Our Monozukuri (Manufacturing Process)

Responding to customer needs
and expectations with passion
and making the future better
through the manufacturing of aluminum castings

Cast with Passion

Based on our management creed of responding to customers' needs with “Enthusiasm, Sincerity and Creativity,” we have developed an integrated manufacturing system that covers everything from manufacturing designs for castings and mold design and fabrication, to casting, machining, assembly, inspection, and quality assurance. To ensure that the end user receives a reliable product, we handle each process with extra care as if we handed it down to our customer, allowing us to deliver reliable products to the next process without neglecting to check the workmanship level, valuing the principles we stand by and giving due consideration to what is expected of us. Our strength lies in our vertically integrated production system, in which machining and assembly processes are located at each of our casting bases, as well as in our ability to build an integrated production system that extends all the way through to finished products for shipment.

Manufacturing is all about people. As such, we truly value each and every employee. In order to continue to protect our employees and their families, our customers, the local community, the global environment, and all that is important to every one of us, we at Hiroshima Aluminum Industry will do our utmost to tackle the manufacturing tasks that lie ahead of us with simple honesty, drawing on the wisdom we have accumulated over the years. And we will continue to be committed to sustainable manufacturing into the future.

Hiroshima Aluminum Industry’s Monozukuri (Manufacturing Process)

Casting Design

Casting Design for Manufacturing
(3D Design)

To begin with, we give shape to the customer’s request by coming up with a casting design that incorporates our manufacturing know-how. Starting with setting the basic shape of the castings, we weave all of our experience and know-how into ensuring the optimal manufacturing, including mold planning and casting quality, and express the design in the digital virtual space of 3D-CAD.

Design Verification

Design Verification
(Functional CAE, Casting CAE)

We verify manufacturing conformity, such as required product functionality and castability, by utilizing CAE simulations and other methods. We then confirm the appropriateness of design parameters through linear and nonlinear structural analysis, vibration analysis, fluid analysis, casting analysis for filling and solidification, and machining/cutting simulation, and other tests.

Mold Design& Fabrication

Mold Design & Fabrication
(Digital Mold Making)

Casting models, molds, and die-casting molds for casting are designed and manufactured both internally and externally. For die-casting molds, the main core, which forms the main cavity, undergoes design verification, such as digital design using 3D-CAD, and large-scale structural analysis. It is then passed on to CAM (machining program) production in a paperless process, where it is subjected to rigorous checks through cutting simulation before the mold is manufactured.

Trial Production & Product Verification

Trial Production & Product Verification
(QMS According to ISO 9001)

Manufacturing design is not limited to product shape, but also includes process design, facility and equipment design, and jig and inspection tool design so that we can proceed with preparing detailed processes. In trials, we verify the reliability and stability of each of the facilities, equipment, jigs and inspection tools, and manufacturing conditions.

Casting & Finishing

Casting & Finishing
(Mass Production) (Utilization of IoT)

The mass production process of casting and finishing has become fully automated, and we are trying to create an advanced environment where humans and machines work harmoniously together, by proactively utilizing cooperative robots. We also view environmental considerations as a critical issue in sustainable manufacturing, and are actively working on the utilization of waste heat and electric energy saving.

Machining & Assembly

Machining & Assembly (Mass Production)

Our advanced assembly process enabled fully automated inspections using diagnostic imaging technology. From process data collection to failure diagnosis and maintenance programs, we are also actively promoting visualization through digital linkage. At the same time, we are focusing on traceability and other safety and security considerations.