JA / EN
Oka Tekkousyo Co., Ltd.
Oka Tekkousyo Co., Ltd.

Efficiency via DX & Multi-skilling.
Opportunity-driven reforms lead to
integrated production from material to assembly.

  • Oka Tekkousyo Co., Ltd.

  • Sheet metal fabrication, steel fabrication, and precision machining

Katsuyuki Oka

Prefecture
Okayama
Business Activities
Sheet metal fabrication, steel fabrication, and precision machining
Company Name
Oka Tekkousyo Co., Ltd.
Representative Name
Katsuyuki Oka
Location

〒710-0262

1200-4, Mizue, Funao-cho, Kurashiki-shi, Okayama, Japan

Phone Number
086-552-2453
Website

https://www.okatetsu-works.com/

Factory Stories

Starting with Steel Fabrication and Sheet Metal

Oka Iron Works Co., Ltd. provides integrated production from material procurement to assembly, focusing on steel fabrication and machining. The company was founded in 1969 by Katsuyuki Oka's grandfather, along with Katsuyuki's father and uncle. Katsuyuki now leads the company as the third generation.
Although they originally ran a farming business, they entered the industrial world because Katsuyuki's father went to an industrial school and his uncle worked for a machinery manufacturer.
"At the time of its founding, the company apparently only did steel fabrication and sheet metal, manufacturing health equipment and jigs used in Mitsubishi's automobile production lines."
From there, the company evolved into a system capable of handling everything from material procurement, cutting, bending, welding, steel fabrication, machining, painting, and assembly/on-site assembly, provided a drawing is available. This integrated system, capable of undertaking a wide range of processes, has been in place for about 15 years.

The Lehman Shock as a Catalyst for System Transformation

Around the time of the Lehman Shock, orders were primarily centered on machine tools and food processing machinery. When the volume of work drastically decreased due to the Lehman Shock, new customers frequently asked how many processes the company could handle in-house.
"For buyers, it's ideal to entrust everything to one place and have it managed completely. Moreover, using external contractors inevitably incurs time and cost."
Thus, amidst financial difficulties, the company dared to make capital investments and decided to expand its scope of business.
This proved successful, and now, while maintaining machine tools and food processing machinery as its foundation, the company undertakes work in various industries such as shipbuilding, plant engineering, and public works.

Manufacturing that Leverages Individual Strengths

In manufacturing, it is common to inherit techniques by imitating the methods of predecessors.
However, Oka Iron Works Co., Ltd. starts from the perspective that "the methods of predecessors are not necessarily the only correct way."
"While inherited methods can be considered correct, we encourage employees to find their own correct methods that allow them to produce good quality products quickly. This leverages their individuality and brings the joy of working with their own ideas."
This aligns with Oka Iron Works Co., Ltd.'s corporate philosophy: 'Contributing through manufacturing by leveraging the individuality of each employee.'
This approach applies even to repeat orders.
Instead of doing the same thing every time, they continuously devise new approaches. This accumulates know-how.
"If you keep repeating the same inherited methods, you lose your adventurous spirit, and when a difficult project comes along, you tend to think negatively, 'We can't do this.' By constantly thinking and devising solutions, you become able to think positively, 'Maybe we can do it this way!' even for challenging projects."
It is precisely this stance that enables the company to continuously respond to small-lot, multi-product requests from a wide range of industries.

Overcoming Challenges by Combining Know-how and Wisdom

When difficult projects arise, employees at Oka Iron Works Co., Ltd. not only think individually, leveraging their strengths, but also overcome challenges by gathering the collective wisdom of all employees.
"Led by the factory manager and team leaders, we create opportunities to gather everyone's wisdom and exchange ideas, including employees not directly involved in the processing of that particular product."
By combining the ideas and know-how that each person possesses, even difficult projects can be overcome.
In fact, there are products that have been completed by utilizing all available machines, such as vertical machining centers, horizontal machining centers, lathes, and milling machines.
Furthermore, for products requiring sub-millimeter precision in welding, they improved accuracy by grinding the welding surface before welding to achieve perpendicularity and flatness.

Digital Transformation with Reverse Thinking During the COVID-19 Pandemic

Katsuyuki took over as president in 2020.
It was the year when the COVID-19 pandemic spread, and the entire Japanese economy stagnated.
In such a difficult situation, Katsuyuki promoted the digital transformation (DX) of the factory.
"It was reverse thinking. Since work decreased, we leveraged that situation to achieve 100% DX, gathering all employees for training. Additionally, we cross-trained employees so that everyone could perform all on-site tasks."
As a result, all drawings and process management were moved to the cloud, allowing anyone to check progress. Furthermore, with accumulated data, quotations can now be generated quickly.
Moreover, they advanced the AI integration of accounting. Monthly trial balances can be issued by the 5th of the following month, and annual financial statements by the 20th of the following month. Additionally, since sales rankings and year-on-year comparisons for each client can be generated from financial data, sales personnel can now formulate sales strategies based on this data.
"It costs money, but I believed it would be better to have everything in order for the future, so we pursued it."

Quotations Generated Through Collaboration Between the Shop Floor and Sales

With the shop floor thinking for itself and DX implementation, quotation efficiency has also changed. When a customer consults us and we receive a drawing, we pass that drawing to the shop floor team.
The shop floor reviews the drawing, calculates the time required for each work process, and provides feedback to sales. Furthermore, if any tools are needed for the work, they obtain quotations from trading companies themselves and inform sales.
Sales then calculates the quotation based on the information fed back from the shop floor and conducts negotiations, enabling more accurate and concrete discussions.
"When an order is received, the shop floor can promptly begin work as they have already reviewed the drawing, cutting down on time loss. Moreover, since they calculate the time themselves, they can approach the work with a sense of responsibility."
Because this system functions effectively, Katsuyuki rarely has to prepare quotations himself.

Building a Manufacturing Network

Katsuyuki has formulated a business plan until 2030 and is implementing it step by step. With manufacturing as its foundation, the company operates in the construction and automotive industries at three locations, and by 2030, it plans to establish a trading company to consolidate these operations into a group company.
Furthermore, they will expand sales channels by developing business overseas.
However, Katsuyuki is not only thinking about the future of Oka Iron Works Co., Ltd.
He envisions a system that can support the entire region by creating a network of companies specializing in manufacturing.
Traditional manufacturing society had a pyramid structure, with a vertical flow where what the top received flowed downwards. Katsuyuki aims to flatten this structure, creating a system where any company can undertake a project and produce a single product while complementing all processes.
He believes that by having the corporate network function cohesively as an assembly (ASS), they can eliminate constraints and collaborate to create new manufacturing.
This might be because Katsuyuki had experience as a general consultant before joining Oka Iron Works Co., Ltd.
"I don't think it's interesting if only one person benefits. It's much more enjoyable if everyone involved prospers, isn't it?"
The new system Katsuyuki envisions might just bring a fresh breeze to Japan's manufacturing world.