TECHNICAL INFORMATION

PRODUCTION SYSTEM

Production System

Production System

  • 1

    Intergrated System

    Development and Design

  • 2

    Intergrated System

    Production System

  • 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

    Production System

    • Use of press
    • Punching raw material to shape the product

    Add the coil material and punch out the product shape.

  • Washing

    Production System

    • Washing
    • Drying process after washing

    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.

  • Second Pressing

    Production System

    • Second pressing machines
    • Irregular step process

    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.

  • Hot Water Washing

    Production System

    • Hot water washing
    • Example of hot water washing

    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.

  • Heat Treating/Coating

    Production System

    • Heat Treating
    • Coating

    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.

  • Inspection

    Production System

    • Visual inspection
    • Several inspections are made

    Only the highest quality products clear the inspection process, which includes numerous checks using inspection equipment, sensors, and visual inspection.

  • Assembly

    Production System

    • Plate fastening
    • Assembling using eyelet machines

    Multiple plates are joined together using Kokusan Parts Industry’s proprietary eyelet machine, which includes various weight and lamination sensors.

  • Final Inspection and Shipping

    Production System

    • Final inspection
    • Product packaging

    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

  • Pressing

    Production System

    • Example of press use and process check
    • Example of presse use
    • Example of the squeezing process

    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.

  • Spot Welding

    Production System

    • Example of using a robotic welding machine
    • Example of the completion of a product

    Products undergo final forming using robot welding machines and various spot welding machines.

  • Assembly

    Production System

    • Example of assembly work
    • 部品を組み付けている様子

    After welding, products are assembled with sound-insulating, heat-shielding, and vibration-isolating components, resulting in a high-performance product.

  • Inspection and Shipping

    Production System

    • Example of final Inspection
    • Example of shipping

    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

  • Meshing

    Production System

    • Knitting machines
    • Screen used to monitor knitting operations

    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.

  • Product Processing

    Production System

    • アッセンブリー作業をしている様子
    • Products after assembly

    Mesh products formed using a forming press are assembled to specific parts such as heat insulators.

Support System

  • Molding Maintenance

    Production System

    • Employees performing mold maintenance
    • Example of Maintenance
    • 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.

  • Equipment Maintenance

    Production System

    • 2人体制で機械を点検している様子
    • ロボットの保守を行っている様子
    • パソコンを見ながら点検を行なう専門の保全員
    • 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

  • Servo press (200 tons)

    1 unit

  • Crank press (200 tons)

    2 units

  • Crank press (300 tons)

    2 units

  • Sequential press (150–250 tons)

    7 units

  • Single press (35–400 tons)

    8 units

  • May press (160–250 tons)

    2 units

  • Hydraulic press

    2 units

  • Riveting machine

    7 units

  • Eyelet machine

    4 units

  • Spot welding machine

    10 units

  • Robot welding machine

    2 units

  • Caulking machine

    5 units

  • Electric muffling chamber

    1 unit

  • Continuous drying chamber

    3 units

  • Flow coater

    2 units

  • Screen printer

    3 units

  • Automatic cutter

    1 unit

  • Leveler

    1 unit

  • Ultrasonic cleaner

    1 unit

  • Hot water washer

    1 unit