SAYAMA MOLD MANUFACTURING CO,.LTD.

Concept of SAYAMA MOLD / Representative director OsamuOba

Pursuing the ideal in the macro-scale to fulfil commitments in the micro.The serene environment of this location also contributes.

Embraced by the abundant nature of the surrounding hills, Sayama mold manufacturing is at the forefront of the precision mold industry. The lofty cherry blossoms of the garden burst into dazzling colour in spring and the surrounding mountains allow us to take pleasure in the seasonal scenery throughout the year. Precision molds and tranquil nature - perhaps this could be thought an unexpected partnership, however there is a solid reason behind the selection of this location. In the fabrication of molds requiring an accuracy of down to the submicron scale, even the slightest vibration from passing traffic has an impact on the precision manufacturing process. In order to avoid this, the company was daringly established on a plot distant from main roads. Whilst being aware of the inconvenience for visitors to our company, we have taken the liberty of prioritising this single commitment to accuracy. At the same time the “ease” of each of our employees is also an important reason. Tired eyes are soothed by the scenic view. A fresh breeze caresses the face. Perhaps this graceful environment, removed from the bustle of the city, is the best location to relax and devote oneself to craftsmanship. Molds are a precision product and that is why such careful consideration is required.
All of this is to pursue the ideal in the environment of the location, in order to fulfil our commitments as professionals.

A technological strength to respond to submicron requirements.Refusing to compromise even the slightest - herein lies the pride of Sayama.

A relaxed environment in which each employee can work with ease - this ideology is strongly reflected by the entrance. In order to sweep away the image of a factory that tends to be cold and inhuman, an architect was commissioned for the design. Thorough attention was given to a calm and comfortable ambience as a community space in which employees relax or as a meeting space with customers. Also the break room and conference room are designed to give an unbroken view of the outside. Consideration is given to the production of a space that feels bright and open. The facilities in which machining and polishing is performed are also administered with a thorough maintenance, ensuring they are always hygienically maintained. Furthermore efforts are put into employee training so that each employee can work with motivation. in addition to scrupulous management by objectives, a complete education system is constructed including periodic communication training and an overnight study tour in a rest home etc. all employees are free to fully demonstrate their abilities and a generous support is given to enable each employee to move closer to their individual objectives. Sayama will continue to be committed to “a comfortable environment and people-friendly work culture”. Since any kind of product is produced by human hand, product quality is cultivated by a richness of spirit.

A technological strength to respond to submicron requirements.Refusing to compromise even the slightest - herein lies the pride of Sayama.

A commitment to everlasting quality

Cellular phones that are rapidly becoming more multifunctional, consumer electronics with built-in microcomputers, automobiles with increasingly sophisticated electronics - it would not be an exaggeration to say that the evolution of all electronics depends on the miniaturisation and refinement of the parts composing them. Sayama mold manufacturing is a specialist in the precision molds from which ultra small parts are born. This range extends to the submicron world of 1/10000(mm). In addition to the above mentioned environment, human techniques hold the greatest key to realising the perfect “job” in this world. From CAD operators engaged in design to manufacturing, polishing, assembly and furthermore prototype cast production, all processes are supervised by top-level technical experts. Each one has pride in their craft and performs high accuracy work. Also, similarly top level facilities are necessary to realise 100% of technical expert’s abilities. For example, the measurement error of the room temperature in which machining is carried out is kept to within ±1℃. Complete temperature control is carried out in order to prevent the deformation of a metal due to temperature difference. furthermore, we employ the absolute cutting-edge in equipment such as polishing machines that can automatically polish down to 0.1 microns and top-class GP at drilling machines etc. the introduction of this advanced equipment contributes to the automation of the manufacturing process. We currently have a system in place that can carry out the finishing cut of a mold for 30 hours without human supervision. Environment, people, facilities. This trinity brings about our propriety know-how and fosters unparalleled techniques at Sayama mold manufacturing. This name is spreading around the world as a supplier of precision molds that represent Japan.

A customer orientated attitude that lives up to its trust

No matter how excellent a product, it first becomes “merchandise” only when there is a customer for it. A group of craftsmen in the precision mold industry, Sayama always encompasses more than the self-centred pursuit of technology. This is because we propose to faithfully embody our customers’ needs and gain their heartfelt satisfaction. Take, for example, the delivery period. An abundance of mold materials is always in stock at Sayama, and a system is arranged that can smoothly respond to any commission. Heat treatment is administered to all materials in advance to prevent variation due to ageing. This is a time-consuming operation, but we are making efforts to advance even faster machining of good products. Moreover, a work process control tag specifying from date of order to date of delivery is created. We have constructed an ideal process control system, whereby all employees can grasp all manufacturing schedules. These various efforts are to strictly comply with the delivery period of a product. The delivery of the promised product on the promised day – This too, is our pride.

Advanced technology accompanied with added value.Delivering our precision molds to Japan and markets around the world.

Pursuing total benefits

Whilst the economic slump drags on, the value of a product is greatly tending towards its price. At present, with severe cost management sought by all businesses, it cannot be denied that short-term cost benefits have a great appeal. However rather than cost alone, cost performance is what is important. That is to say, the cost in relation to the result. Sayama molds are definitely not cheap. This is because the price concerns the total cost of processes after the actual work performed in addition to the final benefit for the customer. The curtailment of labour such as remaking etc. through exact hearings and consulting; the further suppression of cast variation to the utmost limits of accuracy and the increase of operating ratio; the enhancement of the durability of the mold itself and the facilitation of maintenance; furthermore, support for partial mold repairs at lowest cost - we are proud that the optimisation of this kind of workflow is a kind of value added that cannot be imitated by other companies. The accuracy of our molds can be appreciated upon viewing a sample. On the other hand the benefits in the processes after the actual work cannot be appreciated unless actually used. Please give Sayama mold manufacturing a try. As specialists in ultra-precision molds, we promise a solution that is certain to satisfy.

The technological power to succeed in global competition

Seeking countries in which cheaper and higher quantity manufacturing was possible, production bases for various products have now left Japan. Certainly for simple assembly operations and work repeated according to the manual, it is not difficult to transfer such manufacturing processes overseas. But how about manufacturing requiring the ultimate in accuracy or in which the tact, experience or imagination of the operator is necessary? For these, human intuition and experience, which cannot be explained by theory alone, is indispensable. Simultaneously, improvement of the defective rate and material quality is not something a machine can perform automatically. The greatest weapon in Japan’s arsenal for success in global competition - we are convinced this is the Japanese “technological strength” that will not permit the following in the footsteps of others. as proof, there many products that even now cannot be manufactured outside of Japan such as the core components of cell phones, HDDs, and computers, computer control system parts for automobiles, and industrial products for which a high-quality exterior or level of finish is required. The ultra-precision molds that Sayama produces embody this essence. Approximately 25% of current sales are from business overseas, but we are planning to further enlarge this hereafter. We believe our mission to be the realisation of this unique technology appreciated throughout the world, it's materialization as products, and the supply of such products to our customers.

Focusing on an abundant coexistence with the environment

Now consideration for the environment is becoming the responsibility of every business. At Sayama we are proactively implementing initiatives in support of the environment. For example we are striving to the utmost of our ability to reduce refuse created when manufacturing a mold. Hence we are committed to “molds that do not waste resources” right from the design stage whilst continuing to diligently realise molds of the utmost precision. As a result we have achieved the objective of reducing resources used. The realisation of this could also be said to be the result of our technical strength. Through these initiatives we acquired ISO14001 in 2006. From here on, we are planning to incorporate coexistence with the environment as part of our corporate social responsibility. Also this kind of precision mold contributes to cost and molding cycle reductions. By means of highly accurate mold we provide superior benefits to all of our customers from now on.

Every day is a checkpoint towards a new target.Moving furthermore towards the ideal hereafter. Earnestly. Intently.