Industry Vision

Fostering a growth cycle for the industry
Ensure profit ⇒ Reinvest in technology, equipment, human resources ⇒Market differentiation ⇒ Enhanced international competitiveness

October 2006
Japan Forming Machine Association
Ｐ・１
Ｐ・１ ＮＥＸＴ：
ＮＥＸＴ： Table
Table ofof Contents
Contents

TableTable ofof Contents
Contents

An analysis of the forming machine industry as it is today
and where it needs to go from here to fulfill its potential!!
Chap. 1: An analysis of the forming machine industry today
Chap. 2: Strengths and weaknesses of the forming machine industry

Chap. 3: Biggest priorities for association members
Chap. 4: Customer needs and seeds

10 years from now

Chap. 5: The direction of forming machine technology

The undisputed industry
leader worldwide

Chap. 6: Why eco-products?
Chap. 7: Tasks for the forming machine industry going forward

An industry performing atfull potential in 10 years!!

Ｐ・２
Ｐ・２ ＮＥＸＴ：
ＮＥＸＴ： Chap.
Chap. 11

Ｐ・３
Ｐ・３ ＮＥＸＴ：
ＮＥＸＴ： Analysis
Analysis ofof membermember enterprises
enterprises

The
The industry
industry
today
today

Forming machinery: member enterprises andrange and numbers of machines producedEnterprises in the forming machine division
Distribution of sales and employee numbers
5002 member survey

Total revenue for all members
and for 11 largest firms
Unit:¥100 million

Total for all members

％

4,500

Total for 11 largest firms

100

Straight side press

90

High-speed press

C-type press

Ratio

4,000

80

3,500
3,000

73

75

79

70

Sales

60

2,500
50

2,000

40

1,500

Number of employees

Number of firms manufacturing
particular machine types

30

1,000

20

500

10

0

0

2003

2004

2005

Hydraulic press
Forming machine
Thread rollingmachinePunching press
Press brake
Shearing machine
FeederSafety equipment
0

10

20

30

1. JFMA consists of 62 members. Around 10 members are large firms with the remainder being
medium and small enterprises. The 11 largest firms account for about 80% of total order revenue but
have limited areas of expertise, while the medium and small firms have expertise in custom machines
for specific customers and produce specialized, automated, and safety-focused equipment
incorporating novel technologies.
Ｐ・４
Ｐ・４ ＮＥＸＴ：
ＮＥＸＴ： The
The industry’s
industry’s main
main products
products

40

The
The industry
industry
today
today

The
The industry’s
industry’s main
main products
products
Press-type forming machinery: machine press, forging
machine, hydraulic press, automated equipment

Sheet metal forming machines
Punching press
Press break
Shearing machine
Bending machine
Other
Ｐ・５
Ｐ・５ ＮＥＸＴ：
ＮＥＸＴ： Industry
Industry machinemachine order
order trends
trendsThe
The industry
industry
today
today

Forming machine order trends: member
survey on industry conditions

Press machinery is defined as encompassing machinepresses, forging machines, hydraulic presses, andautomated equipment. Sheet metal machinery is definedas punching presses, press breaks, shearing machines,
bending machines and others.

Unit:
Forming machine order trends:
Total Orders in yen by year
¥100
million quarterly member surveys on industry conditions

160.9 164.4

6000

136.9

132.4

5000

4000

103.3

90.0

3842 3926

98.7

3000

2148
782

2358

95.2
3271

1367 1412

98.9

93.6 96.7

70.5

1538 2274

1416

974
1745

2114 2159

1300

64.8

1683 1827

921

961

97.0

1125

97.9

796
1031

854
1554 1348 1537

50

59.6

907

721

1986
816

1547 1424
595

1104 1170

953

120.5

77.9
2877
2338

1133 1761 1826

％

1860

0
798

771

-50

524

457
967

150

110.3106.91002514 2473 2670

763
1733

73.7 76.4 83.1

76.5

1728 1767

946

1000

105.3 103.6 111.8

107.2

3161

2000

Sheet metal machinery
Press machinery
CI index of economic
performance (outlook)
Industrial output index
Forming machine index

1336 1567

2079

2005

2004

2003

2002

2001

2000

1999

1998

1997

1996

1995

1994

1993

1992

1991

1990

1989

1988

1987

-150

1986

0

-100

1. Forming machine orders fluctuate about five times as widely as the economic performance index,
the industrial output index, and machine industry infrastructure investment. The 20-year average
declined over the last few years but finally moved upward in 2005.
Ｐ・６
Ｐ・６ ＮＥＸＴ：Machine
ＮＥＸＴ：Machine tool
tool order
order trends
trends andand comparison
comparison

The
The industry
industry
today
today
Unit: ¥100
millionForming machine order trends compared tomachine tool order trends

Machine tools

％

100.0

18000

96.5

Press recovery
16000
14000

68.0

44.9

42.9

80.0

Press machines
Sheet metalmachines

73.3
13632 60.0

50.6

12000

Forming machines
total

96.3

14121

54.7

100.0

45.2

36.3

10000
8000

0.0

6000

-20.0

3926

4000

2877

-40.0

Press machines
Sheet metalmachines
Machine tools total

Sheetmetal?

2005

2004

2003

2002

2001

2000

1999

1998

1997

1996

1995

1994

1993

1992

1991

1990

-80.0

1989

0

1988

-60.0

1987

2000

1986

Forming machines
total

40.0
20.0

25.9

Machine tools total

1. The machine tool industry recovered to a level close to its 1990 bubble era peak in 2005 (96.5%) and exceededbubble era performance in 2006, whereas the forming machine industry was still only at 73.3% of its bubble era
peak.
2. Like the machine tool industry, the press machine sector of the forming machine industry has recovered. On theother hand, the sheet metal machine sector is at 45.2%, less than half the bubble era peak. The primary factor in thisis thought to be the push by the machine tool industry to promote laser technology.
Ｐ・７Ｐ・７ ＮＥＸＴ：
ＮＥＸＴ： Order
Order trends:
trends: domestic
domestic andand international
international comparison
comparison

The
The industry
industry
today
today
Unit:
¥100
millionForming machine order trends: domestic and overseas

Domestic and overseas proportions of forming machine order revenues
48.5

43.8

5000

42.1

50.0

31.5

30.1
15.8

Domestic
Overseas
Overseas percentage
Forming machine total

3926

4000

3207
3000

0.0

2877

2670

-50.0
2000

1730

1683

1000

1212

940

719

1665

1424

-100.0

834
590

2005

2004

2003

2002

2001

2000

1999

1998

1997

1996

1995

1994

1993

1992

1991

1990

1989

1988

1987

-150.01986

01. Domestic orders dropped to 1/4 the level of the 1990 peak, as a result of manufacturers moving
overseas due to the rising yen and labor costs. By 2005, orders had recovered to more than 50% of their1990 bubble era peak, but we do not anticipate significant growth beyond this level.
2. Overseas orders recorded their highest level ever in 2005, 1.7 times greater than in 1990. Overseas
orders are expected to continue growing, which will require stronger international competitiveness.
Ｐ・８
Ｐ・８ ＮＥＸＴ：
ＮＥＸＴ： Analysis
Analysis ofof overseas
overseas orders
ordersThe
The industry
industry
today
today

Forming machine overseas order trends
Overseas exports by country 2005
Pressス
machinery
プレ系機械

鍛圧機械 受注海外向け 2006年輸出国別

タイ、インド、
Thailand,India,
インドネシア,
Malaysia, Indonesia
18 18

1

China andSE Asia
account
for 60% of
exports

シンガポール、
マレーシア、他,
Singapore,
Malaysia, etc.
その他,
1.9
1.9
Other 0.8
0.8

20

1
2
3
3
5

39

板金系機械
Sheet metal machinery
3

Europe欧州, 77

中国, 3325

北米, 26
North America 26

中南米,
1
South
America1

China 33

0

2

12

29

ロシア、東欧,2
Russia,Eastern Europe
2
中近東、
Middle and Near East,
アフリカ, 3Africa 3
韓国、台湾,
Korea,
Taiwan77

15

North
Americaand Europe
account for
50% ofexports

2
13

19
5

0

1. China, North America, Thailand, and India account for 77% of exports.
2. China accounts for 40% of press machinery, followed by North America and Thailand. Europe’s share is small.
3. North America accounts for 30% of sheet metal machinery and Europe 20%, which comes to 50% of the total.
Ｐ・９Ｐ・９ ＮＥＸＴ：Order
ＮＥＸＴ：Order analysis
analysis by
by demand
demand source
source

The
The industry
industry
today
today

Forming machine order source analysis: press machine/sheet metalmachine comparison
From domestic industry 2005

国内業種構成比2005年 2005
Forming 鍛圧機械合計
machine total makeup
for domestic industry
その他,
Other industries
1212
精密機械
Precision
製造業, 4machinery 4

Steel
2
鉄鋼業,
2

プレス
系機械
Press
machines

1213

Non-steelmetal manufacturing2
非鉄金属製造業,
2

17

4

3

金属製品
製造業,
25
Metal
components
25

10
50

Sheet metal machines
板金系機械 29

3 2

7Transportation
輸送用機械
machinery
製造業, 37 37
manufacturers

Generalmachinery 7
一般機械製造業, 7
Electric machinery 11
電気機械製造業,
11

1.

16

44

17

Press machinery is heavily weighted to the transportation category. This category, together with metalcomponents and automobile-related manufacturing, comprises more than 70% which can be attributed toautomobile manufacturing. The growth in investment in overseas automobile manufacturing has contributed
greatly to the growth of press machine manufacturing.

2. User distribution by industry has been largely unchanged over the last 15 years. One issue for growth of ourindustry is the cultivation of new users (industries) to follow the healthy share taken by the automobile industry.
Ｐ・１０
Ｐ・１０ ＮＥＸＴ：
ＮＥＸＴ： Analysis
Analysis ofof correlation
correlation between
between JapaneseJapanese automobile
automobile trends
trends andand industry
industry

The
The industry
industry
today
today

Correlation between yen totals of press-type forming machine orders andvolumes of Japanese automobiles manufactured worldwide
Forming machines: machine presses, forging machines, hydraulic presses, automated equipment(¥100 millions)2500

Machine presses
Forging machines
Hydraulic presses
Automated equipment
Japanese auto units manufactured worldwide(1,000s of units)
25000

2000
20000
1500

1000
15000
500

0

10000
’８６ ’８７ ’８８ ’８９ ’９０ ’９１ ’９２ ’９３ ’９４ ’９５ ’９６ ’９７ ’９８ ’９９ ’００ ’０１ ’０２ ’０３ ’０４ ’０５●A significant correlation between press machines and worldwide Japanese auto output●This correlation is especially pronounced from 2003
Ｐ・１１
Ｐ・１１ ＮＥＸＴ：
ＮＥＸＴ： Movement
Movement ofof JapaneseJapanese auto
auto output
output by
by region
regionThe
The industry
industry
today
today
(millionsof units)Japan

W Europe
China
Growth %N America
S America
Africa, Mid E

Mid-, E Europe, CIS

120

Asia-Pacific
100

20%
79.3

80
60

SourceThrough 2006: FOURIN Inc. automobile
statistics
Year 10 : US JD Power And Associates

Shift in auto output by global region

57.8

59.7

57.7

60.3

62.2

10%

3.3%

7.2%

4.6%

40

67.1

69.4

5.1%

3.2%

54.0

65.4

-3.5%

3.1%

3.6%

2.6%

0%

’０５

（暦年)

-3.2%

20
0

-10%
’９８

’９９

’００

’０１

’０２

’０３

’０４

’０６

’１０

Statistics through 2005 from

Automobile Manufacturers
Shifts in worldwide Japanese auto output Japanese
Association, year 10 is an estimate(millionsof units)

Japanese auto output worldwide
9.7%

35

3.3%

3.5%

5.6%

Japanese auto growth
6.6%

7.0%

5%

15

0.6%

-7.2%

20
15.4

15.9

16.5

16.6

18.2

19.2

20.5

0%

21.9

-5%
-10%
-15%

10

-20%

5

-25%

0
’９９

’００

’０１

’０２

’０３

’０４

’０５

JapaneseJapanese auto
auto worldwide
worldwide
manufacturing
manufacturing trends
trends
・5
・5 to
to 7%
7% annualannual growth
growth・Around・Around 6%
6% annualannual growth
growthgoing
going forward
forward-30%(year)’９８

While
Whilenonogrowth
growthisisanticipatedanticipatedfordomestic
output,for domestic output,increasing
increasing
outputofoverseas
Japanese
output of overseas Japaneseauto
auto
manufacturers
manufacturersand
andsuppliers,
suppliers,
andandthetheestablishment
establishmentofofnew
newoverseas
manufacturing
overseas manufacturing
centers
centersare
areexpected
expectedtotoincrease
increasepress
pressmachinemachinedemand!!
demand!!

10%

30
25

・3
・3 to
to 5%
5% annualannual growth
growth・Growth・Growth mostly
mostly in
in China,
China, Asia
Asia・3%・3% annual
annual growth
growth going
going
forwardforward’１０

Ｐ・１２
Ｐ・１２ ＮＥＸＴ：
ＮＥＸＴ： Chap.
Chap. 2:
2: Industry
Industry strengths,
strengths, weaknesses
weaknesses

Ｐ・１３
Ｐ・１３ ＮＥＸＴ：
ＮＥＸＴ： Industry
Industry strengths
strengths andand weaknesses
weaknesses (global(global analysis)
analysis)Analysis
Analysis ofof current
current
globalglobal conditions
conditions

Industry strengths and weaknesses(press machinery global competitiveness)

Share: 43%

Our
Ourindustry
industrypossesses
possessesthe
theworld’s
world’s
best
technologicalexpertise!!
best technological expertise!!

Europeanenterprises
Approx. ¥ 200
billionSchuler

Fagor

Weingarten

Share: 3%

Ravne

US enterprises
Approx. ¥15billionJapanese

Share: 45%
Japaneseenterprises
Approx. ¥210 billion

Strengths: Excellent technology
and international competitivenessof the two German companies
Weaknesses: Poor business performanceof BIG 3 and dealing with a rising Euro
Trend: Business expansion with the
expanding Euro zone

Share : 10%★Overseas results ofJapanese overseas manufacturers
are included in Japan
results

Asian enterprises
Approx. ¥45
billion

SEYI

Chin
Fong

WIA

Hyundai Japanese

Jinan

Strength: Price competitivenessWeaknesses: Technology and quality
Trends: Improve technology andquality; enter Japanese market

Minster JapaneseForming machine
Industry (presses)
Strengths: Technology, manufacturing processes, customer service, forming
process technologies
Weaknesses: Price competitiveness, developing global production capability(with some exceptions), competitiveness in EU market
Trend: Market growth accompanying entry of Japanese automobile
manufacturers into overseas markets (growth of BRIC markets)

Ｐ・１４
Ｐ・１４ ＮＥＸＴ：Analysis
ＮＥＸＴ：Analysis ofof current
current machinery
machinery imports
imports

Analysis
Analysis ofofcurrent
current conditions
conditions
Unit:
¥100
million5000

Forming machinery order trends: domestic orders
Domestic
and import total in yen
Imported amount

Import % (vs. domestic)

Forming machinery: yen amount and percentage of imports

Yen rate

160
143

104

102

100

4000

¥ rate

132

130

122

US$/¥
rate

118

200
150
100

3207
50

3000

10.4

9.8

8.0

9.5

8.6

％
0

2000

1730

1665
-50
834

1000

-100
258

170

79

142
-150
2005

2004

2003

2002

2001

2000

1999

1998

1997

1996

1995

1994

1993

1992

1991

1990

1989

1988

1987

1986

0

1. In response to domestic demand, imported machinery moves in the 8% range. This will notsignificantly change since yen-dollar fluctuations and the growth of the machine industry inneighboring countries will not impact the industry’s novel technology, price competitiveness,and established customer base.
Ｐ・１５
Ｐ・１５ ＮＥＸＴ：
ＮＥＸＴ： Chap.
Chap. 3:
3: Biggest
Biggest priorities
priorities forfor industry
industry members
members

Ｐ・１６
Ｐ・１６ ＮＥＸＴ：
ＮＥＸＴ： The
The most
most important
important priorities
priorities forfor members
members

Priorities of members of the Japan Forming Machinery Association（According to a METI survey)

Members are most focused on: developing novel technology and expertise
Priority score by industry group

Enhancing originality【Enterprise priorities】

0.50

1.00

1.50

2.00
1.87

① Novel technology and expertise, organizational capability,

1.63

customer network, etc. awareness and utilization

1.60② Articulating the company’s core management principles and strategy

1.48
1.5

③ Cultivate new users and industries

1.21

Japan Forming Machinery
Association members

1.20
1.14

④ Enhance ability to flexibly adjust to what customer’s require
1.07⑤ Develop overseas business by gathering overseas data, entering overseas markets,

Total enterprises
responding (13 enterprises)

0.84

and forming partnerships with local business entities.

1.07⑥ Ensure human resources by strengthening connections with universities and

0.95

technical and vocational schools

1.07⑦ Create an employee friendly working environment

Extremely high priority = 2 points
Somewhat a priority = 1 point
1.28 Not a high priority = 0 points

1.0⑧ Correct inadequate business practices

1.25
1.0
0.94

⑨ Develop technology through partnerships with upstream/down stream businesses

0.87⑩ Correctly evaluate and assess company technology

1.07⑪ Stimulate constructive communication between closely connected departments

0.67⑫ Constructive partnerships with businesses in the same and different industries

0.67⑬ Training the next generation of managers

0.67

0.81

0.75
1.22

Ｐ・１７
Ｐ・１７ ＮＥＸＴ：Chap
ＮＥＸＴ：Chap 4:
4: Industry
Industry customer
customer needs
needs andand seeds
seeds

Ｐ・１８
Ｐ・１８ ＮＥＸＴ：
ＮＥＸＴ： Industry
Industry customer
customer needs
needs andand seeds
seedsCustomer needs and seeds*(*new materials and technology supplied by the industry)

Customerindustries

Forming machinery industry positioning and fabrication processing

CoreCore industry
industry
FormedFormedand
andfabricatedfabricatedmaterials
materials

Key
Key industries
industries
Automobiles
Automobiles
electricalelectricalmachinery,machinery,electronics
electronicsindustry,
industry,otherotherindustries
industries

Needs & Seeds
Transport
equipment

Forming
Forming
machinerymachinery

Safetyequipment

Fabrication
Fabrication

Materials
Materials

High
High
ValueValueadded
added
components
components

Molding
Molding
Lubrication
Ｐ・１９
Ｐ・１９ ＮＥＸＴ：
ＮＥＸＴ： Automobile
Automobile part
part needs
needs

1)
1) Automobile
Automobile parts
parts manufacturing
manufacturing needs
needs
Relations between metal press technology and automobiles
Good

Car exterior
panels(single-piece
forming)

FutureGeneral-use
cold-rolled steel

Formability

Carstructure(structuralcomponents)

38kg
high-tension

Chassis parts
Wheel discs

45-55kg
high-tension

Door impact beams
Bumper reinforcements
80-120kg
high-tension

Poor

Present
Mpa

Data on high-tension material trends: JFE SteelSource: Mitsubishi Research Institute basic research on
strengthening competitiveness of key national industries byimproving metal press technology
Ｐ・２０ ＮＥＸＴ：
ＮＥＸＴ： Home
Home information
information applianceappliance part
part needs
needs
Plate formed components Ｐ・２０

2)2) HomeHome information
information applianceappliance parts
parts needs
needs
Relations between metal press technology and home information appliances
Devices for reading/writing data at magnetic disc surfaces

1 inch1.8 inch

0.85
inch

2.5 inch

3.5 inch
Various sizes of hard discs

HDD structure

Motor
Magnetic desk

Notebook computerwith HDD

Magnetic head

HDD development trajectory(NEDO technical materials)
Source: Mitsubishi ResearchInstitute basic research on
strengthening competitivenessof key national industries byimproving metal press
Micro-fabricated component
technology
parts required by mobile
phones (NEDO technicalmaterials)⇒ RF antenna (high-frequency antenna)⇒ RF switch(micro high-speed frequency-conversion switch)⇒ RF resonator, RF condenser(variable condenser and resonator)⇒ Tuner, filter⇒ Directional microphone

Ｐ・２１
Ｐ・２１ ＮＥＸＴ：
ＮＥＸＴ： Needs
Needs ofof thethe robotics
robotics field
field

3)
3) Needs
Needs ofof thethe robotics
robotics field
field
Example of robot structural elements(Integration of technologies for a wide rangeof elements. Areas in which Japan is a leader
are underlined.)

Artificial
intelligence

Networking technology

Human interface- Image recognition- Voice recognition,
composition- Others

Image sensor
Voice sensor

Autonomous control
Remote operation

Drivingmechanisms
Including joints,
sensors, positioning

Motion control
Design,materials,
Motion control
machining,systems, andbattery technologies
Honda’s ASIMO robot

Power sensors

Robot structural elements(NEDO technical materials)
Basic structure of a single cell
From the left:-Separator-Air electrode (cathode, catalyst)-Electrolyte (e.g., solid polymer)-Fuel electrode (anode, catalyst)-Separator

Stack

Cell
Air
Air

Fuel cell structure(NEDO technical materials)

Source: Mitsubishi Research Institute basic researchon strengthening competitiveness of key national
industries by improving metal press technology

Cell structure
Separator
Hydrogen electrode(catalyst)
Electrolytic
membrane
Air electrode(catalyst)

Separator

Ｐ・２２
Ｐ・２２ ＮＥＸＴ：
ＮＥＸＴ： Needs
Needs ofof advanced
advanced technology
technology products
products

4)4) Needs
Needs ofof advanced
advanced technology
technology products
products
Airbag highspeed sensor

Micro Machines
MEMS: Micro Electro Machine System

Plan
view

Acceleration sensor
Ignition control
electronic circuit

Side
view
(A-A)

Bending of sensing elementchanges with acceleration

Airbag acceleration sensor chip

Micro-chemical chip (DNA analysis)-MEMS etching technology is used to etch microscopic reaction channels on materials such as glass substrates.
Chemical substances react in these channels.

Chip size: 2 cubic mm
Device size: 15 cubic mm-Design is crucial for optimizing the efficiency of test reagents and extracting reaction products.
(Calculating optimal chip layout, calculating flows for optimal chemical reactions, and so on.)The benefits of reduced size
- Reaction completes in a short period of time
- Possible to use micro-substance reactions

Airbag control unit with acceleration sensor chip

Sample reagent

Sample undergoes reaction!
Structural elements

Problem

Energy Supply
Abrasion and viscosity

Substancetoreact withreagent

Actuator
Heating
SensorSubstance to extract
reaction product

Only extract reaction productMicro-chemical chip

Reaction product extracted!

Principle mechanism of a micro-chemical chip

Source: NEDO technical description

1 yen coin
Diameter 20 mm

Inner diameter
10 mm

Ｐ・２３
Ｐ・２３ ＮＥＸＴ：
ＮＥＸＴ： Forming
Forming processprocess seeds
seedsForming
Forming processprocess seeds
seeds

The five categories
Forming materials

1. Composite forming
Difficult to work
materials

2. Double-action forming
3. Sequential forming
4. Hydraulic forming

High-performancematerials
Light-weight materials

Unusual materials
Tailored blank

5. Micro-precision forming
Ｐ・２４
Ｐ・２４ ＮＥＸＴ：
ＮＥＸＴ： Composite
Composite forming
forming seeds
seeds

1)
1) Composite
Composite forming
forming (combining(combiningseveral
severaltechniques)
techniques)
Deformation processing
and cutting

Deformation processing
and bonding

Hot forging and cold forging

Smoothchamfering
Reverse gear

Forged and formed
helical teeth
Helical gear with dog teeth

Courtesy Seki Corporation

Sheet metal forming-cold forging composite forming

Courtesy O-Oka Corporation

Magnesium forming inner mold heating
Inner moldheating system

Notebook computer catalog

Consistenttemperatures- Warm forming- Forming rate
control- Material
temperature control

Slide position

A forming device
Capable ofquantitative control

The world’s lightest
B5 notebook computer
Time

Courtesy Sanki Corporation
Ｐ・２５
Ｐ・２５ ＮＥＸＴ：
ＮＥＸＴ： Double-action
Double-action forming
forming seeds
seeds

2)
2) Double-action
Double-action forming
formingVibration
Vibrationforming
forming
Characteristics
・Forms high-precision, high-value added shapes
・Reduces processing steps and therefore mold andequipment costs

Sheet metal forming
Precision blanking
FCF method

Drawing ⇒ Compression
drawing

Courtesy Hadano Seimitsu

Courtesy Toyota Motor Corporation

Forging
Enclosed forging
Back pressure forming
Courtesy Alpha

Hydraulic forming
Hydro-forming
Hydraulic counterpressure forming
Courtesy JFE Steel

Ｐ・２６
Ｐ・２６ ＮＥＸＴ：
ＮＥＸＴ： Sequential
Sequential forming
forming seeds
seeds

3)
3) Sequential
Sequential forming
forming
1.Characteristics

Flow forming

Resource, energy efficient

Sequential forming can be performed
with small capacity, compact
equipment
Suitable for producing a large
number of parts in moderate amounts
Reduces die number and cost, postprocessing in-line forming

Vibration
forging

2. Methods
Sheet metal forming
Spinning, Rolling
Flow forming
Incremental forming

Cold forging
Vibration forging

Incremental forming
Ｐ・２７
Ｐ・２７ ＮＥＸＴ：
ＮＥＸＴ： HydraulicHydraulic forming
forming seeds
seeds

4)
4) HydraulicHydraulic forming
forming
Extrusion force

1. Characteristics

Die-clampingforce

Die-clamping
force

Die

1) Hydraulics do the molding
・3D stress (hydrostatic pressure) enhances
formability
・Reduces number of die parts
2) Environmentally friendly, emission free process3) Small, medium volume production of multiple
parts

Internalpressure

Extrusion
force

Intensifier

Functional overview

Hydro-forming

2. Methods

Applicationof pressure

Applicationof pressure1) Hydro-forming2) Counter-pressure hydraulic forming
Hydraulicallyapplied pressure

Counter-pressure hydraulic forming
Ｐ・２８
Ｐ・２８ ＮＥＸＴ：
ＮＥＸＴ： Micro/precision
Micro/precision forming
forming seeds
seeds

5)
5) Micro/precision
Micro/precision forming
forming0.25 mm diameter gear

1. Characteristics★ Growing production of environmentally friendly,
compact, and light products★ Growing demand for micro-precision parts★ Shift from etching and micro-machining techniques

The dark object in theforegroundis a 0.5 mm pencil lead

Organization for Small & Medium Enterprises and Regional Innovation:
Project to Strengthen Strategic Core Technologies

2. Object components★ Automobile fuel injector nozzle★ Inkjet printer nozzle
254±0
.5μm

Φ120～300μm

Illustration of Piezo element driving

t = 0.2 mm【12-nozzle component】

Ink surface【Electron microscope photographof a slanted hole made by press
punching】

Piezo element

Courtesy Komatsu
Komatsuseiki
KosakushoSeiki
co.ltd.

★ Micro-level forming: Multi chip module grooves

Holediameter

穴径: Φ28.5±0.5μm

1 line, 48 hole
6 line forming

Moving image

Ｐ・２９
Ｐ・２９ ＮＥＸＴ：
ＮＥＸＴ： Chap
Chap ５:
５: TheThe direction
direction ofof forming
forming machinemachine technology
technology

Ｐ・３０
Ｐ・３０ ＮＥＸＴ：
ＮＥＸＴ： The
The direction
direction ofof technology
technology development
development (1)
(1)

The
The direction
direction ofof technology
technology development
development (1)(1)
3-1 Forming machine technology that contributes to net-shape forming1) Ultra-precision, high rigidity

2) High-performance with digital control






Optimal slide motion control
Optimal press moving part pressure
force, speed, and position
Dynamic geometrical accuracy control
Elastic deformation, bottom dead center
position control

Slide
Upper dieLower die
Bolster
Bed(2) Slide(3) Parallelism
Slide gib

Improves mother machine dynamic
geometrical precision (slide and bolster
straightness, parallel positioning, angles,bottom dead center, eccentric load, etc.)(1) Straightness[Slide and bolster]

Slide
Slide
Upper dieLower die
BolsterBed

Upper dieLower die
Bolster
Bed

Slide geometric precision

Optimal slide motion settings
Ｐ・３１
Ｐ・３１ ＮＥＸＴ：
ＮＥＸＴ： The
The direction
direction ofof technology
technology development
development (2)
(2)

The
The direction
direction ofof technology
technology development
development (2)(2)
3-2 Forming machine technology that contributes to energy andresource conservation

Press machines
1) Energy efficient running systems and operating mechanismsServo technology for optimal motor drove control
Reduced friction drag, lubrication free sliding parts

2) Compact structure (resource, energy efficient)Net shape forming with high-precision, highly rigid press
Has benefits of reducing workplace size (installation area, height),
reducing material and energy costs, and enhancing LCA (life cycle
assessment) performance
In-line forming3) Universal applicability

1 unit performs the functions of a wide variety of press machines
Ｐ・３２
Ｐ・３２ ＮＥＸＴ：
ＮＥＸＴ： The
The direction
direction ofof technology
technology development
development (3)
(3)

The
The direction
direction ofof technology
technology development
development (3)(3)
3-2 Forming machine technology that contributes
to energy and resource conservation

Press machines4) Composite formingComposite forming with techniquesfrom other fields
Composite forming using multiple
techniques

Multi-process forming
Module press

5) Multi-operation
Up-down, left-right, forward-reverse operation

6) Forming of hard to work
materials


Slide motion, speed setting discretion
Localized heating, temperature control

Net-shape forming with reduced
process steps, complex shapes

Light materials (high-tensile,aluminum alloys, magnesium,
titanium, etc.)

Ｐ・３３
Ｐ・３３ ＮＥＸＴ：
ＮＥＸＴ： The
The direction
direction ofof technology
technology development
development (4)
(4)

The
The direction
direction ofof technology
technology development
development (4)(4)
3-2 Forming machine technology that contributes
to energy and resource conservation
Press machine forming system
1) Intelligent forming system

Optimal control system for high output and high energy efficiency
Full turn key forming system including die
24 hour unmanned running system
Inline output inspection and correction system (robust sensor)
Die, material replacement system

2) Small-medium output of manydifferent parts

Sequential forming
compatible

Reduced die, material replacement time
Equipment with flexible material and handling

3) Highly energy efficient warm and low temperature forming
Material and die temperature control system including localized heating of

hard to work materials
Ｐ・３４
Ｐ・３４ ＮＥＸＴ：
ＮＥＸＴ： The
The direction
direction ofof technology
technology development
development (5)
(5)

The
The direction
direction ofof technology
technology development
development (5)(5)
3-3 Operator friendly press machines
Focus on smart operation in a comfortable working environment

1) Safety2) Environment

・ Combines safety and productivity

Motion, speed control
Low vibration and noise ・ Silent forming
Emission free・ Dry press forming
No lubricant
Maintenance free・ Production management, preventive
maintenance, malfunction diagnosis

3) Information Technology for enhanced running efficiency
Reduced set up time

Reduced trial time・Automatically set forming criteria
and conveying time・ Automatically replace die and material
・ Forming simulation and press docking
Ｐ・３５
Ｐ・３５ ＮＥＸＴ：
ＮＥＸＴ： The
The direction
direction ofof technology
technology development
development (6)
(6)

The
The direction
direction ofof technology
technology development
development (6)(6)

3-4 Micro-precision press for advanced technology fields
Creating new demand1) Micro-precision forming
・Robot, micro-machine
Single micron, nano
Micro-chemical chiplevel press processing2) Vibration forming
・ Vibration forming promoting enhanced formability and dry
processing
3) Forming hard to work materials
・High-performance materials: inconel, niobium, tantalum,
molybdenum, plastics, plastic-metal composites, metal glass
Ｐ・３６
Ｐ・３６ ＮＥＸＴ：
ＮＥＸＴ： Chap.
Chap. 6:
6: WhyWhy ecoeco products?
products?

Ｐ・３７
Ｐ・３７ ＮＥＸＴ：
ＮＥＸＴ： The
The demand
demand forfor eco-technology
eco-technology is
is aa result
result ofof customer
customer needs
needs

The
The demand
demand forfor eco-technology
eco-technology is
is aa result
result ofof customer
customer needs
needs
The customer’s environment and innovation in forming machine industry technology
・aluminum and high-tensilematerial techniques
・Fuel cell compatible

・Hybrid cars
・Hydro-forming

Industry-govt-academia
Industry-govt-academia
partnerships
partnerships
Upstream-downstream
Upstream-downstream
partnerships
partnerships

・Safety standards

Customer’s business environment

Eco-products
Eco-products

Low fuel costs
Alternative energy

・High productivity
・Energy efficient・Low noise

・Net shape forming
・Reduce CO2 emissions
Manufacturing processshipping, installation,customer production
processes

Adopting global・Complying withstandard for regulations regulations of each country

M&A

・Shift to CAD/CAM, NC

Customer:
Increased
Value-Added
Environmentally conscious

・Automation
Global in scopeproduct development andmanufacturing

EnergyEnergy efficient,
efficient,
low
noise
equipment
low noise equipment
・Resource efficient・Enhanced die life cycle

・Japan’s unique regulations

Forming
industry
response

Best
Best techniques
techniques forfor newnewmaterials
andsubstancesmaterials and substances・Servo press standards

Equipment that is easy
to set up, does not
malfunction, easy tomaintain, and easy to operate

Consumer needs
Diversification

More flexible equipment
Shorter delivery time・Simplified operation

・Life cycle assessment technology
・Malfunction diagnosis, analysis technology

・Preventive maintenance technology
・Manufacturing
technology

・System technology

・Remote diagnostics

Ｐ・３８
Ｐ・３８ ＮＥＸＴ：
ＮＥＸＴ： Why
Why eco-products?
eco-products? Eco-principles
Eco-principles andand elements
elements

Why
Why eco-products?
eco-products? Eco-principles
Eco-principles andand elements
elements
All user needs are tied to eco-products
1. Eco-products are products andservices differentiated by afocus on easing environmental
burden.

Achieving value-added

Ｗｉｎ－Ｗｉｎ
Ｗｉｎ－Ｗｉｎ2. Primary elements of eco-products
1) Resource and energy efficient2) Reduced waste and toxicity
3) Light, durable, enhanced recycling
4）Enhanced die life cycle5）Net shape forming

Strengthen market competitiveness
Enhanced added value
Development and supply of eco-products
User

Enterprise

Direct and indirect benefits
from improved
environmental performanceof products
Sense of security for
future generations

Purchase of eco-products

Strengthen market
competitiveness
Enhanced added value

Framework of
Win-Winrelationship

Purchase of eco-products

Environment

Source: METI Eco Products andManagement Strategy Study Group

Easing environmental burden

Ｐ・３９
Ｐ・３９ ＮＥＸＴ：
ＮＥＸＴ： Forming
Forming industry
industry eco-products
eco-products

Forming
Forming industry
industry
eco-products
eco-products
Current eco-products produced by the forming machine industry
Machine nameEcofeatures

Function

Benefits

Target industry

Energy efficient, low noise, oil
efficient
Energy efficient, low noise, oil
efficient
Energy efficient, low noise,smaller size resource efficient

C-press○

Servo motor drive

Straight side press○

Servo motor drive

High-speed press○

Servo motor drive

Hydraulic press○

Hydro-forming
machine○Hydraulic pump drive
servo motor
D.D.V type hydraulicservo pump

Former○

Incorporation of highprecision ball bearings, etc.

Energy efficient, low noise, lowvibration

Pipe bender○

D.D.V type hydraulicservo pumpThread rolling machine○

Servo motor drive

Punching press○

Press brake○

Servo motor drive.
Regeneration mechanism
Hydraulic pump drive
servo motor

Low noise, energy efficient, oil
efficient
Low noise, low vibration, oil
efficient
Energy efficient, low noise, lowvibration○

Versatile form roller

Energy efficient, low noise
Energy efficient, low noise, oil
efficient

Automobile, metal
products
Automobile, metal
products

Global value
World’s only one ofits type
World’s only one ofits type

Electronic components
Automobile, metal
products
Automobile, metal
products
Automobile, nut andbolt manufacturers
Automobile, metal
products
Nut and bolt
manufacturers

World’s only one ofits type

Metal products

Energy efficient, oil efficient

Metal products

Energy efficient, resource
efficient

Automobile, metal
products

Shearing
Seam welding andforming equipment
FeederSafety equipment

The use of servo motors in ecoproducts is spreading rapidly!!

Ｐ・４０
Ｐ・４０ ＮＥＸＴ：Servo
ＮＥＸＴ：Servo press
press order
order trends
trends forfor ０３
０３ to
to ０５
０５

Analysis
Analysis ofofcurrent
conditions
current conditions

Forming machines order trends: servo press

Percentage of machine presses
that are servo press (transfer press base excluded)

Unit:
¥100
million億円

Servo press
Past machine (flywheel press)
Servo press %Machine press total (TR excluded)

1,400

50

800

1,215

899
26.0

830

25

15

7.4
6.2

200

42

2003

316

0

2005

80.8
1,000

69.5

600

50
40
30

400

241

0

80

60

Servo punching
Past punching
Servo press %Punching total

800

200

85.6

70

10
5

66

2004

90

1,200

30

20

642

400

0

35

897

600

100

1,400
40

685

Unit:
¥100
million

45

1,200
1,000

Percentage of punchingpresses that are servo presses

164
114

50

2003

195 46

313
20

267
45

10
0

2004

2005

1. In 2005, growth for the old flywheel machine press was small while servo press machines
increased almost five fold to 26% of the total.
2. The shift of sheet metal punching presses to servo machines continues and has exceeded the
projection of 80%.
Ｐ・４１ ＮＥＸＴ： Eco-products presentation (universal press)

Ｐ・４１ ＮＥＸＴ： Eco-products presentation (universal press)

Universal
Universal servo
servo press
press
Only product of its kind

1. Technology features

Amp, power source

Greatervalue-added

Balancer, tank

Main gear

Global market
Market competitiveness★Free motion★Low noise and vibration★Enhances productivity★Increases product precision★Processes difficult to work
materials★Reduces number of processing
steps

2. Technological strength and competitiveness

MonopolymarketTechnological strength
Condenser

Servo motor

Break

Drive shaft

Ｐ・４２
Ｐ・４２ ＮＥＸＴ：
ＮＥＸＴ： Eco-productEco-product presentation
presentation (straight(straight side)side)

Link-type
Link-type servo
servo press
press(tandem(tandem press
press line)
line)

Only product of its kind

1. Technology features
Free motion press= free motion

Bottom dead centerstop time(processing stop time)High precision due
to bottom dead center stop

Noise (dB)Time

Reduced vibration
And workpiece-lifting
when workpieces
stick to mold

Processing while idle
(composite processing)Market competitivenessProcessing range

Forming speed
appropriate tomaterial

Crank (link) press= fixed motion
Synchronized operation
with adjacentequipment

H2F processing time
Minimum
StrokeSlide position

AdjustablestrokelengthCrank press processing time

2. Technological strength and competitivenessGlobal market

MonopolymarketTechnological strength

1/100th thenoise energy!
AC servo motor
PulleyBall-screwSpecial link
Crank press

AC servo press
Bolster

Liner sensor(Two-way)

Ｐ・４３
Ｐ・４３ ＮＥＸＴ：
ＮＥＸＴ： Eco-productEco-product presentation
presentation (high-rigidity(high-rigidity press)
press)

Ultra-highUltra-high precision,
precision, highhigh rigidity
rigidity press
press
Only product of its kind
2. Technological strength and competitiveness1. Technology features
Net shape, high-value added forming

・ Strong structure for bearing concentrated
loads

Market competitiveness・”0” clearance slide gear face contact
ensures high dynamic precision
・ Excellent eccentric load performance

Global market
MonopolymarketTechnological strength

Ｐ・４４
Ｐ・４４ ＮＥＸＴ：
ＮＥＸＴ： Eco-productEco-product presentation
presentation (composite(composite forming
forming press)
press)

Ultra-highUltra-high precision
precision composite
composite forming
forming press
press
Only product of its kind
2. Technological strength and competitiveness1. Technology features
・Composite forming with all servo drive

Global market

・Reduced processing steps and lower die costs
・Ultra-high precision press manufacturing
・Low volume output of multiple product types

Market competitiveness・Multi-point for bearing eccentric loads

MonopolymarketTechnological strengthOne-shot forming
Layer-forming
Ｐ・４５
Ｐ・４５ ＮＥＸＴ：
ＮＥＸＴ： Eco-productEco-product presentation
presentation (incremental(incremental forming)
forming)Incremental
Incremental forming
forming machinemachineOnly product of its kind
2. Technological strength and competitiveness1. Technology featuresdevelopment costs
Utilizes information technology

・Tool controlled by 3-axle servo motor

Global market
市場競competitiveness
争力MarketFrom press machine to forming machine・ Flexible no die processing
・ Low volume output
・ Reduced process time, reduced prototype andMonopolymarketTechnological strength

Ｐ・４６
Ｐ・４６ ＮＥＸＴ：
ＮＥＸＴ： Chap.
Chap. 7:
7: Tasks
Tasks forfor thethe forming
forming machinemachine industry
industry going
going forward
forwardＰ・４７
Ｐ・４７ ＮＥＸＴ：
ＮＥＸＴ： Chap.
Chap. 7:
7: Tasks
Tasks forfor thethe forming
forming machinemachine industry
industry going
going forward
forwardTasksTasks forfor thethe forming
forming machinemachine industry
industry going
going forward
forwardEstablish
EstablishaaＪＡＰＡＮＪＡＰＡＮbrand
brandandandstrengthen
strengtheninternational
internationalcompetitivenesscompetitiveness
Develop
Developan
aninternational
internationalstandard
standard(internationalize(internationalizeJIS)
JIS)
・Servo press international standard
・Safety standards
・Develop forming machine eco-products standard

MarketMarketstrategy
strategy・Domestic and overseas PR promotion of industry products (trade fairs, etc.)

10 yearsfrom now

IntellectualIntellectualproperty
propertystrategy
strategy
・Establish intellectual property rights
・Counterfeit goods countermeasures

Industry-academia-government
Industry-academia-governmentpartnerships
partnerships
・Effective use of public funding
・Strengthen partnerships

Ｐ・４８
Ｐ・４８ ＮＥＸＴ：
ＮＥＸＴ： Effective
Effective use
use ofof public
public policy
policy supporting
supporting businessbusinessMajor public measures in support ofsmall and medium businesses
Effectively
Effectivelyapply
applypublic
publicsupport
supportfor
forbusinesses
businessestotodeveloping
developingeco-machines
eco-machines
Management Support
z Project promoting strategic IT for small and medium businessSupport developing company systems

z Strategic, high-level core technology support

17 key industry sector, including metal press processing, forming, and diesz Project to support the Transfer of Key Small and Medium
EnterpriseTechnologies

Software development accumulating and applying the skills of experienced
technology, and expertise of experiences engineers

z Small Business Innovation Research (SBIR) program

Reduced patent fees and guaranteeing of debt when commercializing newly
developed technologyz Tax program to strengthen small and medium businesstechnology baseSpecial tax measures received when conducting testing and researchz Program to ensure small and medium business intellectual
property rights

Support for a portion of the cost of special investigations performed overseas
to determined the manufacturing and sales source of counterfeit and pirated
product by small and medium business that have suffered intellectual property
loss in overseas markets

z Small and medium business overseas business development
supportFree advice from specialists. Provision of information. (Advice oninternationalizing business)z Small business equipment capital loan program

No interest loan of half of equipment purchasing costs

Credit support
z Credit guarantee program association issues

When receiving loans from a financial institution, a credit guarantee a credit
thereby making it easier to raise capital

Financial support
z Tax program to promote small and medium business
investment

Applies special tax measures when acquiring machinery, equipment and otherinfrastructure and capital assets

Ｐ・４９
Ｐ・４９ ＮＥＸＴ：
ＮＥＸＴ： Business-academia-government
Business-academia-government partnerships
partnerships

Determining
Determining needs
needs andand developing
developing seeds
seeds
Strengthen
Strengthenthe
thepartnerships
partnershipsofofindustry
industryassociations
associations
andmanufacturers
withacademia
andresearchand manufacturers with academia and researchinstitutions
institutions

Automobile and electronics

Japan Metal Stamping
Association

Steel

Japan Auto Parts
Industries Association

Non-steel metals

Japan Dies Mold Industry
Association

Universities, research
centers, testing facilities

Forming
Formingmachinemachineindustryindustry

Electronic Industries
Association of JapanThe Japan Society forTechnology of Plasticity
Japanese Society of Die
and Mold Technology

Japan Electrical
Component Association

Determine
Determineneeds
needs

Develop
Developseeds
seedsJapan Forming Machine
Association

Eco-machine
Eco-machinedevelopment
development⇒⇒
Enhanced
Enhancedinternational
internationalcompetitivenesscompetitiveness
Ｐ・５０
Ｐ・５０ ＮＥＸＴ：
ＮＥＸＴ： AnAn industry
industry at
at full-potential
full-potential inin 10
10 years
years

Strengthening
Strengthening international
international
competitivenesscompetitivenessThe key to sustained industry growth: Taking the global lead in eco-machine development!!
A growing formed andfabricated materials industry

Industry vision: Outstanding international competitiveness

Developing
Developingand
andsupplying
supplyingeco-products
eco-products
Enhanced industry
value-added

Enhanced customer
value-added
Reduced environmental
burdenＷｉｎ-Ｗｉｎ

Ｐ・５１
Ｐ・５１ ＮＥＸＴ：
ＮＥＸＴ： Vision
Vision development
development committee
committee members
membersJapan forming machine industry vision development committee members
Company(in Japanese alphabetical order)

Name
Chairman

Enomoto Kiyosho

Aida Engineering, Ltd.
Director, Special Operating Officer

MemberNakano Takashi

Aida Engineering, Ltd.
Director, Development Head Office Forming Technology Center

MemberOrita Naoki

Amada Co., Ltd.
Director
Amino Inc.

MemberHachiken Yukiharu

MemberNishikawa Yoshiaki

Member

Komori Ryo

Sales Consultant
Hitachi Zosen Fukui Corporation
Tokyo Branch Manager
Komatsu Ltd.
General Manager, Industrial Machine Head Office Business Department

Hoden Seimitsu Kako Kenkyusho Cp., Ltd.

MemberMurata Tsutomu

Development Project Section Processing Development GG Leader

Secretariat

Sato Takehisa
Matsumoto Kenji

JFMA Executive Director
JFMA Executive Secretary

Ｐ・５２
Ｐ・５２ End
End