佐藤電機製作所 List of Products and Services

To achieve R bending while keeping costs down, we will introduce a case where the need for dedicated molds for R bending was eliminated through multiple R bends. In response to requests for R bending processing, it was necessary to have dedicated molds tailored to specific bending radii, which posed a challenge due to the high production costs. Therefore, by performing multiple bending processes without using dedicated molds, we were able to accommodate R bending. Although traces of the R bending remain, we reduced mold production costs and shortened processing time. We provided cost-effective R bending processing that met our customers' needs. With the elimination of the need for molds, investment in processing equipment can also be reduced. This allows for the use of general-purpose equipment, enabling the establishment of a flexible production system. [Challenges] - Dedicated molds tailored to specific bending radii are required for R bending processing requests. - Due to high production costs, we want to achieve R bending while keeping costs down. *For more details, please download the PDF or feel free to contact us.

• Processing Contract

We would like to introduce a case where the use of laminated jigs improved prototype costs and lead times. Previously, we outsourced welding jigs used during welding to other companies, which was a factor in high costs. While jigs are essential for accurate and reliable welding, the outsourcing costs remained a continuous issue. By changing the process to manufacture laminated welding jigs in-house, we achieved stabilization of quality and reduction of lead times without incurring additional costs. We succeeded in improving efficiency and reducing costs through in-house production, thereby enhancing productivity. Our company is working on speeding up processing and reducing costs with laminated welding jigs, eliminating the high costs and long lead times associated with outsourcing traditional jig manufacturing, and enabling immediate response through in-house production. [Challenges] ■ Outsourcing welding jigs used during welding to other companies resulted in high costs. ■ While jigs are essential for accurate and reliable welding, outsourcing costs remained a continuous issue. *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing

We would like to introduce a case where the use of resin molds for prototype production significantly reduced costs and time during the early stages of development. In the case of single-item production and small-lot processing, there are many instances where mold production is necessary, resulting in a combination of mold costs and processing fees that lead to very high costs. In particular, the costs and time associated with molds during the prototype stage have been a significant burden, and improvements have been sought. Therefore, we propose the use of resin molds for prototype production. This approach allows us to reduce mold costs to less than half compared to metal molds. At the same time, we achieved shorter delivery times, enabling flexible responses for prototypes. While there are approaches such as layered molds for prototype molds, we recommend resin molds that can achieve shapes as close as possible to the original mold. [Challenges] ■ The combination of mold costs and processing fees results in very high costs. ■ In particular, the costs and time associated with molds during the prototype stage have been a significant burden, and improvements have been sought. *For more details, please download the PDF or feel free to contact us.

• Resin mold

We would like to introduce a case where we achieved cost-effective domestic production transfer even without drawings. When our customer considered transferring production from overseas to Japan, they faced challenges related to drawing management and information, such as discrepancies in the thickness and material specifications compared to Japanese standards, or the inability to locate the drawings themselves. Even in cases of differences in drawing specifications or when information is unclear, we created the necessary drawings to address the issues. While there may be a temporary increase in costs during the transition from overseas, we managed to suppress cost increases through appropriate design changes and procurement reviews, thereby supporting a smooth domestic transfer. Additionally, by simultaneously reviewing materials and processing methods, we provided proposals to minimize cost increases. [Challenges] - When considering the transfer of production from overseas to Japan, the thickness and material specifications of the drawings differ from those in Japan. - The drawings themselves cannot be found. *For more details, please download the PDF or feel free to contact us.

• Other contract services

We received a request to reduce the cost of rack attachments, and we would like to introduce a case where we proposed a paint-free solution to a customer, as manual powder coating on SPCC and SECC accounted for a large portion of their costs. The challenge was that the long and narrow parts were difficult to automate, leading to rising labor costs due to manual work. To address this, we changed the materials from SPCC and SECC to paint-free materials such as 430KD and 304KD, thereby reducing both the painting process and labor costs. This resulted in significant cost reductions and shortened lead times. [Challenges] - There was a request to reduce the cost of rack attachments, with manual powder coating (melamine) on SPCC and SECC accounting for a large portion of the costs. - The long and narrow parts were difficult to automate, leading to rising labor costs due to manual work. *For more details, please download the PDF or feel free to contact us.*

• Special Steel

We would like to introduce a case where we changed from SUS430 to SUS430KD and achieved cost reduction. When using SUS430 for enclosures and frames with the assumption of painting, the surface finish grade of the material can become excessively high quality, which may increase product costs. Therefore, reducing costs at an appropriate quality level for painting was a challenge. SUS430KD is a non-standard product that omits the surface finishing process, making it less expensive (10-15% reduction in material costs). The adhesion of the paint has also improved, achieving cost reduction without significantly changing the quality. [Case Summary] ■ Challenge - Cost reduction at an appropriate quality level for painting ■ Proposal/Result - Proposed replacing SUS430 with SUS430KD - Improved paint adhesion and achieved cost reduction without significantly changing the quality *For more details, please download the PDF or feel free to contact us.

• Special Steel

We would like to introduce a case where we proposed the painted steel sheet "View Coat" to shorten the painting process after sheet metal processing. The customer required a solution for an outdoor cabinet for gasoline station payment machines that simultaneously addressed cost reduction, lead time shortening, and conductivity for internal equipment's electromagnetic interference. Meeting these multiple requirements was a challenge. Therefore, we selected a type with high corrosion resistance and heat absorption that meets conductivity standards. This eliminated the need for a painting process, achieving a cost reduction of up to 30% and shortening the lead time. 【Case Overview】 ■ Challenges - For an outdoor cabinet for gasoline station payment machines, cost reduction, lead time shortening, and conductivity for internal equipment's electromagnetic interference were required. ■ Proposal/Results - We proposed the painted steel sheet "View Coat" to shorten the painting process after sheet metal processing. - This eliminated the need for a painting process, achieving a cost reduction of up to 30% and shortening the lead time. *For more details, please download the PDF or feel free to contact us.

• Special Steel

We propose a chrome plating-free process that eliminates the chromate plating treatment and introduces a case where the production lead time for parts was shortened by one week. In response to frequent requests for short lead times for semiconductor equipment parts, the conventional chromate plating process extended the lead time. While cost reduction was also a challenge, customers particularly highlighted the shortening of lead times as the most critical issue. By changing from conventional steel materials to black ZAM materials with high corrosion-resistant plating, we were able to shorten lead times and achieve cost reductions of up to 10-20%. Furthermore, the dense plating layer unique to ZAM materials exhibits far superior corrosion resistance compared to conventional hot-dip galvanized steel sheets. [Challenges] ■ The conventional chromate plating process extended lead times in response to frequent requests for short lead times for semiconductor equipment parts. ■ Cost reduction and, in particular, lead time shortening are necessary. *For more details, please download the PDF or feel free to contact us.

• Special Steel
• Other metal materials

In the current situation where the prices of materials such as stainless steel, aluminum, and iron used in precision sheet metal are soaring, we would like to introduce a case where we proposed dual-layer steel plates as an alternative to SUS304 for cost reduction. While SUS304 is excellent, its material cost is high, making the utilization of alternative materials during new product development an important issue for cost reduction. Dual-layer steel plates are less expensive than SUS304 and can enhance strength while reducing weight. They are also adopted in automobiles and industrial machinery, contributing to our customers' cost reduction. Additionally, it is possible to incorporate specific functions that cannot be achieved with a single material, such as improved thermal conductivity. [Challenges] ■ The prices of materials used in precision sheet metal are soaring, with SUS304 increasing by about 7% ■ Cost reduction through the use of alternative materials during new product development *For more details, please download the PDF or feel free to contact us.

• Special Steel
• Other metal materials

We would like to introduce a case where we proposed a material change from SUS304 to SUS443 to customers who are considering a review of SUS304 materials in existing products and new product development. As an urgent issue, the price of stainless steel materials has skyrocketed compared to two years ago, making it necessary to review materials to reduce product costs. SUS443 is generally inexpensive and is characterized by higher corrosion resistance compared to SUS304. It also has low thermal expansion and high thermal conductivity, contributing to cost reduction. [Challenges] - Considering a review of SUS304 materials in existing products and new product development - The price of stainless steel materials has skyrocketed compared to two years ago, making it necessary to review materials to reduce product costs *For more details, please download the PDF or feel free to contact us.

• Special Steel

We would like to introduce the products manufactured and assembled by our company. Starting with the "Bridge Console Housing" made through rivet fastening processing, we also offer the "Flight Planning Operation Desk" and "Mail Sorting Machine" in our lineup. By equipping ourselves with state-of-the-art facilities and establishing a consistent production system, we have achieved ultra-small lot production of a wide variety of products. Leveraging the know-how cultivated in various industries, we are committed to high-quality manufacturing with short delivery times. 【Product Lineup】 ■ Bridge Console Housing ■ Flight Planning Operation Desk ■ Mail Sorting Machine *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Contract manufacturing

We would like to introduce the "infrastructure-related equipment" that we manufacture and assemble. Starting with the "automatic ticket gate exterior parts" processed by fiber laser welding, we also offer "EV charger enclosures" and "disaster prevention wireless enclosures." By equipping ourselves with cutting-edge facilities and establishing a consistent production system, we have achieved ultra-diverse small-lot production. With the know-how cultivated in various industries, we provide high-quality manufacturing with short delivery times. 【Product Lineup】 ■ Automatic ticket gate exterior parts ■ EV charger enclosures ■ Disaster prevention wireless enclosures *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Contract manufacturing

We would like to introduce the "information communication equipment" that we manufacture and assemble. Starting with the "server door" made through spot welding and riveting processes, we also offer a lineup that includes "OCR enclosures" and "industrial computer enclosures." By equipping ourselves with cutting-edge facilities and establishing a consistent production system, we achieve ultra-diverse and low-volume production. Leveraging the know-how cultivated across various industries, we provide high-quality manufacturing with short delivery times. 【Product Lineup】 ■ Server Door ■ OCR Enclosure ■ Industrial Computer Enclosure ■ Storage Enclosure *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Contract manufacturing

We would like to introduce the "semiconductor-related equipment" that we manufacture and assemble. Starting with the "semiconductor inspection equipment housing" created through riveting and assembly processing, we also offer the "semiconductor manufacturing equipment exterior (before painting)" and "semiconductor manufacturing equipment exterior" in our lineup. By equipping ourselves with state-of-the-art facilities and establishing a consistent production system, we achieve ultra-small lot production of a wide variety of products. Leveraging the know-how cultivated in various industries, we deliver high-quality manufacturing with short lead times. 【Product Lineup】 ■ Semiconductor inspection equipment housing ■ Semiconductor manufacturing equipment exterior (before painting) ■ Semiconductor manufacturing equipment exterior *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Contract manufacturing

We would like to introduce the "medical devices" that we manufacture and assemble. Starting with the "ultrasound diagnostic device casing" made through riveting and spot welding processes, we also offer the "sample pretreatment device casing" and the "sample pretreatment device exterior (before painting)" in our lineup. By equipping ourselves with advanced facilities and establishing a consistent production system, we achieve ultra-small lot production of a wide variety of products. With the know-how cultivated in various industries, we provide high-quality manufacturing with short delivery times. 【Product Lineup】 ■ Ultrasound diagnostic device casing ■ Sample pretreatment device casing ■ Sample pretreatment device exterior (before painting) *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract
• Contract manufacturing

We are the official domestic sales agent for Enersys, a manufacturer of industrial storage batteries, and we handle various types of batteries for applications such as metal jacket cyclone batteries, mobile phone base station batteries, and forklift batteries. Additionally, Enersys batteries are used in our storage systems, including the "Portable Power Supply with Built-in Lithium Battery CE2400-1K" and the "Hybrid Storage System." Please feel free to consult us when needed. 【Features of the Portable Power Supply with Built-in Lithium Battery CE2400-1K】 ■ High output of AC100 1KW ■ Equipped with a large-capacity lithium-ion battery ■ Drip-proof structure suitable for outdoor use ■ Usable not only for camping and events but also as an emergency power supply during disasters ■ Rechargeable with a household 100V outlet *For more details, please refer to the PDF materials or feel free to contact us.

• Lithium-ion battery
• Secondary Cells/Batteries

Sato Electric Manufacturing Co., Ltd. supports consistent production from design to assembly through small-lot production of various types using new equipment. By utilizing various subsidies, we have introduced multiple new machines from AMADA. This has enabled us to achieve "ultra-small-lot production of various types," which was previously unimaginable. We will propose cost reductions and realize shorter delivery times by shortening the design process. 【Sales Items】 ■ Sheet Metal Processing Business - Sheet metal pressing and assembly of enclosures, chassis, frames, and covers ■ Battery and Power Supply Sales Business - Batteries, rectifiers, AC/DC, DC/DC *For more details, please download the PDF or feel free to contact us.

• Contract manufacturing
• 3D CAD