightweight" and "quietness" that are accelerated by EV, which is the value that we have been particular about. I will pursue it again.

We will promote our activities as a company in line with our sustainable development goals by working to solve problems such as plastic treatment and disposal of industrial waste and thermal recycling beyond the boundaries of companies and industries.

Not only various waste plastic compatible resin materials, but also fiber and non-woven fabric materials can be crushed and granulated and returned to the sheet.

Reduces CO2 emissions by recycling carbon-neutral to non-virgin materials and waste plastic without industrial waste.

Efforts for upcycling We are also working to improve the commercial value by adding new value in order to eliminate the cheapness and badness of recycled products.

Our company was founded in 1978, and with the idea that the current chairman, who is the founder, wants to be a company rooted in the region, we named the company from Mifune-cho, where we were founded, and have continued to grow in the manufacture of automobile parts.

We manufacture various parts of cars by high-mix low-volume production, and we manufacture more than 2,000 kinds of parts. The products we produce are used in all parts of a wide range of vehicles, from passenger cars to minivans to commercial vehicles. In addition, for more than 10 years, we have been working on the realization of processing technology (mold manufacturing) for products that are strong even if the plate thickness is thin, using steel plates that are harder than before, which are called "high tension materials". ..

Products that have been worked on using the processing technology that has received brand certification this time have traditionally been generally cut, and general press processing did not meet that requirement, forcing the continuation of high-cost processing.

Therefore, we have adopted a plate forging technology that achieves both rigidity and low cost and produces parts with the same accuracy as cutting, and established a processing method that combines "cold forging" and "press molding". This technology combines the merits of both processing methods, making it possible to process thick steel sheets with high strength while ensuring high accuracy and high productivity. Higher productivity has been achieved compared to conventional cutting, and by appealing for low cost, it has been diverted to other models and has expanded its sales channels. We position this technology as a technology that leads to seamless (expansion of selection range) of "cutting / forging" in the next generation of metal processing.

"Company strength" = human resources, people (employees) are treasures. Even if we receive a difficult order, I think that the staff will be the driving force in the future as they work together to overcome it. Looking ahead to the period of transformation of the automobile industry, there is a need to improve production technology using non-ferrous metals such as aluminum, stainless steel, and copper, so we believe that internal technological reform is important. We will work to improve the technology that exceeds the expectations of our customers in both mold and parts manufacturing in-house.

The coil material with t = 4.0 mm is thinned to t = 3.8 mm, and the excess meat is transferred to the flange to increase the wall thickness.Uniformly molded the thickened part to achieve t = 5.3 mm

When the excess meat generated by thinning flows into the flanges on both sides, the amount changes depending on the shape of the mold.

Cutting = 100 pieces / hour ⇒Our technology (plate forging) = 3,000 pieces / hour * Processing speed 50spm Productivity increased by 30 times

We manufacture body parts (mainly skeletons) for automobiles that are being prototyped and under development before they are put on the market, and dies necessary for stamping parts. Just like making a waffle or taiyaki, the upper and lower molds are applied to the product, and the pressed parts that are shaped are combined to complete the car body. We manufacture such parts and molds to manufacture them.

The mold is made by cutting the shape one by one with a cutting tool with a drill called a machining center to make the upper mold and the lower mold. Since it is a product that requires know-how, employees are working on mold making while refining their skills every day.

The award this time is a product called "Reversal-kun". Molds that handle hard iron plates are very heavy, but the work of reversing the molds is indispensable for mold manufacturing and maintenance work. Normally, it is necessary to reverse the work using a hoist crane, but crane operation is dangerous and can damage the mold. We have developed "Reversal-kun" as a facility that anyone can easily, safely and securely perform such dangerous reversal work, and that can be introduced at low cost and in a small space. Most of the general reversing machines are expensive and require a large space, but the price is 1/3 of the conventional one, and the space is also compact, making it easy to introduce even in small business establishments.

We will continue to utilize the strengths of in-house development and in-house production to contribute to safe and high-quality mold production and maintenance work with simple operations with products that can flexibly respond to specifications that match the molds handled by our customers. I would like to go.

Safe work with simple operation Eliminates reversing work with a hoist crane and prevents various dangers and accidents! Easy operation with simple buttons! One of the attractions is that you can perform light work such as assembly and adjustment on the equipment!

Space-saving, energy-saving, and low-cost Space-saving by designing according to the mold size to be handled! Energy saving by using only reverse power! Achieves low cost by eliminating waste with a simple mechanism!

Compatible with a wide variety of molds With the slide adjustment function, it is possible to support various mold sizes! The range of movement and depth are as you wish!