INDEX
1. Things which Only a Small Factory Could Achieve.
2. And Here Comes the Ambition.
3. Endress Trials.
1.Things which Only a Small Factory Could Achieve.
Fujita Metal MFG is the small-town factory located in an industrial area of Yao City in Osaka, Japan.
Since its funding in 1951, they have been manufacturing various metallic daily necessities such as frying pans, tumblers, teapots and so on.
Let’s take a quick look at how frying pans and tea pots are manufactured at this factory.
① A flat metal plate is punched out by large machine just like cutting out cookies by mold.
② Set the punched-out metal plate to a press machine, then make rough shape of product by sandwiching from the top and the bottom with strong force.
③Set the rough shaped metal plate to a metal spinning machine, then slowly press the roller against highly spun metal plate. It will be slowly stretched, and the shape of a frying pan or a pot will be formed.
④The proprietary hardening and tempering process will be applied after product shape is formed.
⑤The manufacturing process will be completed by attaching a handle and other necessary parts after performing surface finishing.
We have seen processes of metal pressing and spinning however, there is one indispensable tool on those process which we have not mentioned yet. It’s a “mold”
A “mold” is a lump of metal which is indispensable for forming the shape of metal products.
Ice cubes can be very good familiar example. Shape of ice cubes can be round or square depending on the shape of an ice cube tray (mold). It doesn’t matter how complicated shape is. Hundreds of same shaped ice cubes can be made by using same mold. Likewise, molds for metal products are indispensable tool for continuously manufacturing same products.
Most factories in Japan only perform product processing in their factories and production of mold is normally outsourced to other factories. However, here in Fujita Metal MFG manufacture their molds in house.
Mr. Shunsuke Fujita, the father of Fujita Family and also the second-generation president of Fujita Metal MFG, is in charge of production of molds. (on the right of the picture.)
Mr. Kosaburo Fujita, the third son of Fujita Family (on the left of the picture), is currently inheriting mold manufacturing techniques from his father.
Mr. Shinjiro Fujita, the second son of Fujita Family, is in charge of metal spinning process.
The eldest son, Mr. Seiichiro Fujita is the planner of all the projects in the company while taking control of sales.
Fujita Metal MFG can be simply descried as “the family owned small-town factory”. This sort of company structure may not be uncommon in industrial areas. However, it was actually essential structure for developing the frying pan “JIU”
Efficiency of production and Reduction of cost is an important factor to every manufacturer.
Regardless of product categories, many of Japanese manufacturers outsource each process to its specialized factories.
Outsource production of molds to mold factories.
Outsource pressing process to metal pressing factories.
Outsource spinning process to metal spinning factories.
The division of labor generally increase efficiency of production as each specialist can focus on their specialties and run non-stop operation from upstream through downstream.
However, in the case of creating non-existent product, it is not very ideal to run such non-stop operations by outsourcing as there is a pile of issues which is unknown unless you actually try.
The most essential factor here is not the production speed but the environment which allows us to go back and forth between each division, and repeatably tries, amend and make experiment.
Every process from mold manufacturing to product sales can be done in-house. Moreover, each member of Fujita Family is in charge of each division and they can have discussions at any time.
Fujita Metal MFG can be seen as just one of small-town factories however, it has the best environment for creating new and innovative products.
At one night, while we were having drink together, Mr. Kosaburo Fujita said to me,
“We are just like Elon Musk, we are just like Tesla!”
Not only Tesla but also Apple has high-tech processing machines in-house and produce hundreds of prototypes.
At first glance, this small-town factory can be seen as they are running inefficient productions however, it in fact has the most suitable environment for creating new and innovative products.
On the next story, we will write about how Fujita Metal MFG and TENT decided to collaborate together, and how we came up with new ideas for new products.
FRYING PAN JIU & HANDLE SET
Size S / Beech Wood
¥ 6,600-
Product Size and Weight (Approximate Size in cm / inch /g / lbs)
JIU Outer Size (O.D x H): 21.5 x 3.6cm / 8.5 x 1.4inch
JIU: Inner Size (I.D x D x B.D) 16 x 3 x 12cm / 6.3 x 1.2 x 4.7inch
JIU Weight: 560g / 1.23lbs
HANDLE Size (L x H): 19 x 3.5cm / 7.5 x 1.4inch
HANDLE Weight: 195g / 0.43lbs (subjected to change)
FRYING PAN JIU & HANDLE SET
Size S / Walnut Wood
¥ 7,700-
Product Size and Weight (Approximate Size in cm / inch /g / lbs)
JIU Outer Size (O.D x H): 21.5 x 3.6cm / 8.5 x 1.4inch
JIU: Inner Size (I.D x D x B.D) 16 x 3 x 12cm / 6.3 x 1.2 x 4.7inch
JIU Weight: 560g / 1.23lbs
HANDLE Size (L x H): 19 x 3.5cm / 7.5 x 1.4inch
HANDLE Weight: 195g / 0.43lbs (subjected to change)
FRYING PAN JIU & HANDLE SET
Size M / Beech Wood
¥ 7,700-
Product Size and Weight (Approximate Size in cm / inch /g / lbs)
JIU Outer Size (O.D x H): 25.5 x 4.2cm / 10 x 1.7inch
JIU: Inner Size (I.D x D x B.D) 20 x 3.6 x 14.5cm / 7.9 x 1.4 x 5.7inch
JIU Weight: 780g / 1.7lbs
HANDLE Size (L x H): 19 x 3.5cm / 7.5 x 1.4inch
HANDLE Weight: 195g / 0.43lbs (subjected to change)
FRYING PAN JIU & HANDLE SET
Size M / Beech Wood
¥ 8,800-
Product Size and Weight (Approximate Size in cm / inch /g / lbs)
JIU Outer Size (O.D x H): 25.5 x 4.2cm / 10 x 1.7inch
JIU: Inner Size (I.D x D x B.D) 20 x 3.6 x 14.5cm / 7.9 x 1.4 x 5.7inch
JIU Weight: 780g / 1.7lbs
HANDLE Size (L x H): 19 x 3.5cm / 7.5 x 1.4inch
HANDLE Weight: 195g / 0.43lbs (subjected to change)
FRYING PAN JIU & HANDLE SET
Size L / Beech Wood
¥ 8,800-
Product Size and Weight (Approximate Size in cm / inch /g / lbs)
JIU Outer Size (O.D x H): 30 x 4.5cm / 11.8 x 1.8inch
JIU: Inner Size (I.D x D x B.D) 24 x 4 x 18cm / 9.4 x 1.6 x 7.1inch
JIU Weight: 1040g / 2.29lbs
HANDLE Size (L x H): 19 x 3.5cm / 7.5 x 1.4inch
HANDLE Weight: 195g / 0.43lbs (subjected to change)
FRYING PAN JIU & HANDLE SET
Size L / Walnut Wood
¥ 9,900-
Product Size and Weight (Approximate Size in cm / inch /g / lbs)
JIU Outer Size (O.D x H): 30 x 4.5cm / 11.8 x 1.8inch
JIU: Inner Size (I.D x D x B.D) 24 x 4 x 18cm / 9.4 x 1.6 x 7.1inch
JIU Weight: 1040g / 2.29lbs
HANDLE Size (L x H): 19 x 3.5cm / 7.5 x 1.4inch
HANDLE Weight: 195g / 0.43lbs (subjected to change)
FRYING PAN JIU & Handle Set,
M POT / Beech Wood
¥ 8,800-
Product Size and Weight (Approximate Size in cm / inch /g / lbs)
JIU Outer Size (O.D x H): 26 x 7cm / 10.2 x 2.8inch
JIU: Inner Size (I.D x D x B.D) 20 x 8 x 13cm / 7.9 x 3.1 x 5.1inch
JIU Weight: 875g / 1.93lbs
HANDLE Size (L x H): 19 x 3.5cm / 7.5 x 1.4inch
HANDLE Weight: 195g / 0.43lbs (subjected to change)
FRYING PAN JIU & Handle Set,
M POT / Walnut Wood
¥ 9,900-
Product Size and Weight (Approximate Size in cm / inch /g / lbs)
JIU Outer Size (O.D x H): 26 x 7cm / 10.2 x 2.8inch
JIU: Inner Size (I.D x D x B.D) 20 x 8 x 13cm / 7.9 x 3.1 x 5.1inch
JIU Weight: 875g / 1.93lbs
HANDLE Size (L x H): 19 x 3.5cm / 7.5 x 1.4inch
HANDLE Weight: 195g / 0.43lbs (subjected to change)
