Micro Research is a group of companies with operations in three areas. At the headquarters in Hachioji the company concentrates on high-grade tools for the Japanese semiconductor industry. Since the Miyagi subsidiary was set up in 1992 it has concentrated on the production of precision parts. With their 1000-strong workforce, the two Chinese factories in Wuxi and Suzhou focus on simpler mould tools and the manufacture of products such as clock and watch works.
Micro Research headquarters in Hachioji
The Hachioji operation is impressive. Modern multi-operation machines, wire and die-sinking EDM machines, climate-controlled metrology rooms with first-class equipment, but the heart and soul of the operation can be found in the grinding department. A large number of surface, profile and jig grinding machines work flat out to achieve the last thousandths of a millimetre.
Three years ago, as part of Hachioji’s constant effort to increase quality, the decision was taken to scrap the accessory systems they had been using for ten years, mostly supplied together with the machines, and to replace them with System 3R’s Macro system – throughout the entire workshop.
Deputy CEO Masuhiko Komazawa explains – “The upgrade to Macro turned out remarkably well. We now work at a completely different level in terms of precision, repetition accuracy and reliability. And this is essential, since today’s demands on the tools far exceed those of the past, not least because of extreme miniaturisation. And what’s more, we estimate the total increase in productivity to be at least 30 percent.”
Komazawa continues – “We’ve only just started to deliver the first tools with the Micro-X brand. Punch and stage tools with extremely high precision and longer life. This product group is the result of our deliberate application of the Japanese 5S method*, and of the Macro system. The fact is, these tools maintain a standard that we used to find very difficult to achieve.”
Masuhiko Komazawa – “Macro gives us precision, repetition accuracy and reliability”
At Miyagi, where the company is devoted solely to the manufacture of precision parts, 40 percent of which are parts for punching and cutting tools, they have now installed their first automated production cell. A Fanuc Robodril has been equipped with a vibration-damped Macro chuck on the machine table. The machine is served by a WorkPal Compact Servo with a 60-position magazine for Macro pallets.
The new Micro-X with extremely high precision and longer life
“Bearing in mind our positive experiences of Macro, we clearly have great expectations of this investment”, explains Masuhiko Komazawa.”
Micro Research also produces a small EDM machine, the µ SPARK 1000, developed in-house and mainly used within the group. However, every year the company supplies a small number of these to other companies which, like Mikro Research, require extremely high precision. The machine has interchangeable spindle heads, with Macro and MacroJunior being used as coupling elements.
* Sort / Shine / Set in place / Systemise / Standardise
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Related links:
Macro
MacroJunior
WorkPal Compact Servo
Automation in general