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quality assurance
Monitoring and measurement
other controls		  

Monitoring and measurement
 

"Quality must be built into each process" is our basic concept of quality assurance. We do not send any defects on to the next process.
Products are measured and inspected in each process and the results are monitored according to clearly specified quality standards. Poka-yoke devices and automated measuring machines are set up at an automated line to prevent manufacturing defects. Operators and the quality control department regularly carry out efficient sampling inspections and 100% inspection will be carried out if required.
 
Monitoring by equipment
Our automated production line is usually equipped with automated measuring devices for rectifying product dimensions automatically, a picture processing device for preventing outflow of incomplete products or defects in appearance and various poka-yoke devices. A gear checker machine is equipped in the production line for pinion gears.
Picture processing device   Automated measuring device in NC lathe
Picture processing device   Automated measuring device in NC lathe
Quality inspection in the production line
On production line employees and production line setup personnel check products regularly in accordance with inspection instructions in addition to the measurements for changing controls at setup and the cutter change etc. Using a 'quality check stand' other monitoring is carried out by outside inspection personnel at regular intervals.
Quality check stand   Sampling inspection by operator
Quality check stand   Sampling inspection by operator
Gear accuracy quality assurance
The accuracy of gears and the distortion of dimensions from heat treatment are measured at regular intervals by a specialist inspector in our temperature controlled internal laboratory. The manufacturing conditions and cutter designs are adjusted in relation to these measurements.
NC profile lead & pitch measuring instrument   Inspection by microphotograph
NC profile lead & pitch measuring instrument   Inspection by microphotograph

Other controls
 

Accumulated skills and experience realize the customer's needs. As a specialist gear manu- facturer all aspects of maintenance is taken into consideration.
For providing high quality products continuously, we perform other various controls required as a specialized gear manufacture such as machine maintenance, sharpening & grinding cutters and special handling at delivering and packing．
 
Machine maintenance
Preventive and predictive maintenance for equipment used in the main processes is carried out in accordance with an inspection plan based on our extensive experience. Production tools and replacement parts are stored and controlled efficiently.
Registration of schedule for maintenance   Store for replacement parts controlled by PC
Registration of schedule for maintenance   Store for replacement parts controlled by PC
Sharpening and grinding cutters
In order to keep up with the change in product accuracy efficiently we sharpen hobs, shaper cutters and drills and also grind shaving cutters at our factories.
Saving cutter grinder   Hob cutter sharpener
Saving cutter grinder   Hob cutter sharpener
Special handling
To prevent defects in appearance related to gears such as burrs, dents and flaws, various methods are adopted using container boxes, heat treatment tools among others in addition to One-piece Flow manufacturing supported by automated conveyors.
Packaging design for delivery   Heat treatment tools
Packaging design for delivery   Heat treatment tools
 
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