Inherited steel fabrication, new challenges.Venturing into new genres,sharing the fulfillment and joy of manufacturing.
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Mountech Co., Ltd.
- Steel fabrication and sheet metal fabrication business manufacturing switchboard enclosures such as cubicles and frames.
Takeshi Yamada
- Prefecture
- Aichi
- Business Activities
- Steel fabrication and sheet metal fabrication business manufacturing switchboard enclosures such as cubicles and frames.
- Company Name
- Mountech Co., Ltd.
- Representative Name
- Takeshi Yamada
- Location
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〒496-0025
20, Shinmei, Nakaisshiki-cho, Tsushima-shi, Aichi, Japan
- Phone Number
- 0567-32-1781
- Website
Factory Stories
The Origins of Mountech
Mountech Co., Ltd., which specializes in steel fabrication and sheet metal fabrication, is currently led by the third-generation president, Takeshi Yamada.
It was founded in 1948, shortly after the war, by Takeshi's grandfather, Saichi, who was a highly skilled craftsman, and his grandmother, Ayako, who handled sales and other operations, working together.
Saichi reportedly grew the company with the aim of becoming "Nagoya's best sheet metal fabricator."
His father, Kenzo, then took over the business.
Kenzo focused on "delivering high-quality products," meticulously enhancing their aesthetic appeal and quality.
Takeshi, who took over as president in 2016, says he carries on the aspirations of his grandfather and father, yet also grapples with internal conflicts.
"It's a dilemma whether customers truly demand the level of quality that the chairman (my father) seeks. I believe quality and speed are two wheels of the same cart. Quality is crucial, but speed and cost are equally important. I believe finding the optimal balance is key."
In a Position to Oversee All Operations
After graduating from university with a degree in architecture, Takeshi worked for about a year at a company specializing in resin prototyping before joining Mountech Co., Ltd.
"I could read drawings, but beyond that, I had absolutely no knowledge of Mountech's operations."
From there, he became responsible for CAD/CAM and gradually learned Mountech's work.
Design and drafting involve breaking down the customer's desired finished product into individual parts for manufacturing. It also requires considering what kind of processing will be involved.
To understand the entire manufacturing process, including welding, Takeshi actively listened to discussions on the factory floor.
He also mentioned that when there was no design work, he would go to the factory floor and perform welding.
"When I tried it, this work was incredibly enjoyable. I thought, how wonderful it would be if I could do this job as an employee for the rest of my life."
At Mountech Co., Ltd., the design engineers conduct meetings with customers.
This is because they consolidate the processing methods discussed with customers into drawings.
Although Takeshi found the factory floor work enjoyable, his father Kenzo might have entrusted him with design, overseeing the entire manufacturing process as the company's point person, anticipating him to become the third-generation successor.
Reliable Technical Expertise Cultivated Over Many Years
Since its founding, Mountech Co., Ltd. has been engaged in steel fabrication and sheet metal fabrication for items such as distribution boards.
This work is backed by reliable techniques passed down from Saichi and Kenzo.
In general steel fabrication, steel plates are bent and the corners are welded to create a box shape.
This method results in fewer welded parts, making it less prone to distortion and easier to achieve high precision.
However, Mountech Co., Ltd. creates box shapes by assembling L-shaped angles, similar to building a dice.
This method involves numerous welded sections, making it prone to distortion and highly labor-intensive.
"There are specific sequences to minimize distortion and methods to correct it. Still, the way distortion occurs also changes depending on the speed at which the welding rod is moved, so it's not something easily imitated."
Although it is a highly difficult manufacturing method, it results in lighter weight and higher strength.
Into a Phase of Challenge and Evolution
Leveraging its high technical expertise, Mountech Co., Ltd. has primarily focused on manufacturing distribution boards for clients in the Tokai region, including Aichi and Gifu.
After becoming president, Takeshi began efforts to increase business with companies in the Kanto and Kyushu regions.
"I thought that if we expanded our areas, the economic trends might differ."
As a result, they have increased their client base outside the Tokai region, and the number of clients has reportedly grown by approximately five times.
Furthermore, they decided to venture into new genres.
Previously, most of their work was related to electrical equipment, but now it accounts for about 60%.
However, venturing into new genres was not easy.
"Previously, if we worked on anything other than distribution boards, there was a feeling within the company that 'this isn't our kind of work.'"
Nevertheless, by continuously taking on new projects, the employees' resistance gradually diminished.
Work That Provides a Sense of Purpose
They began challenging new genres because they wanted young craftsmen to feel a sense of purpose.
"Distribution boards are crucial for supporting infrastructure. However, I personally felt it was difficult to explain to people what we were making. That's why I wanted to create something everyone would recognize."
Their first challenge was highway guide signs.
From there, they expanded into various genres, even working on the "@NAGOYA" monument installed in Nagoya City.
That monument became an Instagram photo spot and even appeared in a movie scene.
"I want them to be able to say, 'I made this! Isn't it great to be able to say something like that?'"
He hopes that new projects will give employees a sense of purpose, and that people who see such products will think, "I want to do manufacturing at Mountech Co., Ltd."
Shaken by Rapid Sales Decline and Employee Departures
While many manufacturing companies struggle with labor shortages, Mountech Co., Ltd. had been successfully recruiting personnel.
Learning from the significant blow received during the Lehman Shock and when a major client underwent civil rehabilitation, they were able to build a stable management foundation by expanding their client industries and regions.
Consequently, they reportedly remained calm even during the global upheaval caused by the COVID-19 pandemic.
"I heard a lot about the difficulties caused by COVID-19, but I thought we would easily get through it. However, the semiconductor shortage arrived later."
The impact of the semiconductor shortage, which hit Mountech Co., Ltd. from late 2021 to summer 2022, dealt a significant blow to their business.
Due to the semiconductor shortage, manufacturers of control panels and circuit breakers faced unpredictable lead times, and despite receiving orders, they were unable to produce.
Consequently, orders to Mountech Co., Ltd. also came to a halt.
"Our annual sales, which were around 350 million yen, dropped to about 280 million yen. Although we had expanded the range of work we accepted, 60% of our total business was related to electrical equipment like distribution boards, so the impact of the semiconductor shortage was significant."
The decline in performance also led to a decrease in employee morale.
This was because even when they came to work, there was nothing to produce, and they could only clean or perform maintenance. As a result, six of the approximately 30 employees at the time resigned.
The departure of young employees, especially those in their 20s and 30s, cast a significant shadow over Takeshi's mind.
"I thought, 'Perhaps this company no longer has any value. Maybe the market doesn't need us anymore...' It felt as if everything I had done since becoming president was being negated."
The Seeds Sown Steadily Begin to Sprout
Looking back, employees reportedly didn't notice Takeshi's despondency at the time.
"In reality, it was quite tough. I didn't know which direction to go, so I couldn't give instructions to my employees. I had lost all confidence and thought everything was hopeless."
Nevertheless, to move forward, Takeshi decided to change his environment and took on mountain climbing, invited by a client.
"I hadn't exercised at all, but I challenged myself to things I'd never done before, like going mountain climbing, participating in local volleyball, and serving as the representative for a business owners' association. Gradually, my mindset began to shift positively."
Amidst this, a significant request came in from a company they had spoken with about six years prior, though it hadn't led to business then.
Furthermore, new orders came in from a company they had visited consistently for three years before COVID-19, once every two months.
"At the time, there wasn't any specific work, but I wanted to do business with a company in Shizuoka, so I kept driving there and building communication."
This accumulation of past efforts became a great salvation in the midst of the crisis.
The new work led to transactions worth 40 million to 50 million yen annually.
"I started to feel that what I had been doing might not have been wrong after all."
As they confronted these difficulties, the semiconductor shortage was resolved, and orders gradually returned.
As a result, they expect to record their highest-ever sales this fiscal year.
The True Enjoyment of Manufacturing
What Takeshi himself felt when he joined Mountech Co., Ltd. was the enjoyment of manufacturing.
Welding is not about handling just one part in an assembly line; it requires thinking and devising solutions to create everything from start to finish.
This is both a challenge and an enjoyment.
When new work comes in, veteran craftsmen reportedly prefer to take on those tasks.
Veteran craftsmen want to create high-quality products and, at the same time, take pride in their ability to finish excellent work.
However, Takeshi wants young craftsmen to take on challenges and experience the true enjoyment of manufacturing. Yet, they seem to feel the weight of responsibility.
"I want them to challenge themselves, even if they fail, because I will take responsibility."
Manufacturing, which involves creating shapes from a single plate or rod, is very difficult.
That's precisely why it offers a sense of purpose and enjoyment.
Takeshi hopes that both veteran and young craftsmen will experience such enjoyment.
Making Manufacturing More Appealing
Japan is a country with limited natural resources.
"Because we are a country without abundant resources, we must engage in manufacturing. I believe our national character is also well-suited for manufacturing."
However, fewer and fewer people are entering the world of manufacturing.
This might be a problem not just for manufacturing but for Japan as a whole.
"Still, there must be children who find manufacturing enjoyable. I want children who weren't interested in manufacturing to find it enjoyable by challenging themselves in it, and I hope Mountech Co., Ltd. can become a company that welcomes such children."
It is with these aspirations that they continue to challenge various genres, alongside the reliable technology cultivated in control panel manufacturing.
"If enjoyable work accumulates, employees will be happy, and I believe more people will want to join. And by working happily, we can also please our customers."
Takeshi continues to ponder what can be done to make manufacturing feel 'appealing'.
Mountech Co., Ltd.
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