BIG DAISHOWA opens new plant on Awaji Island; boosts productivity with multitasking and robotics

Tool manufacturer BIG DAISHOWA (Osaka, Japan; President: Kaito Nakatani) has completed its 9th plant at its main production base, the Awaji Plant, in July last year and started operation in January this year. More than 10 billion yen was invested in the construction of this new plant to improve productivity by consolidating processes with multi-tasking machines and promoting automation with robot transport. The company is set to further expand its production capacity in preparation for future market recovery and increased orders. 

Strengthening inventory by activating new plant 

The center of the photo is the entrance, the building on the left is the plant, and on the right is the “Mega VIP Center” where visitors are entertained.

BIG DAISHOWA has been strategically expanding its Awaji Plant, and in recent years has also built its own thermal processing plant and distribution center to eliminate shipping bottlenecks. With the startup of Plant No. 9, the company has increased its production capacity to match its shipping capacity. Hideya Nishino, President of BIG DAISHOWA Japan, who oversees the sales division, said, “Market conditions are challenging, but we are enhancing our inventories and aiming for zero shortages when the economy recovers”. 

With a total investment of more than 10 billion yen, including processing equipment, Plant No. 9 was constructed in July last year and started operations in January this year. With a total floor space of 49,500 square meters, the plant handles the machining of taper spindle BT and BTT No. 30 to 50 tool products. The initial plan is to produce 20,000 tools per month, which can be increased to about double the current capacity. President Nishino says, “We have consolidated the processes that are easy to automate and that are expected to benefit greatly from automation into the 9th plant”.

The floor of Plant No. 9 is color-coded for areas where people can enter, areas where AGFs travel through, etc. Labor saving has progressed, and there are only a few people working on the floor.

Emphasis on labor saving and environmental improvement 

Hideya Nishino, President of BIG DAISHOWA Japan, says, “We are receiving more and more requests for tours of the Awaji Plan “.

The plant is equipped with 21 new multitasking machines and 23 automatic lathes that were transferred from the conventional plant. The automatic lathes mainly machine collets, while the multitasking machines machine taper holders and boring head parts. The multitasking machines are individually combined with robots to load and unload workpieces. Three AGFs (Automated Guided Forklifts) also operate throughout the floor to supply materials and collect finished products by pallet. 

Coolant used in the cutting process is recycled through a central filtration system installed at three points in the facility. 80% of the oil mist is captured and treated within the machine, and the 20% that exits the machine is captured through an air inlet near the ceiling of the facility. These efforts ensure that the environment inside the facility is always clean and that emissions outside the facility are minimized. 

The “Mega VIP Center” built as part of Plant No. 9 is a new gateway for the company, welcoming a large number of plant visitors each year. 

By: Yuki Matsukawa 
Staff Editor, SEISANZAI Japan