Manufacturing quality dies as the best solution partner Matsuno has a variety of "special elements" which make this possible. Flow analysis for predicting problems during molding, MOLD720h for 24-hour-a-day, 365-day-a-year operation, and decorative molding technique all of these contribute to making Matsuno's accurate manufacturing happen.
Today, with everything becoming thinner and smaller, precision requirements for dies have become so severe that even the tiniest problem can ruin the value of end products. We have introduced the flow analysis system Autodesk Moldflow from the United States to simulate the flow behavior of plastic melts within the die at the planning and design stage, allowing us to objectively examine beforehand any possible problems or stress on the die during molding, and to manufacture dies in both an efficient and cost-effective manner. This helps us to significantly reduce the number of design changes and post-manufacture modifications and to finish the dies without having to make several attempts.
Using CAD/CAM data, the MOLD720h system makes it possible to check work breakdown and the shape of dies on-line via PC, thus eliminating the need to do so on paper and realizing a complete parallel setup. The entire process from CAD/CAM and NC programming to cutting, measurement, and electric discharge machining has been integrated on-line, thus ensuring faultless exchange of products and data via the ID reader. The end result is literally around-the-clock, 365-day-a-year (720 hours per month) operation, with no mistakes.
Our original development, M-PROC is a brand new process control system which sets a delivery date for parts and manufacturing process two fundamental parameters for dies manufacturing - and monitors progress in the manufacturing process, thus managing manpower and machines in an optimal manner. Production lines at the three plants are monitored on a real-time basis by network cameras, so that accurate instructions may be given from a remote place. The system also incorporates various advanced subsystems, such as those for by-type balance control and shape identification.
The decorative molding technique achieves a shorter process by also processing the product surface during molding. Matsuno became the first to apply this technology to a three-dimensional curved surface, which had previously been deemed extremely difficult. This technique makes secondary working printing, pasting, coating, etc. unnecessary. Also, because of its applicability to any type of material, including Japanese paper, cloth, leather, metal, and light diffusion membranes, this technique adds to design variations, and is also capable of adding new functions, for example, using the material as an electric circuit by attaching a PCB on the back.

Our "3+1 Manufacturing Network" covers the Tokyo Metropolitan Area, Kansai, and Kyushu. Established in April 2008, the Kiyama Plant in Saga Prefecture is our principle manufacturing base featuring the state-of-the-art equipment. Our design team at the Head Office and Plant in Higashi Osaka - the pivot of Japan's manufacturing - functions as the brain of our operations, while the Shin-Yokohama Plant serves as a contact for our customers in the Tokyo Metropolitan Area and Eastern Japan. At the Creation Core Higashi Osaka, we conduct R&D of new technology through industry-university collaborations. With each facility based in a prime location, they all demonstrate outstanding mobility.
Through industrial-academic collaboration, Matsuno is committed to R&D in the metal manufacturing category. One such example is the "polishing robot." No matter how automated dies manufacturing has become, the final "polishing" process cannot be done without the mastery of skilled craftsmen. When all the other processes were made more efficient, it was difficult to shorten the time for this key process. Working closely with the Ryukoku University Faculty of Science and Technology, Matsuno succeeded in quantifying and objectifying craftsmen's skills for "automated polishing." The development of this groundbreaking technology is close at hand.
The more automated the manufacturing process becomes, the more important the human role is in determining quality. It is not just the skills of experienced, uncompromising engineers, but also the ability to optimize manufacturing by making the most of our vast stores of knowledge and information. We are developing multi-skilled workers by encouraging engineers from different fields to learn from each other and share individual wisdom and ingenuity through daily QC circle activities and research work.