MP Tool Shop Engineering
Supporting Department -Tools Section
Comprehensive technical documentation for metal parts production and tooling operations. This guide covers all aspects of our manufacturing capabilities, from cutting tools to quality control systems.
Confidential: Internal use only. All rights reserved © SEIKO EPSON CORPORATION
Metal Parts Manufacturing Tools Overview
Our comprehensive tools portfolio spans multiple product development stages, supporting precision manufacturing across all metal parts divisions. From cutting tools to specialized fixtures, each category plays a critical role in production excellence
Cutting Tools
High-precision cutting implements for machining operations across PD1-PD6 divisions, including specialized drills, cutters, and grinding tools.
Metal Parts
Custom-fabricated components including baito, cams, jigs, and fixtures designed for specific production requirements and quality standards.
Precision Support
Specialized support tools and measurement devices (PSD) ensuring dimensional accuracy and process control throughout manufacturing.
Our tooling department specializes in precision fabrication across six primary categories: cutting tools, drills, baito components, jigs and fixtures, cams, and bushings. Each department operates with dedicated machinery and specialized expertise to ensure optimal quality and efficiency.
PD1 - Cutting Tools
Primary cutting operations including single, hob, and musosei cutters
PD2 - Drill Production
Specialized drill fabrication including center drills and flat drills
PD3 - Baito Manufacturing
Normal and special baito production with brazing capabilities
PD4 - Cam Fabrication
Flat, drum, and timing cam production using advanced milling
PD5 - Jig & Fixtures
Custom fixture design and manufacturing for production support
PD6 - Bush Production
Precision bushings, holders, plates, and ring gauges
Process & Product Structure
Our integrated manufacturing ecosystem connects specialized shops with distinct product lines. Each facility focuses on specific tool types, ensuring expertise and quality consistency across operations.
Drill Fabrication
Complete drill production including normal, timing, center, and uramen types with multiple diameter options
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Baito Manufacturing
Normal baito, special baito, and uramen production with first-process capabilities for various applications.
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Cutter Production
Single, hob, musosei, and toggle cutters manufactured to exacting specifications.
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Shop 1 & 2
Manufacturing baito, cams, and specialized cutting implements using CTG and EWAG WS11 equipment
Shop 3
Jigs and fixtures manufacturing supporting production assembly and quality control.
Bush & Cam
Specialized components including bushings, ring gauges, holders, plates, and cam profiles.
Tooling Applications Across Manufacturing
Lathe Operations
Turning tools for cylindrical components with various geometries and specifications
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Gear Cutting
Specialized hob cutters for gear manufacturing with precise tooth profiles
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Forming Tools
Custom forming cutters for specialized shapes and contours in production
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Instrumentation
Precision measurement tools including ring gauges and verification instruments
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Advanced Manufacturing Equipment
State-of-the-art equipment forms the backbone of our manufacturing excellence. Our machine portfolio includes specialized grinders, lathes, milling centers, and precision finishing equipment strategically distributed across production facilities.
Precision Grinding
EWAG WS11, STUDER, and specialized baito grinders for surface finishing and profile grinding operations.
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CNC Machining
MAKINO V22 milling, WASINO GLS, and AMADA DV1 for complex geometry and automated production.
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Turning Operations
CTG, bench lathes, WACHIGAI, and TSUGAMI C300H NC lathes supporting cylindrical component fabrication.
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Wire Cutting
Advanced EDM wire cut systems (CW 200HA) for intricate shapes and hardened material processing.
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Bench Lathe Operations
Precision turning for baito and cam components
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CTG Grinding System
High-precision grinding for tool finishing
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EWAG WS11
Specialized drill grinding with 2005 technology
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MAKINO V22 Milling
Advanced 2017 5-axis milling for cam production
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WASINO GLS 821
Profile grinding for cutter production
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Wire Cut CW200HA
Precision EDM cutting for complex geometries
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Our comprehensive equipment portfolio includes STUDER grinding machines, AMADA DV1 systems, TSUGAMI NC lathes, and WACHIGAI NC turning centers, all maintained to exacting standards for maximum precision and reliability.
Skilled Workforce Development
Our comprehensive SVS (Skill Verification System) ensures consistent competency across all technical positions. Multi-level certification from beginner to expert supports continuous improvement and operational excellence.
Level 5: Beginner
OJT training phase with supervised operations and foundational skill development.
Level 4: Guided Operations
Performing standard tasks with guidance availability, building independence progressively.
Level 3: Independent
Autonomous operation on assigned equipment with proven quality output capability.
Level 2: Multi-skill
Cross-trained on multiple processes with troubleshooting and setup change competency
Level 1/Expert
Process expertise with training capability, optimization skills, and technical leadership.
Current Status
23 certified operators across all tool manufacturing categories including:
- 5 Baito Manufacturing experts (Level 3)
- 5 Cutting Tool Grinding specialists (Level 3)
- 4 EWAG operators (Level 2)
- 3 Wire EDM technicians (Level 2)
- Additional specialists in cam and cutter production
SVC Grade 2 Excellence
28 participants in FY10-FY23 competitions with 13 medal achievements demonstrating world-class technical skills.
Sample Parts Process
Bush Fabrication Workflow
Bush manufacturing integrates wire cutting precision with advanced grinding techniques. Our systematic process ensures dimensional stability and surface finish quality critical for bearing and guide applications.
Material Preparation
Precision-cut blanks from certified steel stock ensuring consistent material properties.
Wire Cut Length
CW 200HA wire EDM (2008) establishes exact length specifications with minimal material waste.
EDM Rough Processing
Initial inner diameter formation creates near-net shape before precision grinding operations.
Precision Grinding
WACHIGAI (2006) NC lathe and PEMAMO (2021) achieve final dimensional accuracy and surface finish.
Bush
20-30 pcs monthly
Ring Gauge
10-20 pcs monthly
Bush
5-10 pcs monthly
Total Capacity
35-60 pcs combined
Drill Fabrication Technology
Material Preparation
Premium carbide material procurement and initial sizing verification
EWAG WS11 Grinding
Advanced 2005 grinding system for complex drill geometries and profiles
Quality Inspection
Comprehensive verification of dimensions, angles, and cutting edge quality
Length Cutting
Precise length determination and cutting using specialized equipment
1994 CTG Finishing
Final profile grinding and edge preparation using proven CTG technology
Drill Production
200-300 pieces monthly including standard and custom configurations for various applications.
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Center Drills
200-300 pieces monthly for precision starting operations with accurate point geometry.
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Gauges & Pins
200 pieces monthly combined production of measurement standards and alignment components.
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External purchase supplements in-house capacity with 1,100 twist drills monthly, optimizing cost-effectiveness while maintaining supply reliability.
Baito Processing Detailed Workflow
Component Assembly
Carbide tips prepared with copper and silver strips using specialized flux compounds
Outgoing Inspection
Final quality verification ensuring dimensional accuracy and surface integrity
Marking & Store & Issues
Safety cap application, identification marking, and preparation for delivery
External Coating
Application of protective coatings through external specialized services
Brazing Operation
High-temperature brazing process ensuring secure carbide attachment to tool body
Surface Grinding
Flatness achievement through precision surface grinding operations
Profile Grinding
Baito-specific profile creation using specialized grinding machines
Mirror Face Shining
Final finishing process achieving mirror-quality surface finish for optimal performance
Normal Baito
Special Baito
Uramen Type
7K
Monthly Output
Combined production of normal baito, special baito, and uramen meeting diverse application needs.
80K
Cost Savings (KRM)
Monthly cost advantage achieved through in-house fabrication versus external procurement alternatives.
Manual Lapping Process Innovation
Traditional Manual Lapping
Labor-intensive process requiring skilled operators to achieve mirror finishes. Manual methods limit throughput and consistency while demanding significant physical effort and time investment per component.
PEMAMO Automated Lapping
Revolutionary 2021 automation system delivering consistent surface quality with reduced cycle time. Automated process ensures repeatable results while freeing operators for higher-value tasks.
Improved Lead Time
Faster processing cycles through automation
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Full Automation
Reduced manual intervention requirements
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Manpower Optimization
Reallocation of skilled labor to critical tasks
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This strategic investment in PEMAMO lapping technology represents a significant advancement in our finishing capabilities, supporting both quality improvement and operational efficiency goals.
Cam Fabrication Technology
Advanced CNC milling and wire cutting technologies enable complex cam profile generation with exceptional accuracy. MAKINO V22 integration (2017) represents a significant capability enhancement for both flat and drum cam production.
Material Procurement
Hardened steel blanks selected for dimensional stability and wear resistance in demanding applications.
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Profile Milling
V22 5-axis machining center creates intricate cam geometries with micron-level accuracy and excellent surface finish.
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Surface Grinding
Post-hardening grinding operations restore precision dimensions and ensure proper timing relationships.
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Final Inspection
CMM verification of profile accuracy, timing validation, and surface finish confirmation before release.
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Product Range
- Flat cams for linear motion control
- Drum cams for rotary indexing
- Timing cams for synchronized operations
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Flat Cam Output
200-300 pieces monthly supporting majority of production requirements.
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Drum Cam Output
20-30 pieces monthly for specialized rotary applications.
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Cam Manufacturing Evolution
Progressive technology adoption transformed cam fabrication from manual slotting operations through millcam and wire EDM to current state-of-the-art CNC milling. Each generation delivered improved accuracy, expanded capabilities, and enhanced productivity
Legacy Slotting
Traditional manual operations limited to simple flat cam profiles with significant setup time and skill requirements.
Wire EDM Integration
Wire cutting enabled hardened material processing with excellent surface finish and tight tolerances on complex shapes.
Millcam Era
Computer-aided milling expanded geometric complexity for flat, drum, and timing cams with improved repeatability.
V22 Advanced Milling
Current 5-axis CNC technology delivers superior control of R-values and “zero” reading portions below 5µ tolerance.
Each technological advancement enabled increasingly complex cam profiles while reducing manufacturing cycle time and improving dimensional consistency. Investment in cutting-edge equipment positions the facility for future production challenges.
Cam Manufacturing Process Improvements
Previous: Millcam System
Current: V22 System
Programming Complexity
Difficult manual programming requiring extensive operator expertise and time investment
Simplified Programming
Advanced CAM software with intuitive interface reducing setup time and operator training requirements
R-Value Limitations
Tool outer diameter usage only, requiring r3 finishing endmill with limited market availability
Enhanced R-Control
Dual operation using both tool outer diameter and edge, enabling r2 with finishing endmill Ø~Ø2.0
Control Challenges
Difficulty controlling ‘0’ portion values below 5µ, resulting in larger radius shapes on production parts
Precision Achievement
Smaller radius shapes at production actual parts, meeting tighter customer specifications consistently
Equipment Stress
High tension cutting operations placing excessive load on spindle bearings, reducing equipment life
Deep Drilling Capability
Able to perform high-depth drilling with broad market tool availability and superior service support
The V22 upgrade represents a fundamental improvement in cam production capability, addressing previous system limitations while enabling new product opportunities through enhanced precision and flexibility.
Cutter Fabrication Process Flow
Raw Material Sourcing
High-grade carbide and tool steel procurement with material verification protocols
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14° Relief Angle Grinding
CTG operations establishing primary cutting geometry with precision angle control
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Profile Shaping
STUDER and GLS grinding for single, musosei, and hob cutter profiles
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Quality Verification
Comprehensive dimensional inspection and surface finish validation
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Equipment Fleet
- 2002 STUDER Profile Grinder
- 2011 WASINO GLS 821
- 2019 AMADA DV1
- 1994 CTG System
Monthly Capacity
- Single: 200 pieces
- Hob: 40 pieces
- Musosei: 20 pieces
Cutter Fabrication Enhancement
Strategic equipment modernization initiatives focus on expanding in-house capabilities while reducing external dependencies. Investment in next-generation grinding technology addresses both short and medium-term capacity requirements.
Current State: Legacy Equipment
STUDER and WASINO GLS machines serving production needs but approaching technological limits for complex geometries.
Short-term (5 Years): DV1 Integration
AMADA DV1 (2019) provides enhanced capabilities for single and musosei cutters with improved programming flexibility.
Medium-term (10 Years): Advanced Grinding
Next-generation profile grinding platform targeting complete replacement of legacy systems with expanded capacity.
Strategic Advantages: Modern equipment enables both outer diameter and edge utilization, supports high-depth operations, and provides superior market availability for tooling and service support. Smaller radius capabilities improve product actual part quality.
Manufacturing Capacity and Capabilities
100%
Baito Production
Complete in-house fabrication capability with monthly output of 6000-7000 pieces
100%
Cam Manufacturing
Full in-house production for flat cams: 200-300pcs, drum cams: 20-30pcs monthly
80%
Bush Fabrication
Predominantly in-house with monthly capacity of 25-30 pieces for bushings
90%
Cutter Production
High internal fabrication rate: Single 200pcs, Hob 40pcs, Musosei 20pcs monthly
40%
Drill Manufacturing
In-house production 150-200 drills, 200-250 centers monthly, supplemented externally
20%
Jig & Fixtures
Specialized fixture production with monthly output of 100-150 pieces
Cost Efficiency: In-house baito fabrication generates monthly cost savings of approximately 80,000 KRM through reduced outsourcing and optimized production workflows.
Strategic Summary
MP Tools Section represents comprehensive manufacturing excellence spanning cutting tools, metal parts, and precision support equipment. Our integrated capabilities, skilled workforce, and strategic equipment investments position us for continued success.
Manufacturing Excellence
World-class fabrication capabilities across baito, cams, cutters, drills, bushings, and specialized tooling with exceptional quality standards.
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Technology Leadership
Strategic equipment modernization including V22 milling, PEMAMO lapping, and advanced grinding platforms driving competitive advantage.
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Workforce Development
Comprehensive SVS certification system ensuring consistent competency across 23 certified operators with continuous skill enhancement.
Cost Optimization
Strategic balance between in-house production and external sourcing achieving 80KRM monthly savings while maintaining supply flexibility.
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Looking forward, continued investment in automation, process optimization, and workforce development will sustain our competitive position while expanding capabilities to meet evolving production requirements. Our commitment to excellence drives continuous improvement across all aspects of tools manufacturing operations.
Contact Information
MPD / TECH DEPT Tools Section
For technical inquiries, production planning, or quality matters related to metal parts manufacturing and tooling operations, please contact the appropriate department through established channels.
Key Capabilities Summary
- Comprehensive tooling fabrication across 6 primary categories
- Monthly production capacity: 6,000+ baito, 200+ cams, 300+ drills
- Advanced equipment fleet with CNC and EDM technologies
- SVS-certified workforce with specialized expertise
- Rigorous quality control with 100% in-process verification
- 80,000 KRM monthly cost savings through in-house production
Document Status: Confidential – For internal technical department use only
Documentation Access
This comprehensive technical guide serves as the primary reference for all metal parts tooling operations, processes, and capabilities within the Manufacturing and Production Development department.