This is an introduction to a case study of the machine frame cover made by Mitsuya Co., Ltd. through sheet metal processing.
This case involves a machine cover made solely from steel plates used in sheet metal processing. Initially, it was a product of can manufacturing sheet metal processing that incorporated square pipes and angles as reinforcement materials. However, when welding the corners of the square pipes to the surface of the steel plates, the welding marks on the surface of the steel plates were strongly pulled and distorted due to the welding heat, resulting in significant unevenness. This required a considerable amount of time for finishing work to conceal the welding marks. Therefore, Mitsuya Co., Ltd. proposed changing the components to bent sheet materials that have effects nearly equivalent to square pipes and angles through a value analysis (VA) approach, which reduced distortion and consequently decreased the finishing labor hours. Additionally, while there were initially five different plate thicknesses, the VA proposal narrowed it down to 2.3t and 4.5t, significantly reducing the setup labor hours for mold changes in laser processing and bending operations.
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basic information
This product has a very large number of parts, with 44 components in the manufacturing program and 60 processed parts. Additionally, it is a large product. The manufacturing process involves creating the left and right large covers and the central cover separately, which are then assembled at the end. The task of transporting it from the welding workshop to the shipping area is also quite challenging. Initially, we struggled to determine where to apply pressure, leading to some damage. However, by creatively using plastic pallets, cranes, and forklifts, we have now made it easier to transport. The biggest challenge for this product is its height. With a height of 2,450 mm, it cannot be transported using standard trucks with a van body (with top and bottom wing openings). Therefore, customers pick it up using flatbed trucks and deliver it to the painting contractor. The painting contractor also owns a specialized van body truck, so if the schedule aligns, they will pick it up.
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Applications/Examples of results
Mitsuya Co., Ltd. has been manufacturing a wide variety of metalworking covers, ranging from large machine frame covers to small machine covers, for many years and has a wealth of experience. If you have any issues with machine frame covers, machine covers, or metalworking products, please feel free to consult Mitsuya Co., Ltd.
Company information
We were founded as a company that handles everything from design to installation of safety covers for dedicated work machines in-house. Currently, based on the technology and knowledge cultivated within this field, we provide a wide variety of sheet metal products, can manufacturing products, machined products, painting, and plating in total collaboration with partner companies, in addition to safety covers. Our in-house design utilizes 3D CAD, which has received positive feedback for being easy to understand when we ask customers to confirm specifications. We specialize in small-lot production of various types, and we strive for continuous technical improvement to respond to customer needs, including short delivery times, quality enhancement, and cost reduction through value analysis proposals.