Fukai MFG Co., Ltd.

division
division

Basic Policy on Information Security

Fukai MFG Co., Ltd. (hereinafter referred to as “the Company”) has determined basic policy on information security with an awareness that information on companies that are our clients or transaction partners and personal information obtained through corporate activities are precious assets. This policy was formulated with grave concern about the constant exposure of these information assets to threats such as falsification, destruction, and leakage, whether deliberate or accidental. Its objective is to address the agendum of information security on a both company-wide and ongoing basis, for rigorous assurance of the safety of information assets with a confidential character.
1. Information security management
The Company shall prepare a management organization and in-house rules related to information security, perform risk management concerning the handling of information assets, and continuously promote and improve information security.
2. Responsibility in leadership
The Company shall exercise leadership for proper management of the information assets of the Company and its clients, based on observance of this policy.
3. Observance of laws, regulations, etc.
The Company shall observe information-security-related laws and regulations, guidelines established by the Japanese government, obligations in contracts, and other social standards.
4. Activities of education for employees etc.
To assure information security, the Company shall strive to provide executives, employees, transaction partners, and consigned companies with the education and training needed to assure information security.
5. Accident prevention and countermeasures
The Company shall strive to maintain information security. In the unlikely event that problems occur in the security of information assets, however, it shall respond both swiftly and properly, and strive to prevent any recurrence.
October 1, 2018
Takeshi Fukai
President

Fukai’s Safety and Health Policy

The company emphasizes regard for people and hopes to achieve a “Bright and comfortable work-place without hazards” through practice of the following items by all employees.

1) Making the company policy a principle. Strive to perform industrial safety and health activity that can be a model for the region.
2) In activities, uphold the industrial safety and health regulations and policies based on them as well as any rules regarding health and safety established by the company.
3) Continuously implement and apply the industrial safety and health system in an appropriate manner.

Fukai’s Environmental Policy

Fukai recognizes that conservation of the environment is a most important issue for all people and is under taking corporate initiatives toward conservation of the global environment and being a company that is in harmony with and friendly to the environment in various aspects of business activities.

1. Working to make company policy a principle of having business operations pleasing to the regional community.
2. Build an environmental management system and through full participation strive to achieve continuous improvement.
3. Comply with ordinances, regulations, and regional agreements related to the environment and strive to make environmental improvement and proactively prevent pollution.
4. Define targets and goals for improvement of the environment, take action, and revise these periodically.
5. Of the affects our company’s business operations have on the environment, focus improvement initiatives on the following items.

(1) Proactive initiatives to reduce energy consumption, use of resources, and waste, and to prevent environmental pollution.
(2) Profitable initiatives for better development of the environment.
(3) By focusing on business operations, environmental improvement should not remain within the company but employ improvement activities in cooperation with other companies.

Quality Control

(1) Fundamental Consideration
The Quality Policy of Fukai is “Quality is our highest priority to satisfy customers and acquire the trust of society”. Various activities from the perspective of the customer are being taken targeting further improvement in product quality to enable providing a “feeling of satisfaction” and “reliability” to the customer.

(2) Innovations
1. Practical level improvement activities to the Quality Management System
2. Perfection of critical point control and application activities of APQP
3. Activities to sustain and improve irregularity and modification management

(3) Flow of quality management system structure
ISO9001 Certification obtained April 2, 1998
QS9000 Certification obtained January, 16, 2003
TS16949 Certification obtained September 13, 2004
TS16949/ISO9001 Certification updated September 12, 2010

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FA and CIM

The essence of FA is converting production to unmanned. In addition, use of CIM is to support people.
The starting point for concurrent construction of FA and CIM at FUKAI is harmony between people and machinery. By embodying the ideas and creativity of people through machinery, we can realize the possibility of this harmony.

Further enhancement of service to customers based on CIM configuration
CIM configuration that integrates all business information from receipt of order to product delivery to enable thorough manufacturing engineering control and quality control based on management themes. In addition to providing highly precise products through manufacturing technology, switching to CIM has enabled a significant level of improvement in customer service through high performance quality production.
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Fukai has integrated technical prowess for enhanced die design, system design, press, welding, assembly, and processing enabling reliability at a solid cost performance and maintaining high quality. The level of ability to endure times of a drop in prices provides energy for opening up the next era.

Advancing on a global scale as a comprehensive manufacturer engaged in sheet metal forming including die design, press, weld, and assembly processing
Fukai supports user needs through perfect engineering and design capability from highly accurate die design with CAD/CAM and production, to press, welding, and assembly processing. The basic stance of Fukai is thoroughly prioritizing the customer through quality assurance, adherence to deadlines, and low cost, etc. and pursuit of reliability in the face of global price competition through which we are proving our value.

Establishment of control technology realizes superior “own-process completion,” quality assurance as an absolute condition
Fukai has established control technology for superior “own-process completion” based on CIM to improve product value through leveling up of various tests, completed product features, strength tests, etc. and the conventional quality assurance structure from material tests to production processes as well as to address differentiation issues. Based on a detailed quality assurance plan, all business information from storing of materials, transport, processing, inspection, assembly, testing, and shipping is centralized for control. Also, in the Manufacturing Department, a system where robots themselves can perform measurement and quality verification has been introduced enabling compatibility with higher level needs through control technology set up with quality assurance as an absolute condition.

A flexible management stance, humane organization, and unshakeable technology are what provides Fukai its power
A flexible management stance that continually challenges new themes such as FA and CIM initiatives and ambitiously innovates regarding quality and cost strengthening adaptability to changing times as well as achieving a best environment for accumulating technology and know-how demanded by new eras and reflected in the humane organization development that trains the creativity of engineers. Fukai’s efforts are in being a worldwide pioneer in capital investment, having flexibility in introduction of departments with consideration for its people, as well as unshakeable technology and this provides a power for opening up the future.

Goal is to cultivate advanced technology that has been standardized and contribute through expansion into all industries both vertically and horizontally
How to link technical capability to the future through contributions based on continuously pushing innovation? Switching to FA, CIM has enabled advanced technology that was obtained to grow into production and control technology at an even higher level and has left a new challenge of being able to provide users with overall higher quality products at lower cost. Product backed by superior technology, manufacturing capability, and control capability has been confirmed to be able to support the needs of a broader field and through further cultivation of the system, is targeted to help users through manufacturing of product that can hold up to international competition.

Research and Development

With consideration to weight reduction trends of the automotive industry, the technical development plan of Fukai is focused on weight reduction of sheet metal parts.

[A] Research and development of high tensile strength steel plate
Body weight reduction that contributes to emission gas regulation and fuel economy improvements is an important issue to automobile manufacturers. The Development Group in the Engineering Department oversees development of new technology and with regards to material characteristics, press formability, welding, etc. we are proceeding accompanied by the technical assistance of Nippon Steel Corporation.

1) High tensile strength steel press technology development
Fukai has taken initiatives for press technology for high tensile strength steel plate for the past 10 years and has been using a 540 MPa class bumper beam and a 440 MPa class high tensile strength steel sheet suspension support member for manufacturing. Thereafter, Fukai participated in a 590 MPa high tensile strength steel plate joint project of three members consisting of Fukai, an automobile manufacturer and Nippon Steel in development press technology and this is currently being used to manufacture a lot of models. Currently, high tensile strength steel plate of 590 MPa has become commonplace and Fukai is working on press technology with high tensile strength steel of 780 MPa and 980 MPa class.

(2) Tailored blanking for high tensile strength steel plate
In order to use high tensile strength steel plate effectively, manufacturing of a laser weld tailored blank through welding 270 MPa class normal material with high tensile strength steel plate and high tensile strength steel plates with differing thickness was identified by Fukai as being of interest and research has been performed towards its development for the past 8 years.
Furthermore, development ofa tailored blank method using plasma welding in place of laser welding started 6 years ago and this was taken into production 4 years ago. Also, after 8 years of development, the tailored blank using laser welding is being used by an automobile manufacturer and it entered production 2 years ago.
Please click here for a description of the tailored blank method

Application example of the tailored blank method

(3) Development of 980 MPa ultra high tensile strength steel plate
There are a lot of delayed fracture and other technical issues associated with molding using a press for ultra high tensile strength steel place exceeding 980 MPa and it does not appear to be suitable for manufacturing using a press.
With the help of Nippon Steel Corporation, Fukai has pursued research and development of a “Hot Press Method” as a replacement for press molding starting several years ago and has resolved technical issues of form molding, draw molding, and equivalent components.
Prototype made using a hot press method

[B] Chassis structure research and analysis
Research and analysis of chassis structure is also an important issue for Fukai.
In order to provide favorable proposals to automobile manufacturers, Fukai purchases domestic and foreign automotive components regularly to perform a breakdown study of techniques, materials used, and material properties and as a result is able to propose new techniques and material properties to automobile manufacturers.
Finite element analysis software such as Nastran or Mechanica is used for chassis structure analysis and strength and rigidity calculations to propose optimal structures to automobile manufacturers.
Fukai is also performing non-linear chassis structure analysis such as collision analysis. This type of research analysis is being performed with the help of Nippon Steel.
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Collision analysis example for weight reduction proposal of center pillar area.

[C] Die Research
The Press Engineering Section of Manufacturing Engineering Group in the Engineering Department is responsible for die research.
Use of high tensile strength steel plate has increased and Fukai is improving strength and rigidity of our mold construction. Also, the deformation, spring-back, etc. of press molds have increased compared to conventional materials.
As a countermeasure, press mold simulation software is used to investigate each part and the mold ability and die structure are investigated until the goal is achieved.
Also, three dimensional die design is being performed where finger interference, etc. is performed on a CRT and both manufacturing timing and development timing have been shortened.
Press mold simulation example

[D] Design and Manufacture of Production Equipment and Jig
The Manufacturing Engineering Group in the Engineering Department is responsible for development of new technology related to production technology.
All equipment within Fukai is designed in-house.
In terms of production equipment, high efficiency, low cost, and trouble-free are important priorities. Research is continually performed by the Manufacturing Engineering Group targeting better equipment.
Investigation of assembly equipment and tool and jigs is performed using ROBCAD, etc. at the investigation stage and failures are eradicated through investigation on the CRT leading to reduction in development timing.
Design and manufacturing sales of production equipment and jigs is performed externally. In addition, a door fitting device for Fuji Heavy Industries Gunma Works, bumper assembly equipment ensuring mount precision using a measurement device, as well as floor welding equipment, etc. are supplied to both domestic and foreign automotive manufacturers.
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Description of the Tailored Blank Method

 A so-called tailored blank method is being used regularly for automotive bodies in recent years.
In the tailored blank method, different types of steel plates are joined together enabling local changes to properties within a single sheet of material.
As shown below, this is a tailored press material prepared through welding several steel plates in line with specific purposes.
Different types of steel plates are joined together to enable local changes to properties within a single sheet of material. Because of these characteristics, this has claimed the limelight as a material for automotive chassis.
Tailored Blank Method
Automobile body requirements include reinforcement, durability, rust inhibition, absorption of crash energy, and weight reduction all at the same time and on top of this efficient three dimensional curved surface design is demanded so the panel thickness and material have to be changed meticulously for each of the body panels. On the other hand, from the perspective of body precision and manufacturing performance, reduction in the number of parts to the greatest extent possible is preferable so the need to reduce the number of panels has continually been strong. The primary reasons that tailored blank method is used in the automotive body industry are the reasons described above.

Tailored blank characteristics
1) Optimum configuration of panel thickness and material.
2) Continuous line welding so joint strength is high.
3) Very little overlap material required for spot welding.
4) High degree of freedom in material shape.

Places of application are as follows:
Tailored blank application locations