Complete Programming by Oneself Without Prior Knowledge: Dramatic Improvements to the Deburring Process

Kyowa Altech Co., Ltd.

(Headquarters: Kannami, Shizuoka)

Since its founding in 1960, Kyowa Altech Co., Ltd. has continued to grow by leveraging its strength in die-casting technology. As a partner to major manufacturers, the company primarily manufactures aluminum parts for motorcycles and outboard motors. In recent years, Kyowa Altech has expanded its business domain to include parts for automobiles and home appliances.

Its strength lies in the ability to work with a wide range of materials. It can handle seven to eight types of aluminum alone, as well as manufacture products using zinc. The company has also established an integrated production system that covers every stage, from material procurement to die-casting, machining, and parts assembly.

In addition to its two domestic bases, the headquarters plant and the Tanna plant, the company also operates production facilities in India and Indonesia. A key feature of its global network, both within and beyond Japan, is the ability to consistently supply high-quality products.

Deburring Center DG-1 Delivers Mechanized Deburring

The process of deburring products had long been a problem for the company.

President Watanabe recalled, "Until recently, we had outsourced the work to subcontractors, but the inconsistency in quality caused by manual labor was a constant problem, and it was always an issue for us." In recent years, labor shortages and a lack of successors have also led to more subcontracting operations going out of business, raising concerns about the risks of fewer subcontractors.

In response, the company introduced a deburring robot a few years ago. While mechanization brought clear benefits, such as consistent quality and improved productivity, it also introduced a new challenge: the difficulty of creating programs.

This required specialized knowledge, which was difficult to handle in-house. As a result, the company had to outsource the work to external engineers, incurring additional time and cost. Training employees to write programs for in-house production became a major issue.

It was during this period that they came across information about the Deburring Center DG-1, a newly developed deburring machine from Brother Industries. Upon seeing the machine at its product launch event, President Watanabe said he immediately felt that "this machine would perfectly address the challenges we were facing."

The biggest factor that led to his decision to adopt it was that "it can be used without any knowledge of NC programming." The machine made it possible to create programs in-house, bringing about a major transformation on the workfloor.

In-House Programming Made Fun With a Game-Like Feel

Mr. Hara, who is primarily in charge of the Deburring Center DG-1, candidly shared his experience:
"I had no experience at all with machining centers, so I was anxious at first. However, using the controller to operate the machine was intuitive, and I quickly overcame my fears. It felt like a game, and I was able to learn while having fun."

This ease of operation has also reduced the time to create programs. When the machine was first introduced, the staff received a two-day training course led by an engineer from Brother Industries. After the course, they were able to complete their first program on their own in two to three weeks. Now, depending on the difficulty of the product, their skills have improved to the point where they can complete a program in just one to two days.

Feeling the benefits of being able to create programs in-house, Mr. Sato noted: "When we outsourced programming, we had to provide the jig, have the base made, and then a technician would come to our office and spend two days finishing the work. Altogether, it took about a week."

President Watanabe also praised the machine's operability: "The operation panel is just like a tablet. Route maps and other information are visually displayed, making it very easy to understand. I think this is a major attraction."

Mr. Miyahata also mentioned a secondary benefit. Speaking about Mr. Hara, working on programming, "He has become very proactive, taking initiative to research and ask for advice. I feel this has been a major benefit in terms of education as well."

Advancing Automation Globally for the Future

The issue of labor shortages is affecting Japan's manufacturing industry as a whole, and the situation is expected to worsen even more in the years ahead.
President Watanabe remarked: "The occurrence of burrs is an inevitable problem in die-casting. That's why, in the deburring process, which has traditionally relied on humans, automation is something that we must go through one way or another."

At the same time, human resource development remains essential. As in Mr. Hara's example, the company hopes to foster an environment where young employees can actively learn and grow, while expanding efforts toward greater mechanization.

Kyowa Altech is also broadening its outlook beyond Japan. Labor costs are already rising in Indonesia, and achieving consistent quality is a major challenge in India. Looking ahead, the company is actively considering the introduction of automation at its overseas bases as well. As part of these efforts, they are considering the adoption of the Deburring Center DG-1.

Regarding Brother Industries, President Watanabe had this to say: "With its global network, we're assured of receiving prompt service, even outside Japan. They are our first choice for our overseas expansion." He added, "Brother Industries' machine tools have a reputation for speed. We've looked forward to reducing our cycle times," expressing confidence in their performance.

For Kyowa Altech, a company handling large numbers of small- to medium-sized parts in high-mix low-volume production, the Deburring Center DG-1 is the ideal solution. As their partner, we support them in expanding their potential as they continue to take on new challenges toward a brighter future.