CAST Co., Ltd.
PROFILEGreetings from Representative Director
Our company, CAST, was founded in Fukagawa, Tokyo in 1889. Since then, we have been favored bymany customers as a casting company. On March of 1994, the entire factory was moved from Koto-ku,
Tokyo to Shirakawa-shi, Fukushima.
In the Shirakawa factory, a work environment is realized in which the image of the conventional casting
factory was entirely renovated so as to ensure 100% cleanliness and become a casting industry for thefuture. In order to meet our users’ needs, we have cutting-edge facilities, and a system that can respondto 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.
Representative Director of CAST Co., Ltd.

Hideyuki Sakai

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

Hideyuki Sakai

FoundationMarch 1889

URL

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

3-1-14 Sengoku, Koto-ku, Tokyo 135-0015

Shirakawa factory

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

Phone number

TEL 0248-34-3971

Factory site

Total area: 42,846 m2Capital

35,000,000 yen

Number of employees

60 employees

Description of business

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

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

Office and others: 401m2

History
Year

MonthItem

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(currently Koto-ku, Tokyo).

1942

JanuaryThe company was reorganized to a joint-stock company, and became the Sakai Heatresistant Metal Foundry.

1961

April

The company started sales of ductile cast iron.

January

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

December

A low frequency melting furnace was introduced due to a first plan, and the company
started as an FS method introduced licensed factory.

1975

June

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

1976

February

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

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.

1990

September

The present president was appointed due to the death of the ex-president.

1993

November

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

1994

MarchThe Shirakawa factory (a structure improvement model factory) was completed. All
facilities and analytical equipment were newly installed.

1995

October

The company was awarded “Forges and Foundries of Excellent IndustrialEnvironment.”

1999

October

The C.P.M. activities (a name of the TPM activities in our company) were started.

2001

August

The company entered the field of semiconductor implementation machines.

2002

June

The company entered the robotics field.

March

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

1964

2004
September

A 5 ton continuous molding mixer for a core, a crane with an inverter, a warehousefor a wooden mold, and a painting place were increasingly established.

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

2007
June

2009

2012

The company was selected and published in “3000 active small and medium-sized
manufacturers in 2007.”
The company was entrusted with “Strategic Foundational Technology Improvement
Support Operation of 2007.”

February

The company was selected to be “1,400 Employment Creation Companies.”June

A small emission spectrophotometric analyzer, a black lead rounding ratemeasurement system, and a digital ultrasonic flaw detector were introduced.

March“Intellectual Property Management Report of 2012” was created.

July

A restoration maintenance subsidy of group facilities, etc. for small and mediumsized businesses in Fukushima was approved.

December

The company participated in “AUTOMECHANIKA SHANGHAI 2012.”

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

Molding

Melting
Sandtreatment
Finishing

CarrierName 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 setHigh frequency induced electric
furnace

1400kW 500Hz 2T 2 units

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

Automated Warehouse

Molding

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 ratemeasurement 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
Testing Machine)(φ10 3,000kg load)

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

Warehouse

Ultrasonic flaw detector (RyodenShonan Electronics)

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

Description of Business(1) Description of BusinessWe manufacture and sell castings. Castings of FC (flaky graphite cast iron), FCD(spherical graphite cast iron), and alloy cast iron are manufactured semi-automaticallyand manually with a furan organic self-hardening cast molding process. The weightof handling is 50 to 4,000 kg, and the possible monthly production is max 200castings per one type. We mainly manufacture robot related castings, and we also
manufacture castings for a plastic injection molder, a plastic machine tool, a machinefor civil engineering and construction, etc.

(2) Robot Related Products(i) Frame for a surface implementation machine
Printed circuit boards are inserted in household electric appliances such as a cellphone 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 skeletonof such surface implementation machine. This casting has a complicated shape and isgenerally thin.

(Our Manufactured Casting)Material: FC200
Weight: 800 kg
Production volume: 100 to
150 castings / month(Completed Product)

(ii) Main body for a robot
A robot is active in all assembly steps of automobile parts (handling, spot welding,etc.). We manufacture a large amount of castings that are used in the arms, themain body, etc. of a robot. This casting has many cores, is generally thin, but thethickness partially varies. Therefore, a high level of technique is required.

Material: FCD450(Our Manufactured Casting) Weight: 230 kg(Completed Product)

Production volume: 100 to 200
castings / month(3) Civil Engineering and Construction Related Products(i) A vibro compacter is a machine that presses and hardens (rolling compaction) rollingcompaction soil, sands, asphalt, etc. It is used in construction of a walk way and a water
pipe in which the area of the work is narrow. We manufacture a large amount of castingsof most important rolling compaction parts. A high smoothness is necessary for thesurface of this casting where it directly makes a contact with the ground, and a toughness
is required because it is always vibrating.

Material: FCD450(Completed Product)
Weight: 90 kg(Our Manufactured Casting) Production volume: 150 to 200
castings / month(4) Molding Machine Product(i) Plate for a plastic injection molding machine
A machine for molding a plastic product from granular plastic is the plastic injection
molding machine. The casting is used in the mold closing part. We receive orders ofcastings of the plate and the sliding part mainly made of FCD450 to 600.

(Our Manufactured Casting)(Completed Product)

Material: FCD500
Weight: 3,700 kg
Production volume: 10 to 20
castings / month(5) General Industrial Machine Product(i) Roller for a steam tube dryer
A steam tube dryer is a machine that places resins and food raw materials in a large
tube and dries them with an indirect heat while rotating the tube. A super heavy tube
(about 1,000t) is rotated by supporting the tube with 4 rollers. We manufacture theroller that supports the large tube. The thickness of the roller becomes a maximumof 380 mm, and a uniform high hardness (HB260 to 300) is required.

Air Output
Raw Material Input

SteamHeader

Tire

Girth Gear

Air Output
Heating tubeRoller

PinionGear

Tire

DrainOutput

Motor for Driving theMain Body

Roller(Our Manufactured Casting)(Completed Product)

Material: Bainite based FCD
Weight: 3,000 kg
Production volume: 10 castings / year

SteamInput

ProductOutput

Strength of BusinessA technique that has been accumulated for a long time (123 years)
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 thecasting method was an important factor to be successful in one try. The design of thecasting method by hand calculation using “Modulus” exceeded 4000 pages, and it wasstored by paper. However, all of the designs of the casting method written in paper werecomputerized and put in a database by introducing a technique of database software “CastNavi” produced by Japan Casting Association, and it became possible to search the datafor a design of a casting method, a casting history, a defect, etc. any time.
In 2010, a part in the casting that had been a black box has been visually made clear byintroducing a metal flow and solidification simulation software.
We propose to our user the design of casting at an early stage of development using thesimulation software.

Use of 3D CAD and the solidification simulation

Early design of the casting method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 dangerous
areas, etc. The chairman introduces examples and reports
a current status of improvement measures, and wecontinue this as a common recognition.

Personnel that CAST Recruits
We are a manufacturer, but all we do is not only making athing. A single casting is put on the market by putting
efforts together of all people such as people who
manufacture in the factory, people who inspect, people who
make payment slips, people who arrange transportation,
people in sales, administration, and accounting. Further,
without the castings, industrial products using them cannever be completed.
CAST supports young people.
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 athing” positively regardless of educational background,experience, and gender.

Tokyo Headquarters3-1-14 Sengoku, Koto-ku, Tokyo 135-0015
TEL +81-3-3645-9691

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 Interchange of Tohoku Expressway

Driving (from Sendai)

About 18 km from Yabuki Interchange of Tohoku Expressway