Introduction to Sheet Metal Processing Technology: Zero Mistake Identification Management Using Images
The trend of producing a variety of products in small quantities is a challenge faced by many sheet metal factories. We will introduce our efforts towards the identification management and efficiency of punched parts.
To accommodate the diversification and reduction of production quantities, the identification management and efficiency improvement of extracted parts have become significant challenges in the manufacturing field. We have jointly developed a system linked to a centralized system and associated equipment.
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basic information
Since our founding, we have primarily been involved in the design and manufacturing of box-type enclosures such as lockers and steel furniture. The five basic processes are: punching → bending → welding → painting → finishing. There are joining processes such as "welding" and "screwing/riveting," and there are cases where processing is completed at stages like "only punching" or "up to bending," which naturally leads to a decrease in the so-called "number of parts" as we move downstream in the process. In other words, it is obvious that the punching process has the highest number of parts. On the other hand, processing instructions for the processes are issued through a centralized production management system in the form of parallel "work instructions" and accompanying "work tickets," resulting in an enormous number of daily forms. This trend is not only seen in box-type sheet metal but also in precision sheet metal parts, which have seen an increase in weight, leading to a current situation where there are as many as 400,000 parts annually due to the diversification into small quantities (long tail).
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Applications/Examples of results
One of the pillars of our business is the provision of suppliers, specifically precision sheet metal parts. Recently, the identification of blanks after completion (commonly known as sorting after punching) has become a significant challenge. Inspired by hints from trade shows, we developed a device in collaboration with a certain vendor that uses camera image recognition to identify parts from the punched sheet metal. By integrating with back data, we can now issue real-time labels that print necessary information such as our LOT number and subsequent processes, making it a device we can proudly present to the world. Moving forward, we aim to enhance this system further and are exploring more advanced identification methods that can be implemented for shipping inspections and identification after the BEND process, achieving identification at a 3D level.
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Company information
Since our establishment in 1964, we have been designing and manufacturing custom lockers, office furniture, and steel furniture for over half a century. We excel in collaborating with customers from the design stage, providing products through OEM and ODM, and creating made-to-order lockers. Our strengths lie in our extensive design know-how and processing achievements, allowing us to achieve consistent production and completion in-house due to our knowledge of sheet metal and abundant equipment. The original lockers developed from our experience vary widely and possess unique characteristics that differ from other companies' catalog products, including usability, durability, and design. Our unique product range, including valuable item lockers, smart lockers, sports lockers, work lockers, and mailboxes, is a confident creation that aggregates feedback from our customers. We can provide not only standard products but also customized made-to-order items in various sizes and colors quickly and at low prices, thanks to our in-house design, sheet metal processing, painting, assembly, and production system, along with our quality assurance system. Additionally, our production management system and the manufacturing network in Higashi-Osaka enable us to realize products that include components beyond sheet metal. By becoming your partner with our ISO-certified management system, we can assist in product development and sales expansion.