Background

To establish production processes that do not rely on humans' special skills and contract factories where employee turnover is high

The Kaga Factory produces consumable parts as well as torches and other peripheral equipment for welding. In addition, it has machining, sheet metal working, welding, and coating processes. The processes requiring special skills, including the welding of thin plates, had to be outsourced to operate the factory. However, nor is it easy for contract factories to continuously secure highly-skilled welders due to the high incidence of employee turnover at. Therefore, the Kaga Factory introduced LAPRISS in order to achieve high-quality welding without relying on human skills. (Mr. Kadono, Plant Superintendent)

Reason for introduction

To avoid personnel-related risks at contract factories to maintain production processes where everyone can manufacture good products

Thin plate welding is a process that requires special skills to control heat distortion and burn-through. It is also difficult to secure such skilled workers at contract factories, where workers may be older or less likely to stay at the same workplace for a long time. We decided to install LAPRISS at the Kaga Factory to ensure consistent, high-quality welding. (Mr. Yamada, Production Section)

To promote our products to customers by using them at our factory

Since the Kaga Factory has a welding process, we also face similar issues as our customers' at our own welding site.
Another reason we introduced LAPRISS was to help customers facing similar challenges. We had already installed our own arc welding machines and welding robots in our factory. We decided to install the laser welding robot LAPRISS as well because we wanted to promote its benefits to our customers. (Mr. Kadono, Plant Superintendent)

Benefits of introduction

Establishment of a high-quality production process, requiring only the setting of workpieces and pressing of a button

The greatest benefit of LAPRISS is that it enables a production process that does not rely on special skills. At a contract factory, welding required a series of processes, including tack welding, final welding, finish work, and heat distortion removal. Now we simply set the workpieces and press the button to complete the welding process. Manufacturing often relies on special skills and expertise of humans; however, considering social issues such as business continuity and labor shortages, this effort to replace human operations with the state-of-the-art equipment was significant. (Mr. Yamada, Production Section)

Beautiful bead appearance only achieved through laser welding

High welding quality is also achieved with beautiful finish only achieved through laser welding. After coating, the finish is so impressive that it is impossible to tell whether the components were bent or welded. (Mr. Yamada, Production Section)

Reduced lead times as well as costs

We were able to reduce costs by approximately 40% by working on in-house welding.
In-house welding has also reduced lead times, compared to those required by contract factories, which are now three to four days. The required stockpiling was thereby reduced as well. (Mr. Yamada, Production Section)

Future prospects