仁張工作所 Product Lineup

Recently, our company has been increasingly involved in work related to control panels (boxes) such as distribution boards, sub-distribution boards, and switch boxes. The basic structure typically consists of box-shaped products made from SECC material (zinc-coated steel plate) weighing 1.6t or 2.3t, which are finished with paint and feature stud bolts and various shaped hole processing. One of the key points is our efforts to accurately and quickly produce components like stud bolts and cell spacers. The manufacturing lots are diverse, ranging from about 1 to 100 units. This time, the assembly team members processed a large lot of control boxes while breaking down the steps of the process.

• Contract manufacturing

We specialize in the welding assembly of stainless steel lockers, chemical storage cabinets, and storage units. While peeling off the surface protection vinyl sheet only from the welding areas, we assemble the boxes using a highly flexible table spot welding machine. Our team achieves high productivity by flowing the main body, doors, and other components together. In the previous machining process, the use of laser perimeter cutting and network bending machines has improved dimensional accuracy, making the welding assembly easier.

• Contract manufacturing

By modeling the main body with curved lines using 3D design and unfolding it for sheet metal, the optimal layout for material cutting is determined. After being accurately cut by laser, it proceeds to bending and welding processes. In the welding assembly process, we selected the most suitable methods such as CO2 welding, argon welding, and spot welding, and organized a team of about five people to streamline the line.

• Contract manufacturing

Our company has been manufacturing original delivery locker enclosures, doors, and covers for building hardware manufacturers. With the expansion of online shopping, there has been an increase in customers considering the introduction of delivery boxes that allow packages to be dropped off even when the recipient is not home, in order to address the severe labor shortage in the transportation industry. As a result, the frequency of manufacturing has also increased. By dividing the welding processes for the main body, doors, and parts of different sizes among various teams, we are improving productivity.

• Contract manufacturing

This is a welding operation for a vertical large stainless steel tank. The design is focused on ensuring adhesion from the method of unfolding the sheet metal. The bending accuracy after laser cutting is also an important factor that affects the quality of the subsequent welding process. Argon welding of thin stainless steel sheets is a delicate task, and our company is actively working on the transfer of skills from veteran employees to younger employees.

• Contract manufacturing

Our company mainly engages in the sheet metal processing of catalog OEM products and original lockers. Among these, we have expertise in processing valuable item lockers with multiple compartments, which reach their production peak every year at the end of March. For larger types of products, we utilize table spot welding machines and assemble them with two people.

• Office furniture

The photo shows the assembly of the upper storage unit (slide shelf) of the wall-mounted storage unit. It is designed to be convenient, with a structure that allows the storage unit to come down for easy access, even for women. In the finishing department, we conduct appearance checks after painting and perform assembly work based on work instructions. For products with such movements, we ensure that operational checks and other inspections are thoroughly conducted before proceeding with packaging and preparing for shipment.

• Office furniture

One of the features of our painting line is the "rich variety of colors." In recent office and steel furniture, there are many products with vibrant colors, and our consistent in-house production allows us to maintain an advantage in both quality and delivery times through flexible responses. In particular, for items such as drawers, open cabinets, and multiple locker units, we provide products tailored to your needs based on our years of accumulated technical know-how.

• Processing Contract

Our company has been involved in the production of numerous mass lockers for many years and possesses the appropriate equipment and processing know-how for their manufacturing. For assembling large enclosures, spot welding processes such as table spot, foot-operated spot, and multi-axis my spot are effective, and by having multiple welders work as a team, we achieve high productivity. We have two table spot welding machines suitable for assembling large enclosures at both our headquarters factory and Sanwa factory.

• Contract manufacturing

Our company is capable of a wide range of welding processes tailored to various applications. The laser welding shown in the photo is a method suitable for continuous welding of curves, and we use it for surface doors of equipment unit doors and design posts. Among our welding members, through training, many have now become proficient in using this technique. In the future, we plan to adopt it for welding assemblies such as toolboxes.

• Contract manufacturing

We are currently welding and assembling stainless steel enclosures designed for outdoor use, which incorporate precision electronic equipment. In the sheet metal layout, we have implemented door and gutter structures to prevent rainwater from entering. During welding, we take measures using wood to prevent warping. By effectively applying putty treatment during the painting process after welding, we maintain performance. Our company manufactures sheet metal products such as HUB-BOXes and control units.

• Contract manufacturing

We are assembling large heavy cabinets in lots of about 50 using CO2 welding. By skillfully combining sheet metal components, welding reinforcement parts, and adding bending processes, we can achieve both precision and strength. This is an example of an OEM product we were involved in from the drawing creation stage, after hearing from the customer about the weight and purpose of the items to be stored.

• Contract manufacturing

Recently, we have been receiving many requests for rounded cabinets and machine covers due to a trend that emphasizes design. Our company considers the sheet metal unfolding in the design process and pays attention to the bending process and welding methods, making it possible to commercialize design-focused enclosures. The photo shows the assembly welding and finishing scene of an enclosure with an oval R structure.

• Contract manufacturing

We will continuously assemble large steel enclosures with a thickness of around 1 millimeter. By dividing the process into three parts—highly flexible table spot welding, CO2 welding, and argon welding—and effectively allocating personnel, we can create a more efficient assembly line. The team can be flexibly organized based on the number of units (lots) and the members available that day. In some cases, using welding robots or laser (YAG) welding machines can further promote processing efficiency and lead to faster production.

• Contract manufacturing

50% of the main clients at the Renzo Work Office are supplier jobs. Unlike made-to-order production, we set appropriate LOTs in-house and produce and ship according to orders. Each product is assigned an order number, and when storing inventory, we clearly indicate the order number, product model number, and product name for each item to prevent shipping errors.

• Contract manufacturing

Our company produces about 100 units of control boxes and switch boxes daily, each with different sizes, opening positions, and colors. After the machine NC and laser processing steps, which eliminate manual labor, the products inevitably go through processes that require human intervention. However, we implement various strategies here to enhance productivity and achieve zero mistakes. For example, in the welding assembly process shown in the photo, four workers break down the tasks as much as possible and assign responsibilities, which helps eliminate missed welds and achieve high productivity. The length of the free conveyor is also optimized according to the quantity and personnel arrangement for that day.

• Contract manufacturing

This is a lightweight cart that is manufactured in units of 100 on a regular basis. It features a stylish design. While there are some processes, such as bending pipe curves, that cannot be handled in-house, we collaborate with external processing partners. We utilize jigs (gauges) to achieve precise welding assembly. The optimal assembly methods, such as spot welding, argon welding, and CO2 welding, are selected.

• Contract manufacturing

In our company, we often process thin steel plates by welding them into box shapes, where a highly flexible table spot welding machine plays a significant role. Even for cabinets with arc-shaped designs like the one in the photo, we can carry out assembly work as desired by using this welding machine. We have modified the equipment to make it easier for us to process, and on a large flat surface, two (or sometimes three) people work together to achieve high productivity.

• Contract manufacturing

We are robot welding the front doors of 500 weight cabinets. Considering the time for setup and other factors, we have achieved approximately a 50% reduction in labor. The welding assembly team can focus on the main body of the cabinets, which greatly contributes to increased productivity. In the future, we expect further productivity improvements by increasing the number of products and parts that can be robot welded each month.

• Welding robot

Our company has traditionally been a manufacturing manufacturer specializing in custom-made steel furniture, office lockers, cabinets, and similar products. Due to industry trends, the number of large customers has been decreasing year by year; however, during the end of the fiscal year, particularly from February to April, especially in March, we often receive large orders for such lockers and cabinets. This special type of cabinet is a product that has been continuously ordered by banks and companies for many years. We continuously produce thin steel plates of about 0.8 to 1.0 tons using spot welding and CO2 welding.

• Office furniture

This is a scene of painting large outdoor panels. To maintain rust resistance, we perform acrylic resin baked coating. We may also carry out powder coating and polyurethane resin dry coating. To prevent rust, not only the paint (coating) but also the material of the substrate significantly affects the outcome, so we make it a point to inquire about the material and coating methods when receiving requests.

• Contract manufacturing

Our company has been manufacturing various fixtures related to post offices for many years. We have produced a wide range of steel products designed for usability, including various sorting shelves and mail storage boxes used in regular post offices, as well as counters and drawers in specific post offices. Currently, the "Stamp Storage Box," which is used in post offices nationwide, is one of our representative products. It features a structure that takes into account the usability for postal workers and has been loved for a long time.

• Contract manufacturing
• Mechanical Design
• Processing Contract

We are currently welding and assembling box-type fixtures that will be installed in convenience stores. This includes various types of steel furniture such as those around the cash register, loading areas, and restrooms. We have previously worked on steel fixtures for cash registers and counters in supermarkets and similar establishments. The structure is similar to lockers and cabinets, making it suitable for our equipment. We assemble in batches of 30, 50, or 100 units. The process proceeds in the following order: NC cutting → bending → spot welding and CO2 welding → finishing with a grinder.

• Contract manufacturing

At our headquarters factory, which has two combined processing machines (laser and turret punch), we are currently implementing efforts to produce more efficiently through innovative nesting. By constructing diagrams between the combined machines, we expect to significantly enhance the effectiveness of our operations. With the involvement of the design department, we can categorize sheet thickness and create assemblies, and we will aim for production rationalization by working on lot production tailored to personnel and equipment.

• Contract manufacturing

The work in the field known as architectural sheet metal, which I had little experience with until now, has recently increased, particularly with products and parts that have a high architectural sheet metal element, such as ducts in factory manufacturing lines. The photo shows a scene where we are welding pieces that are over 2mm thick and more than 2 meters long, using various techniques to join them together. At first, I struggled due to my lack of familiarity, but now I have become skilled at handling it.

• Contract manufacturing

This is an assembly scene in the unit storage. When flowing in lots, high productivity can be achieved by forming a line with the finishing group members and breaking down the tasks. The key point is how to optimize the line and personnel during work instructions. This time, since it involved small units and there were many detailed tasks such as door installation and screw tightening, the work was carried out on the second floor of the headquarters, mainly by female staff.

• Contract manufacturing

We are currently assembling large heavy cabinets. For the cabinet enclosures, after the appearance inspection following painting, we perform tasks such as attaching hardware and adjusting doors. This time, we lined up about 40 units and proceeded with the work efficiently. We handled everything from assembly, inspection, packaging, to shipping.

• Contract manufacturing

We are engaged in the welding assembly of sheet metal components such as complex-shaped desktop monitors and speaker enclosures. The processed parts are intricate, and we are making efforts to achieve high productivity by utilizing kit assembly and line work at the component level. Our company often produces products and units in lots of around 50 to 100 units, and we frequently develop strategies while meticulously considering the flow, equipment, and personnel arrangements.

• Contract manufacturing

We manufacture various types of control panels and distribution board enclosures. Recently, there has been an increase in requests for outdoor panels such as those for solar power generation and energy storage, leading to larger production lots. In welding assembly, we operate in a line production manner with a team of about five people. By dividing responsibilities and processing equipment for the main body, doors, and components, we effectively distribute tasks to improve productivity.

• Contract manufacturing

The photo shows a continuous assembly line for the outer panels of devices and machines. In our company, we proceed with the processes in the order of punching (laser, turret punch) → bending → welding assembly. The welding line for the panels utilizes suitable free conveyors and involves multiple workers sharing the tasks to keep the flow going. This approach clarifies the division of processing responsibilities, making it easier to ensure productivity and stable quality. In this job, we ensure the reliability of the welding by tapping it with a hammer after welding to confirm its validity.

• Contract manufacturing

The laser processing machine owned by Renzo Works is a two-dimensional laser processing machine. It is equipment capable of processing along the XY axes, allowing for the drawing of free lines and curves on a smooth flat plate and cutting out shapes freely. On the other hand, there are three-dimensional laser processing machines in the world, which are capable of cutting out free shapes from three-dimensional objects. One of our strengths is that we can address challenges that we cannot handle alone by leveraging the inter-company network of "Monozukuri Town Higashi-Osaka," which has built a history of over half a century.

• Other processing machines

We are engaged in the integrated production of large boxes made of stainless steel. We specialize in the procurement and processing of hairline materials and 2B materials such as SUS304 and SUS430. The photo shows the production of a stainless steel chemical storage cabinet.

• Contract manufacturing

We powder coat FA boxes of various sizes and structures every day. By improving the hangers to prevent dust accumulation and continuously enhancing the hanging methods, we strive to maintain quality and improve productivity. We also have multiple paint colors and implement measures for labeling and identification to prevent mistakes. In the early stages, we faced various challenges, but now we have made progress in standardization and other areas.

• Contract manufacturing

It seems that a meeting is being held in the conference room to discuss the production of a new product. The technical department is reflecting customer requirements from sales into production instruction documents such as drawings, and this is the phase where those are communicated to procurement and manufacturing. In this meeting, the topic was how to effectively develop and weld three-dimensional R curves (surfaces), and we struggled to find a solution. This meeting, where design and manufacturing consider product realization, plays an important role in maintaining the quality system.

• Mechanical Design

At Ren Zhang Works, we have a painting line located within the main factory (3FL and 4FL). The completed sheet metal products, which have undergone machining on the 1st floor and welding assembly on the 2nd floor, are transported to the 3rd floor via an elevator, where they go through a process known as "degreasing" before painting. For items that can be suspended and conveyed on the line, they undergo a phosphate treatment on a conveyor line known as the Parker treatment line. For large lockers, careful wiping with thinner ensures the reliability of the subsequent painting process.

• Contract manufacturing

We will manufacture the welding assembly of housings for precision equipment in lots of 30 to 50 units. The cutting process mainly uses a laser processing machine, ensuring greater accuracy in bending and welding assembly. Our assembly process is characterized by achieving high productivity by flowing in teams for medium-sized lots. This product also falls into a difficult category due to the large number of components and the required precision, but through repeated production, we have now achieved smooth flow through standardization and continuous improvements in processing.

• Contract manufacturing

The work related to control panels (boxes) has been increasing. Among them, particularly in the field of solar power generation, there are many jobs, often processing large lots of around 100 units. We perform outline cutting with lasers, bend them with a bender, and then the welding process is carried out all at once by a team of 7 to 8 people. In the stud welding process, which is typical for control panels, we maintain quality stability by using automated machines. In the assembly process, we are continuously working on improving productivity by refining the line setup and personnel allocation on a daily basis.

• Contract manufacturing

Using a highly flexible table spot welding machine suitable for assembling the main body of lockers, we rationally assemble lockers of various shapes and sizes. Since our founding, we have been skilled in the manufacturing of box-shaped sheet metal products, and we produce lockers as custom-made and original products. For valuable item lockers, changing room lockers, design lockers, etc., we skillfully combine table spot welding and argon welding to achieve high-quality products. Our know-how in manufacturing the main body and doors has been accumulated over many years, and by integrating line production and cell production, we enhance quality and productivity.

• Contract manufacturing

Our company possesses various welding equipment to select welding methods according to the application. An example is a toolbox that undergoes laser welding after spot welding, achieving both strength and sealing. Since conventional spot welding alone could not meet customer requirements to completely prevent water intrusion from the outside, this case was proposed and prototyped, leading to successful mass production.

• Contract manufacturing

By welding and assembling multiple types of materials, we can achieve both application realization and increased strength. In outdoor boxes designed for security purposes, we have successfully improved product quality by effectively combining materials such as steel and stainless steel (304, 420J2). By selecting the appropriate welding machine according to the application and ensuring that operators acquire the necessary skills, we can achieve a wide range of welding assemblies.

• Contract manufacturing

This is the assembly process of our original product, the "valuable item locker." We handle all processes in-house. Not only for standard products but also for custom-made items, we ensure quality manufacturing. In the final finishing process, we check the product quality based on production instruction documents such as drawings and parts lists before shipping.

• Contract manufacturing

In line with the construction, we respond in a semi-customized manner, and it is often the case that specifications change gradually, so we add design and deployment each time. As shown in the photo, in the welding assembly, by skillfully using jigs and dividing tasks among multiple members, we can not only improve productivity but also reduce variations in quality. We carry out tasks in stages, including temporary welding, main welding, and finishing work.

• Contract manufacturing

Our company conducts sheet metal processing for various box enclosures tailored to specific applications. This includes not only enclosures for control panels but also boxes associated with machinery, FA switch boxes, and enclosures for scientific instruments, among others, with a wide range of uses and purposes. The key to efficiently managing relatively small production units (lots) lies in personnel allocation and the selection of equipment. Our assembly department is systematically working on improving QCD through flexible personnel shifts and a rich lineup of equipment.

• Contract manufacturing

We are currently welding a 1.6 mm thick housing cover. It is required to achieve high precision in the butt joint of the circular part without any leaks. At our company, we primarily use argon welding, while also combining other welding methods to ensure a secure bond. Just like in-house processes, the management of external suppliers (stamped components) is also managed through a centralized production management system.

• Contract manufacturing

The photo shows the welding assembly of large panels for amusement equipment. We select the optimal welding method that meets the required functions, such as arc welding, spot welding, and argon welding, while processing. Our company specializes in manufacturing sheet metal units for panels and enclosures using thin steel plates. We produce approximately 100 large panels, around 1800×800 in size, in team production. The process progresses from the punching stage with a multifunction machine to the bending stage and then to the welding assembly, after which it moves on to the painting stage.

• Contract manufacturing