CAST Co., Ltd.
PROFILEwww.kkcast.co.jp

English version

Shirakawa Factory

Description of BusinessWe manufacture and sell castings. Castings of FC (flaky graphite cast iron), FCD (spherical graphite castiron), and alloy cast iron are manufactured semi-automatically and manually with a furan organic selfhardening cast molding process. The weight of handling is 50 to 4,000 kg, and the possible monthly
production is 200 to 300 castings pieces per one type. The production items are mainly related to industrial
robots, we are supplying frames for semiconductor mounting machines, machine frame, civil engineeringand construction machinery, marine engine parts, truck axle parts and so on.

Greetings from Representative Director
Our company, CAST, was founded in Fukagawa, Tokyo in 1889. Since then, we have been favored by manycustomers as a casting company. On March of 1994, the entire factory was moved from Koto-ku, Tokyo toShirakawa-shi, Fukushima.
In the Shirakawa factory, a work environment is realized in which the image of the conventional casting factory wasentirely renovated so as to ensure 100% cleanliness and become a casting industry for the future. In order to meet ourusers’ needs, we have cutting-edge facilities, and a system that can respond to a mass production of casting by
manual molding.
In the casting industry, it is said that handing down the technique and skill is difficult. However, many young
employees have been brought up well, and we are confident that we can be useful as a casting factory of a new age by
combining our technique that we cultivated for many years with Information Technology.I wish you further prosperity.

Management Policies

AIM TO BE BEST
1．We steadily supply the best casting that meets our customers’ needs at present and in the future.
2．We closely contact and contribute to the community.
3．We thoroughly perform environmental improvements inside and outside of the factory.
4．We aim at a healthy and culturally comfortable life.

Company Overview
Name of Company

CAST Co., Ltd.

Representative Director

Makoto Wakabayashi

Foundation

March 1889

URL

http://www.kkcast.co.jp/Headquarters

27F Tokyo-sankei Bldg,1-7-2 Ote-machi,Chiyoda-ku, Tokyo 135-0015
TEL 03-3242-6081

Shirakawa factory

2 Sasakubo, Higashikaminodejima, Shirakawa-shi, Fukushima 961-0302

Phone numberTEL 0248-34-3971

Factory site

Total area: 42,846 m2

Capital35,000,000 yen

Number of employees

40 employees

Description of business

Manufacturing and sales of normal cast iron, ductile cast iron, special cast iron, super hightensile strength cast iron, etc.

FAX 0248-34-3973
Factory building: 3,960 m2

Office and others: 401m2

YEAR

MONTH

HISTORY

1889

March

The Sakai foundry was founded in Ofunaguramae-machi (currently Koto-ku, Tokyo).

1923

April

The Sakai heat-resistant metal foundry was established in Fukagawa Umibe-machi.

1942

JanuaryThe company was reorganized to a joint-stock company,Became the Sakai Heat-resistant Metal Foundry.

1961

April

The company started sales of ductile cast iron.

1971

January

The Sakai Foundry Casting group (SFC) was organized and permitted due to the first foundry structure
improvement projects (Ministry of International Trade and Industry).

1975

June

A high silicon cast iron HISILON 14 was completed. The company was approved by Tokyo small andmedium-sized business product and upscale furtherance operations

1976

February

1985

September

An X-ray fluorescence spectrometer and an Amsler universal thermal expansion meter were introduced,and a quality assurance system (establishment of a quality assurance system group) was established.

1993

November

CI was introduced from the Sakai Heat Resistant Metal Foundry, and the name of the company waschanged to CAST Co., Ltd.

1994

March

1995

October

2001

August

2002

June

2004

March

The company was awarded a letter of appreciation from the Minister of Labor and Emigration of Republic ofIndonesia due to the continuing operation of accepting trainees from Indonesia for over 10 years.

March“Intellectual Property Management Report” was created and disclosed based on the instruction from theMinistry of Economy, Trade and Industry.

The super high tensile strength cast iron BD90 (90 to 110 kgf/mm2) was developed and put on the market.

The Shirakawa factory (a structure improvement model factory) was completed. All facilities and analyticalequipment were newly installed.
The company was awarded “Forges and Foundries of Excellent Industrial Environment.”
The company entered the field of semiconductor implementation machines.
The company entered the robotics field.

The company was selected and published in “3000 active small and medium-sized manufacturers in 2007.”

2007
JuneFebruary
2009

The company was entrusted with “Strategic Foundational Technology Improvement Support Operation of2007.”
The company was selected to be “1,400 Employment Creation Companies.”June

A small emission spectrophotometric analyzer, a black lead rounding rate measurement system, and adigital ultrasonic flaw detector were introduced.

July

A restoration maintenance subsidy of group facilities, etc. for small and medium-sized businesses inFukushima was approved.

September“SHIRAKAWA SOKEIZAI VALLEY” is composed of 10 companies dealing with metal in radius 20km distance.
By using techniques such as casting, forging, die casting and more to create materials, and locallyprocessing them including heat treatment, we will provide a stable feed of products for Japan and all overthe world.

2013

November“SHIRAKAWA SOKEIZAI VALLEY” won the encouragement prize for collaborative management of rawmaterials.

2015

June

“THE LEADING JAPAN FOUNDRIES” is a cutting-edge group to expand the global activities the purpose ofwhich is aimed at the world market, to expand the sales network aggressively in that. This group “THELEADING JAPAN FOUNDRIES” exhibited at "GIFA 2015“.

November“SHIRAKAWA SOKEIZAI VALLEY” won the Nomura Prize of "New Tohoku Reconstruction Business Contest
2016“.

20122016
December
2017

MarchMarch2018
October
2019

June“SHIRAKAWA SOKEIZAI VALLEY” receives the 2nd Fukushima Industry Prize Special Award.
Started selling original 「POWER BLADE」.
“Vibrant HABATAKU Small and Medium Enterprises 300 and HABATAKU" and received the award.
Indonesia trainee acceptance project With a continuation of 25 years, a letter of appreciation is awarded
from the Labor Minister of the Republic of Indonesia.
Exhibited at "GIFA 2019" at 33 companies as "THE LEADING JAPAN FOUNDRIES“.

Shirakawa Factory – List of Main Equipment
A manual self-hardening process is considered to be one of the most difficult processes tosimplify. However, the simplification is performed by standardizing while improving theproductivity.
Category

Name of Equipment

Model, Capacity, and Number

Long arm mixer

20t / 30 t / hr 1 unit

High speed mixer

5t / hr 1 unit

Eco-mixer

5t / hr 1 unit

Vibration table

3.5t / hr 1 unit

Veneer automatic supply machine

1 unitReverse extractor

3.5t / 1 unit

Casting inverter

1.3t / 2 units

Dash painting machine

4 setsCore inverter

2 units

Paint drying furnace

1 set

MeltingHigh frequency induced electric furnace

1400kW 500Hz 2T 2 units

Sandtreatment

Shake out machine with a hood

10t / hr 1 unit

Sand treatment machine

10t / hr 1 set

Crane type shot blast

5t 1 unit

Batch type shot blast

0.5t 1 unit

Semiautomatic molding cover line

1 set

Crane

10t×2 units, 5t×3 units, 2.8t×7 units,
OthersRunning truck

15t×1 truck, 10t×2 trucks, 7.5t(B)X 10trucks, Others

MoldingFinishing

Carrier

Automated Warehouse

Molding
型

Reverse Extractor

Electric Furnace

600m3/min 1 set
Dust collector
Environment

Inspection

400m3/min 1 set
200m3/min 1 set

Ring hood and ladle hood

1 set

Central cleaner

1 set

Emission spectrometry analyzer (AMETEK)SPECTRO MAXx-BT

Molten metal component controller (NISSAB)

CE meter NSP-3601

Molten metal component controller

CE meter KR526

Immersing thermometer (NISSAB)

NSP-203R

Metal microscope (OLYMPUS)

PME-3（x50・100・200・400）

Black lead rounding rate measurement
system (OLYMPUS)

analySIS FIVE

Tensile tester (SHIMADZU)

UEH-50 (Metallic material universal tester)

Brinell hardness tester (Maekawa Testing
Machine MFG)

(φ10 3,000kg load)

King Brinell hardness tester (Fuji TestingMachine)(φ10 3,000kg load)

Shore hardness tester (TAKES Group and Imai
(Hs10 to 80)
Seiki)

Warehouse

Ultrasonic flaw detector (Ryoden ShonanElectronics)

UI-25 (Digital ultrasonic flow detector)

Automated warehouse

147P 640 m2

Tent warehouse

495 m2Tent warehouse

290 m2External warehouse

166 m2

Pouring

Inspection

Sand Treatment

(1) Industrial Robot Related Products

A robot is active in all assembly steps of automobile parts (handling, spot welding, etc.). Wemanufacture a large amount of castings that are used in the arms, the main body, etc. of a robot.
This casting has many cores, is generally thin, but the thickness partially varies. Therefore, a highlevel of technique is required.

ｖ
Material: FCD450
Weight: 230 kg
Production volume:200 castings / month(2) Frame for a surface implementation machine and Machine tool frame
Printed circuit boards are inserted in household electric appliances such as a cell phone
and a personal computer and auto industry products. Using a surface implementation
machine, electronic parts such as IC’s are loaded on the printed circuit boards. We
manufacture a large amount of the frame that becomes a skeleton of such surface
implementation machine. This casting has a complicated shape and is generally thin.

(3) Civil Engineering and Construction Related Products

A vibro compacter is a machine that presses and hardens (rolling compaction) rolling compaction
soil, sands, asphalt, etc. It is used in construction of a walk way and a water pipe in which the areaof the work is narrow. We manufacture a large amount of castings of most important rollingcompaction parts. A high smoothness is necessary for the surface of this casting where it directly
makes a contact with the ground, and a toughness is required because it is always vibrating.

Material: FCD450
Weight: 90 kg
Production volume:200 castings / month(4)Marine engine water-cooled exhaust manifold and lorry axle parts
The Water Jacket is set inside of the Exhaust Manifold by monolithic casting.Thistechnology is intended to increase safety by minimizing exposure of high temperatureparts in their limited engine room as well as improving the performance of the engine.
Marine engine makers appreciate CAST’s products for their engines parts with finetechnology to manufacture complicated and compact casting parts with high quality.

(5)Forklift Attachment “POWER BLADE"
You can use it as a dozer just by stabbing it with a nail of a forklift and fixing it with aratchet. Developed our original products in 2017. It is made of 130-year-old casting
shop seriously made first-class goods, an unified structure of commitment, and thecraftsmanship glows casting products. We have also developed a large-sized blade that
can handle interchangeable replacement blades and 5 ton forks, and increased lineup.

This product is perfect for snowplowing.
It can also be used for scrap and earth and sand.

Strength of Business

Planning and execution of the business
planTechnicalknow-howof 130years

Thorough 5STheintroduction of CAE
technology

Clean
factory

STRONG
POINT ofＶ

Voluntary conservation activities

theCompany

Proposal-based sales
Youngtalent

Simplification of theprocess

Implementation of improvement
activities and SWOT analysis

CAE technology
A technique that has been accumulated for a long time (130years)
A tacit knowledge (craftsmanship) is being replaced by an explicit
knowledge. In the Tokyo factory, we received many orders of a single
casting, and designing the casting method was an important factor tobe successful in one try. The design of the casting method by handcalculation using “Modulus” exceeded 4000 pages, and it was storedby paper. However, all of the designs of the casting method written inpaper were computerized and put in a database by introducing atechnique of database software “Cast Navi” produced by Japan Casting
Association, and it became possible to search the data for a design ofa casting method, a casting history, a defect, etc. any time.

11In 2010, a part in the casting that had been a black box has beenvisually made clear by introducing a metal flow and solidification
simulation software. We propose to our user the design of casting at
an early stage of development using the simulation software.

Safety Education
We holds a safety patrol and a safety meeting monthly
mainly by the safety committee. Not only the employees,
but also all of temporary workers and trainees fromIndonesia are participating.
We patrol the factory, and create reports on dangerousareas, etc. The chairman introduces examples and reports acurrent status of improvement measures, and we continue
this as a common recognition.

Personnel that CAST Recruits
We encourage young employees to participate in a castingcollege where we make a system in which people canacquire various techniques and study chemical explicationsuch as “what is casting?” and promote personnel who
become a core of CAST to acquire a certification of casting
engineer. We look for active people who can participate in“making a thing” positively regardless of educational
background, experience, and gender.

Shirakawa Factory
2 Sasakubo, Higashikaminodejima, Shirakawa-shi,
Fukushima 961-0302
TEL +81-248-34-3971 FAX +81-248-34-3973

Transportation

DistanceTohoku Shinkansen

Tokyo to Shinshirakawa (1 hr 23 min)(outbound), Hachinohe to Shinshirakawa(about 3 hr) (in-bound)

Driving(from Tokyo)

About 24 km from Shirakawa Interchangeof Tohoku Expressway

Driving(from Sendai)

About 18 km from Yabuki Interchange ofTohoku Expressway

CAST Co., Ltd.
PROFILEwww.kkcast.co.jp

English version