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Case Study
Achieved reducing defective products in-process maximum 90% and stabilizing quality by introducing NR-1100 !
Megaro Shizuoka Co., Ltd.
There were many defective products in-process at start molding influence of scale in the mold piping.
Reducing time of elimination defective products in-process maximum 50%%削減
Washing mold impossible, because it need many time for disassembly and assembly of mold.
The piping can be washed in a short amount of time without disassembling the mold, thereby washing a lot of molds.
Since disassembly and assembly of the mold is very hard on the workers, they washed the mold piping after the problem appeared.
The workload is reduced and washing can now be done regularly.
Company Profile of Megaro Shizuoka Co., Ltd.
Factory Location
Maruko Factory : Kitamaruko 1-7-30, Suruga-ku, Shizuoka
Yaizu Factory : Oyaizu 341-3, Yaizu, Shizuoka
Employee
87 perosns
Business outline
・Manufacture of automotive lighting equipment parts and molds
・Manufacture of ship and infrastructure lighting equipment parts and molds
Our products
| Normal injection |
RR  |
bracket  |
cover  |
|---|---|---|---|
lens  |
back lens  |
reflector  |
|
| Thick injection |
guide light  |
inner lens  |
inner lens  |
Background & Problems of introduction NR-1100
Megaro Shizuoka Co., Ltd. manufacures injection parts of lighting equipment for automotive and ship about 2,000 types by injection machine. They had following problems.
The inside of the mold piping was not regularly washed because it takes time to disassemble and assemble the mold. I only cleaned up when a problem came up.
In-process defects occur within a few minutes to 10 minutes when changing molds.
They want to reduce time and material loss by defective products in-process at start molding.
Why did Megalo Shizuoka Corporation choose the NR series? They have tested some machines that pipings can be washed without disassembling the mold. As a result, they chose NR-1100 with high cleaning ability without chemicals and environmental adaptability.
In 2017, They found the NR-1100 at the exhibition and tested it after the exhibition.
In the test, we also conducted a washing machine using chemicals and compared it with NR-1100.
As a result, NR-1100 was superior in the following three points.
1. Cleaning ability
2. Environmental adaptability
3. Running cost
Among these, the point of selection was the environmental adaptability.
Not only is it difficult to use chemicals in factories due to their environmental impact, but it has also become extremely difficult in recent years, including the impact on employee health.
Therefore, It is a appeal point that NR-1100 being able to wash with only water and air, and it was the most important factor that led to this selection.
In addition, the initial cost was higher than other companies' products that use chemicals, but since it does not use chemicals, the running cost is low, so we conclude that it is cost-effective when considering long-term use It was.
Effect after introduction Achieved reducing defective products in-process maximum 90% after changing the mold. Because they changed from washing after the occurrence of a problem to regularly washing the mold pipings.
Since the introduction of NR-1100, the mold pipings used have been washed about once a month.
As a result achieved reducing defective products in-process maximum 90% after changing the mold, and the following effects are appearing.
1. Ratio of defective products
in-process 0.2% / month
2. Improving
customer trust
3. Reducing the load on the mold
maintenance department
Improved customer trust led to long-term sales growth.
It is not only reduces defective products in-process that Cleaning the mold pipings with NR-1100, but also stabilizes the cooling effect, which leads to stable quality of injection parts.
This things proved that we value quality in the manufacture of injection parts of lighting equipment for automotive that require high quality.
Theirs choice
NR-1100
It is the best model for washing the cooling pipes of precision molds and medium-sized molds.
mold size (clamping force of injection machine) 5t - 850t
Maximum flow 100L/min
Connector 15A×6, 25A×1
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