Manufacturing Process

A reliable integrated system that realizes high quality and lower cost. We develop all manufacturing processes under strict quality controls.

To provide high quality gears in a sort lead-time at lower cost, we have always made every effort to establish an automated and integrated production system for the complete production process. We will continue to improve our production process to meet the more diversified and sophisticated needs of our customers.

「Typical manufacturing process for pinion gear」

1 Cutting process
The most suitable materials are selected from production methods such as round bar cutting and drilling, cold forging and hot forging, as well as from application and cost. Normally, for pinion gears, the material is produced through round bar cutting.
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2 Lathe Turning Process
In order to implement continuous improvement activities based on the company policy,we have established important matters to be implemented, as well as targets, with which we are proceeding strategically.
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3 Gear Cutting Process
Various pinion gears are made by hobbing, shaper and rolling machines before heat treat-ment. By using a special hobbing machine developed by Nakamura we can cut high helical gears easily and speedily.
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4 Finishing Process Before Heat Treatment
The tooth surface of a pinion gear is finished by gear shaving or using a rolling machine before heat treatment. The chamfering and trimming processes are usual preceded by the finishing process.
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5 Surface Treatning Process
Surface hardening such as carburizing, nitriding and high-frequency quenching is done to increase gear strength. Shot peening is added if needed.
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6 Finishing Process After Surface Traetment
外The roughness and accuracy of the gear is improved by external and internal grinding and at the edge of the product.
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7 Gear Contact Inspection Process
Burrs, dents and flaws of gears are inspected by special gearing test machines.

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「 Production control based T.P.S methods 」

Production controls on our lines are performed using Kanban and Andon methods.Kanban is used to inform if there is a delay in the production process or if it has advanced. Andon informs operators of the current status of the production system. Kanban is divided into three types: Supplier Kanban, Intra-process Withdrawal Kanban and Withdrawal Kanban.”Kanban” is a sign to give instruction for production or conveyance of items.”Andon” is an electric light board used as a visual control
device in a plant.

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