TECHNICAL INFORMATION
PRODUCTION SYSTEM
Production System
Production System
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Intergrated System
Development and Design
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2
Intergrated System
Production System
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3
Intergrated System
Quality Assurance
Kokusan Parts Industry is dedicated to building an efficient integrated production line—from production preparation to shipping.
Kokusan Parts Industry’s integrated production system includes state-of-the-art production facilities and a rational, efficient layout design. Our system also provides flexibility in responding to new machinery and equipment requirements as well as production line changes to accommodate new products. The highly skilled engineers are one of Kokusan Parts Industry’s prized assets, and the combined strength of these technicians is an important aspect of our ability to manufacture high-performance products. By employing quality assurance methods equivalent to those at our Japanese plants, we are able to provide high-performance products comparable to domestically manufactured products even at our overseas plants.
Cylinder Head Gasket Production Process and Equipment
CYLINDER HEAD GASKET
- First Pressing
- Washing
- Second Pressing
- Hot Water Washing
- Heat Treating/Coating
- Inspection
- Assembly
- Final Inspection and Shipping
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First Pressing
Production System
Add the coil material and punch out the product shape.
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Washing
Production System
Impurities such as oil adhering to the surface of the product are removed using an ultrasonic cleaning device. Washed products are automatically sent to the next step after being cleaned.
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Second Pressing
Production System
This automated line includes four presses connected by a transfer robot. The irregular step processing performed on cleaned products in this step enhance the sealing functionality of the gasket.
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Hot Water Washing
Production System
Products are individually washed from top to bottom with hot water. The environmentally friendly cleaning equipment used in this step does not use any solvents.
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Heat Treating/Coating
Production System
Cleaned products undergo heat treatment to enhance functionality before painting the surface. For surface coating, Kokusan Parts Industry uses proprietary paint that maintains advanced sealability functions.
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Inspection
Production System
Only the highest quality products clear the inspection process, which includes numerous checks using inspection equipment, sensors, and visual inspection.
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Assembly
Production System
Multiple plates are joined together using Kokusan Parts Industry’s proprietary eyelet machine, which includes various weight and lamination sensors.
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Final Inspection and Shipping
Production System
Kokusan Parts Industry’s high-quality, high-functionality products are checked by a final inspector before being packed according to specific packaging requirements and then shipped out.
Heat Insulator Production Process and Equipment
HEAT INSULATOR
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Pressing
Production System
Material is squeezed and processed using multiple interlocked presses to mold the product. In this step, the thin plate material undergoes a process called "deep squeezing" requiring advanced technology.
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Factory Automation Line
Production System
Kokusan Parts Industry has adopted an automated production line for robot-based pressing of heat insulators.
The increased mechanization and automation of the line help ensure greater stability for a higher quality supply. -
Spot Welding
Production System
Products undergo final forming using robot welding machines and various spot welding machines.
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Assembly
Production System
After welding, products are assembled with sound-insulating, heat-shielding, and vibration-isolating components, resulting in a high-performance product.
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Inspection and Shipping
Production System
Only those high-performance products that satisfy the strict checks of a final inspector are prepared for shipping.
Mesh Component Production Process and Equipment
MESH PRODUCT
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Meshing
Production System
The mesh structure is created using heat-resistant stainless-steel wire coils. The process includes efficient operation of 37 meshing machines performed by only a small number of people through remote monitoring.
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Product Processing
Production System
Mesh products formed using a forming press are assembled to specific parts such as heat insulators.
Support System
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Molding Maintenance
Production System
Molds are components that greatly affect product performance, and periodic maintenance of these molds is indispensable. Kokusan Parts Industry’s skilled technicians and dedicated equipment make it possible to continually mass produce high-quality products.
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Equipment Maintenance
Production System
All of the equipment in Kokusan Parts Industry plants, including robots, constantly undergo maintenance by specialized maintenance personnel. Our system allows us not only to perform daily maintenance but also quickly respond to unexpected situations.
Major Manufacturing Equipment
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Servo press (200 tons)
3 unit
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Crank press (200 tons)
9 units
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Crank press (300 tons)
2 units
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Sequential press (150–250 tons)
7 units
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Single press (35–400 tons)
8 units
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May press (160–250 tons)
2 units
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Hydraulic press
2 units
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Riveting machine
7 units
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Eyelet machine
4 units
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Spot welding machine
12 units
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Robot welding machine
2 units
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Caulking machine
5 units
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Electric muffling chamber
1 unit
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Continuous drying chamber
3 units
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Flow coater
2 units
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Screen printer
3 units
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Automatic cutter
1 unit
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Leveler
1 unit
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Ultrasonic cleaner
1 unit
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Hot water washer
1 unit
Kokusan Parts Industry Co., Ltd
