JA / EN

Quick response to 10+ year old projects.
Efficiency & technology transfer via unique production management system.

Hachioji Co., Ltd. Cold forging die manufacturing

Yasushi Nishikawa

Prefecture
Aichi
Business Activities
Cold forging die manufacturing
Company Name
Hachioji Co., Ltd.
Representative Name
Yasushi Nishikawa
Location

〒454-0844

9, 1-chome, Haike-cho, Nakagawa-ku, Nagoya-shi, Aichi, Japan

Phone Number
052-398-5535
Website

https://hach-ouji.com/

Factory Stories

Manufacturing High-Strength Dies for Cold Forging

Hachioji Co., Ltd. was founded by Yasushi Nishikawa's grandfather in 1968. Before its founding, the company manufactured forged parts, and leveraging the technology and know-how cultivated there, it embarked on the design and manufacturing of dies for cold forging.
Among dies, those for cold forging are special. Since it's not the processing of metal softened by heat, general dies would quickly break.
To create high-strength dies for cold forging, superhard alloys are used as the material. Processing this hard material requires the use of diamond tools and special electrical discharge machines.
Therefore, even among factories that perform 'die manufacturing,' there are few that can process hard materials for cold forging.

 

And the technology to finish high-hardness dies with high precision is also one of Hachioji's strengths.
“While it wasn't so much at the time of founding, the required precision has increased with the times, and we have adapted to it.”
As automobiles have evolved, the shapes of parts have also become more complex. And multiple processes are required to achieve these complex shapes.
“The more complex the process, the more precision is required for the die, so setting the die clearance becomes crucial.”
Furthermore, to reduce costs, designs that minimize the number of processes are also required.
“I believe the know-how of a die design and manufacturing company lies in determining which process and what shape to use to produce the desired product.” 

Comprehensive Customer Support with Three Sales Representatives

Yasushi joined Hachioji around 2000. When he first joined, he was juggling both on-site work and sales.
Based on that experience, he decided to assign three people to sales positions.
“I believe we have a relatively large number of sales personnel compared to factories of similar size.”
Generally, many companies have the owner also serving as a salesperson, or they adopt a style of contacting clients during delivery.
“In my predecessor's time, sales were not integrated into the company's system. So, we decided to create a dedicated sales position called 'Sales Technical Design'.”

 

As the job title suggests, they are dedicated sales personnel with technical and design knowledge. Just as Yasushi did when he joined, a system was established where sales representatives with knowledge and technical skills engage in proposal-based sales.
“If sales personnel lack knowledge, it ends up being a game of telephone. I think that causes significant stress for customers.”
Hachioji's sales team can provide concrete proposals, advice, and specific manufacturing methods on the spot when consulted by customers.
“I believe all employees must innovate to provide what customers seek. Besides, it's more interesting to create something after thinking about it than just doing what you're told, isn't it?” 

Repeat Orders Are Where Our Strengths Are Most Evident

There are three patterns for new die orders.
The first is a request to manufacture a die exactly to specifications, with the die and process design already completed.
The second is a request where the client designs the manufacturing process, and we are entrusted with the die design.
The third is a request to show the final product and ask us to design the die and process for its manufacturing.
Hachioji can handle any of these three patterns.
However, repeat orders are the most common. And it is in repeat orders that Hachioji's strengths are demonstrated.

 

In the case of automobiles, the model cycle life is about 10 years. Therefore, a certain volume of parts manufacturing takes place for 10 years. When a model change occurs, new parts are manufactured, but even after the model change, the supply of previous parts must continue for 10 years.
“Dies are crucial for supplying parts. Without dies, parts cannot be produced.”
When parts for older models are needed, Hachioji can immediately retrieve processing details from the original drawings and produce the same die, even if the customer has lost the die drawings.

Effects of Our In-House Developed Production Management System

In small and medium-sized factories, there are still cases where production management is done manually using whiteboards and daily reports. However, Hachioji has been conducting computer-based production management since 1989.
“Initially, we used simple file software. My predecessor wasn't good at explaining things to everyone to gain understanding, so I think he used computers, which he liked, to advance internal management.”
Then, in 2000, we launched our in-house developed production management system. This enabled us to manage drawings, processing details, revision history, dimensions, and production quantities all together.
“We improved it based on feedback while using it, and it was largely completed about 10 years ago.”

 

Additionally, we manage completed dies by laser-engraving manufacturing numbers on them.
“If a customer tells us the manufacturing number, we can tell them what year it was made.”
Furthermore, we can also perform production progress management and sales management.
Since the current factory operating rate is immediately known, sales representatives can quickly plan the process from order receipt to delivery.
And because production status can be grasped through figures and graphs, it is also utilized for setting sales targets and leveling the operating rate.

 

“We make information accessible to all employees. Since the data is clearly presented, for example, sales personnel no longer accept orders at excessively low prices that result in no profit.”
By transforming into a corporate structure that consistently generates profit, we can utilize those profits for capital investment and employee training. 

Responsibility to Inherit Authentic Technology

Japanese manufacturing has been supported by small and medium-sized local factories.
“There was a time when people said that if cheap dies from overseas came in, there would be no work in Japan. But in reality, there are fewer and fewer places in Japan that can do manufacturing, and we are in a situation where we have no choice but to rely on overseas.”
That is why Yasushi feels the responsibility to pass on technology and know-how, and to maintain Japanese manufacturing.
To pass on technology, Hachioji ensures that 5% of working hours are dedicated to study. If working 160 hours a month, that calculates to 8 hours for study.

 

Additionally, we have established a technical certification system and a reward system to enable young people to acquire skills with clear goals.
“If manufacturing technology ranges from 1 to 10, the current situation is like immediately learning processing level 5 by using automated machines. However, you cannot truly understand the technology without mastering the basics on general-purpose machines.”

 

In manufacturing sites, automation and unmanned operations are progressing to reduce costs and increase production efficiency.
However, this alone cannot enhance manufacturing technical capabilities. Nor can it develop adaptability or responsiveness.
Hachioji aims to contribute to society not only by providing the manufacturing that customers seek but also by nurturing engineers who have mastered the fundamentals and inheriting authentic technology.