佐藤電機製作所 List of Products and Services

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.

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.

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.

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.

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.

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.*

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.

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.

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.

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.

We would like to introduce a case where cost reduction was achieved by switching from welded nuts to rivets. A designer consulted us, saying, "The drawings indicate welded nuts, but is there a more efficient method?" After a detailed analysis of the strength and functionality required for the product, we found that changing from welded nuts to rivets would not pose any quality issues. Therefore, we proposed a change to the riveting method, which would reduce the welding process itself. [Case Overview] ■ Before - It was believed that there was room for improvement in the man-hours and costs associated with the welding process using the current welded nut method. ■ After - The elimination of the welding process led to a reduction in man-hours and achieved cost reduction. - Since the consultation was from the design stage, a smooth specification change was made possible. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where cost reduction was achieved by converting a welded structure to riveted joints. We received a request to manufacture a housing used in semiconductor manufacturing equipment, which was entirely welded together, resulting in high costs and long lead times. Therefore, we were consulted on whether there was a way to reduce costs and shorten the lead time from the design stage. We proposed a design that changed most of the welded joints to rivets. This not only led to a reduction in manufacturing costs and shortened lead times but also stabilized the quality. [Case Summary] ■Before - Consultation on whether there was a way to reduce costs and shorten lead times from the design stage. ■After - Proposed a design that changed most of the welded joints to rivets. - Achieved a reduction in manufacturing costs and shortened lead times, while also stabilizing quality. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where color-coated steel sheets were adopted, and the painting process was shortened. The painting process can be costly, so we received inquiries about reviewing it from the design stage to find ways to reduce costs. By eliminating the painting process, we achieved cost reduction and were able to provide stable delivery times and quality. 【Case Overview】 ■Before - In the production of covers for industrial computers, painting was necessary in the finishing process. ■After - By eliminating the painting process, we achieved cost reduction and were able to provide stable delivery times and quality. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we adopted galvanized steel sheets (black ZAM) and shortened the painting process. In a request for the production of battery-related products, painting was required in the final process, but the client wanted to reduce costs as much as possible and consulted us from the design stage. Thanks to our proposal to switch to black ZAM material, painting became unnecessary, achieving cost reduction. Additionally, we were able to shorten the process, satisfying the customer. 【Case Overview】 ■Before - Painting was necessary in the final process, but cost reduction was desired. ■After - Painting became unnecessary, achieving cost reduction. - The process was also shortened. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we eliminated the need for deburring processes through our unique laser processing condition settings. We were processing stainless steel using laser processing, but the customer was handling deburring, which was taking both time and cost, leading them to consult us. As a result, we were able to configure our laser processing equipment and conditions to prevent burrs from occurring after processing. This achieved a reduction in both processing time and costs. 【Case Overview】 ■Before - The customer was handling deburring, which was taking both time and cost. ■After - Through our unique settings and processing conditions for the laser processing equipment, we were able to prevent burrs from occurring after processing. - Achieved reduction in processing time and costs. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where the chamfering process was automated with machinery, achieving stabilization of quality. In sheet metal processing, there are often times when chamfering of corners and edges is necessary. However, performing chamfering in the usual way can lead to increased time and costs due to manual processing. Therefore, our company proposed to carry out chamfering with machinery and implemented automation. We used a mold that creates a tapered cutting surface, and after processing, it was completed with laser machining. 【Case Overview】 ■Before - Performing chamfering in the usual way incurs time and costs due to manual processing. ■After - We proposed to carry out chamfering with machinery and implemented automation. - There were no instances of forgetting to chamfer, which also contributed to the stabilization of quality. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where cost reduction was achieved by printing silk screen using a laser marker. Traditionally, silk screen printing was outsourced, which resulted in high costs. Additionally, the quality of the silk screen printing itself was not stable, and since plates were used, the transfer positions were limited. Therefore, we introduced machinery in-house and performed printing with a laser marker. By using a laser marker, we improved quality stability and eliminated the need for the plates that were necessary for silk screen printing. 【Case Overview】 ■Before - Silk screen printing was outsourced, leading to high costs. - The quality of the silk screen printing itself was not stable, and since plates were used, the transfer positions were limited. ■After - By in-sourcing the marker work in-house, we achieved cost reduction. - Quality stability improved, and the need for plates was eliminated. *For more details, please download the PDF or feel free to contact us.

Here is an example of the production of a layered-type fixture. Welding fixtures are necessary to securely fix the base material in a designated position and achieve accurate and reliable welding, but outsourcing made the costs high. By producing layered-type welding fixtures in-house, we achieved quality stability and shortened delivery times without incurring additional costs. 【Case Summary】 ■Before - The cost of welding fixtures was high due to outsourcing. ■After - By producing in-house, we achieved quality stability and shortened delivery times without incurring additional costs. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where changing the R part of sheet metal to a corner part has achieved improved adhesion and cost reduction. In sheet metal processing, when the corner attachment part is both R and corner, the labor required for filling holes has been a cause of increased costs. By making design changes, we not only reduced processing labor but also achieved higher adhesion during production. 【Case Overview】 ■Before - When the corner attachment part is both R and corner, the labor required for filling holes has been a cause of increased costs. ■After - The design was changed so that the R part became a corner part. - In addition to reducing processing labor, we also achieved higher adhesion during production. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a VA/VE case study for outdoor cabinets. Regarding the outdoor cabinets used for gasoline station payment machines, there was a need for cost reduction, shortened lead times, and conductivity due to the internal equipment emitting radio waves. To shorten the painting process after sheet metal processing, we proposed the use of pre-painted steel sheets called "View Coat." This eliminated the need for the painting process, resulting in a potential cost reduction of up to 30% and a shortened lead time. 【Case Overview】 ■Before - There was a need for cost reduction, shortened lead times, and conductivity for outdoor cabinets. ■After - The use of View Coat eliminated the previously essential painting process. - Achieved a cost reduction of up to 30% and shortened lead times. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where the transition from semi-automatic welding to riveting simultaneously improved quality and cost. In products assembled using semi-automatic welding, dimensional stability was affected by thermal influences during assembly and welding, leading to variations in quality. We proposed a change to a method of fastening with rivets, completely eliminating the welding process. By strictly managing the positional accuracy of the holes in each component required for riveting, we were able to stabilize dimensional accuracy. 【Case Overview】 ■Before - Dimensional stability was affected by thermal influences during assembly and welding, resulting in variations in quality. ■After - Dimensional accuracy of the product stabilized, leading to improved quality. - The reduction of the welding process also contributed to cost reduction through decreased man-hours. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case study that achieved cost reduction by changing from welding studs to the riveting method. Previously, we used welding studs (stud welding), but the welding process required specialized equipment and skilled workers, which posed challenges in terms of production lead time and costs. We carefully examined the strength and specifications required for the product. As a result, we found that switching to riveting would not cause any issues, and it would lead to cost reduction through reduced man-hours and a decrease in defects occurring during welding, so we decided to make the change. [Case Overview] ■Before - The welding process required specialized equipment and skilled workers, which posed challenges in terms of production lead time and costs. ■After - Switching to riveting posed no issues and led to cost reduction through reduced man-hours and a decrease in defects occurring during welding. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where clarifying the processing areas through laser marking has reduced defects. In the joining of parts and part processing, mistakes during processing and joining can inevitably occur. Our company eliminates errors and forgotten processes by marking the processing and joining areas with a laser. As a result, we have achieved a good product rate of 99.4%. [Case Overview] - By marking the processing and joining areas with a laser, we eliminate errors and forgotten processes. - We have achieved a good product rate of 99.4%. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a VA/VE case study for a hinge positioning jig. Typically, the spot welding position of the hinge tends to shift, requiring about 20 minutes for correction work. Based on improvement suggestions from on-site workers, we changed the structure of the jig to be more precise and made the side claws longer, ensuring that the jig itself does not shift. As a result, we have redesigned the jig to eliminate the need for corrections. [Case Overview] ■Before - The spot welding position of the hinge tended to shift, taking about 20 minutes for correction work. ■After - Changed the structure to be more precise and made the side claws longer, ensuring that the jig itself does not shift. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a VA/VE case study of a positioning jig for sheet metal parts. In areas where the sheet metal parts needed to be perpendicular to the counterpart parts, they would slip underneath, leading to misalignment of the welding position and resulting in defects. Based on improvement suggestions from on-site workers, we created a jig with chamfered corners that clamps onto the counterpart parts, which helped prevent scratches during jig use and improved positioning accuracy. 【Case Overview】 ■Before - In areas where the sheet metal parts needed to be perpendicular to the counterpart parts, they would slip underneath, leading to misalignment of the welding position and resulting in defects. ■After - A jig with chamfered corners that clamps onto the counterpart parts was created. - This helped prevent scratches during jig use and improved positioning accuracy. *For more details, please download the PDF or feel free to contact us.

This document is a handbook on the basics of sheet metal parts and enclosure design for product development and designers, as well as VA/VE cost reduction techniques. It includes "Basic Knowledge of Enclosures and Sheet Metal Processing," which introduces the types of knowledge necessary for designing sheet metal enclosures. Additionally, summaries are provided for each section, making it a user-friendly resource. We encourage you to read it. 【Contents (Excerpt)】 ■ Basic Knowledge of Enclosures and Sheet Metal Processing ■ Material Selection for Enclosures ■ Bending Processes ■ Welding and Joining ■ Painting and Surface Treatment of Enclosures *For more details, please download the PDF or feel free to contact us.