Tatematsu meets demanding cost reduction targets with the help of WorkNC

The Japanese company Tatematsu Mould Works Co. Ltd. is based in Inazawa-shi, in the Aichi Prefecture. It manufactures exclusively for the automotive industry and specialises in larger parts, producing complex 3D dies and moulds for interior panels, bumpers and door trim. Toyota is one of its biggest customers, but by no means the only one – Tatematsu deals with all of the Japanese car manufacturers, as well as automobile parts manufacturers. The company is the major producer of die and moulds in Japan, having over 50% of the market. It maintains its superiority by the use of advanced manufacturing technology and management systems.

<< Before we changed to WorkNC, we used to take one week to cut the mould for the inner panel of an ordinary small car. Now it can be completed in 2-3 days. >>
Kikuo Tawara, Business & Planning Department, Tatematsu Mould Works Co. Ltd.

Kikuo Tawara and Naoto Kitayama from the company’s Business & Planning Department explained the challenges the company was facing. “We have to remain competitive; margins can be very tight as the actual cost of the materials used to produce the dies and moulds accounts for around 50% of the finished price. We are faced with cost cutting demands of 20-30% so need to implement major productivity improvements to maintain our profit levels.” By remaining flexible and responsive to new ideas Tatematsu is able to keep up with a rapidly evolving market and maintain its dominant position. The company utilises existing machinery both old and new, and examines the machining methods, workflow and organisational structure to optimise the whole process.

In 1997, after consulting Sescoi through its Japanese reseller, Tatematsu installed 2 WorkNC licences for machining graphite electrodes. Mr. Kitayama explained “WorkNC’s automatic programming was very attractive for us. Previously, finishing an inner panel mould took an average of 14 days – we were able to reduce that time by 20-30 hours.” Soon after these results were achieved, the company installed a further 2 licences.

The new manufacturing department that uses WorkNC consists of production control, three CAM teams, and an assembly department. “First, the Production Control Department develops an optimised machining plan, this means that the other departments don’t have to concern themselves with this, they just have to generate the data”, commented Mr. Tawara. The aim of the company is for data to flow through each department without any editing or reworking. Mr. Kitayama elaborated, “The root of our productivity improvements is to locate and resolve the original cause of problems, rather than trying to correct them during the manufacturing process.”

WorkNC is used on the shop floor at Tatematsu, and is continually monitored to ensure that it copes with the company’s changing requirements. Mr. Kitayama said, “All our operators use the system and are involved in the monitoring – this promotes greater understanding of the whole NC process.” Three years ago the emphasis was on editing the toolpath, now the focus is on improving the process before machining starts. The eventual aim is not to need to edit at all, thereby simplifying the whole process.

One of Tatematsu’s main goals was to reduce considerably the time needed to generate NC data – WorkNC has made a significant contribution to this. In 2001, the ongoing analysis showed that it took 120 hours - 23 for preparation and modification, and 97 to create the programme prior to cutting the tool. Sescoi and its Japanese reseller helped the company set about reducing this time. Once the surface data has been received it is first evaluated by the CAM engineers and surface modification work allocated. Next, steps were taken to increase the efficiency of IGES translation; rationalize the supporting systems for NC programming; and optimise the machining methods. These efficiency improvements reduced the time taken to just 70 hours.

Having achieved its initial aim, the company decided on an even more ambitious target – to generate the NC data in just 40 hours. This was linked with its decision to install another 3 WorkNC licences and implement WorkNC’s new High- Torque Re-Roughing cycle which has contributed to reduced machining times through its efficiency and reliability. Mr. Tawara gave an example, “Before we changed to WorkNC, we used to take one week to cut the mould for the inner panel of an ordinary small car. Now, it takes just 3-4 days to do it for a much bigger recreational vehicle. For a small car the mould can be completed in 2-3 days.” He continued, “We tend to tackle issues one at a time. Our analysis and assessment helps us to identify objectives, and WorkNC helps us to achieve them. Like everyone else, we set ambitious targets, but we are achieving them!”

Mr. Kitayama concluded “By tracing the cause of problems, then addressing them, you achieve technical evolution. With the help of WorkNC, and our mutual commitment to continual development, we have achieved that over the past 7 years, and are still seeing improvements. Together, we look forward to a bright future.”