IndustryOmori and Sanno

[Special] Ota, the Manufacturing City Continues to Take on Challenges!

 

Ota City is widely known as a city of manufacturing, boasting the largest number of manufacturing facilities in all of Tokyo’s 23 wards, 4229*.

This special edition focuses on the origins and characteristics of Ota, the manufacturing city.

First, we interviewed Ms. Kyoko Nishikawa, Director of OTA-KOREN, which supports the promotion and development of manufacturing in Ota City.

* Source: Economic Census in 2016 (Research by the Ministry of Internal Affairs and Communications and the Ministry of Economy, Trade, and Industry)

 


Ms. Kyoko Nishikawa in front of Ota City Industrial Plaza PiO, which communicates industrial information about Ota City

 

- Please tell us why manufacturing is so prevalent in Ota City.

“The most widely known major factor was the Great Kanto Earthquake in 1923.

Many factories operating in the center of Tokyo moved to the coastal area around Ota City due to the earthquake, and these factories were used as munitions factories during the war, making the entire area flourish.

From around 1955 to 1965, the number of nori (seaweed) farms was reduced due to the harbor improvement plan, and the abandoned nori processing areas were turned into sites for factories.

It was around this time when many people started coming from other prefectures in large numbers to work at the small factories in Ota City. With time, the number of experienced people who became independent from their mentors increased, resulting in more small factories being created.”

 

- What are the characteristics and appeals unique to Ota City?

“Each factory site is fairly small, and half of these factories have three or fewer workers. As such, it is difficult for these factories to have an all-inclusive style, so rather than that, they tend to have unique and advanced technology that is extremely competitive.


The core technology is called fundamental technology, which is the foundation of manufacturing. It is mainly in the areas of metalworking such as cutting, pressing, molding, polishing, casting, and plating.

When parts processing is connected between adjacent factories like a relay, the best technology is brought together to create a great product. This “Nakama-mawashi” (work passed around among associates) has been a characteristic style of Ota City’s manufacturing for many years. It is sometimes called a bicycle network because the factories are located so close to one another that it is possible to get around by bicycle.

Through cooperation, even complex, high-precision processing can be completed in a very short time period. As such, manufacturing in Ota City is also highly regarded for its quick turnaround time. While mass production factories throughout Japan are shifting to Asia, small factories in Ota City in recent years have been doing high value work such as prototyping of parts for new product development.

We believe that this will progress even further, and co-creation will be in the spotlight.”

 

- Could you tell us about co-creation in detail?

“In other words, factories are taking the initiative. Basically, instead of a subcontracting structure in which factories wait for jobs from major companies and then work together to finish them, they are trying to create more and more jobs from the factory side.

In addition to the fact that factories in Ota City originally have the technical skills to create great products, they also have the spirit of craftsmanship necessary to produce results beyond what is required of them. By utilizing the network they have fostered up to this point, they are shifting to an innovative form of manufacturing, which is to ‘create what they want to create’ with their associates.”

 

- What is the difference between co-creation and Nakama-mawashi?

“If subcontracting work is passed around among associates and in the unlikely event that the order value continues to be lowered, the technical capabilities of these factories will not be properly utilized and will simply be wasted. This could lead to a decline in technology.

Rather than waiting for work to come in as they did in the past, co-creation is a concept of demonstrating the collaborative power of manufacturing in Ota City, starting from planning, proposal, development, and design, which are the starting points of manufacturing.

Beyond just the existing factories, research and development type and proposal type co-creation initiatives, which are to co-create and collaborate with industry, academia, and venture companies, are becoming more and more active.”

 

- Are there any efforts being undertaken to drive co-creation?

“In Ota City, we are creating a place where co-creation can be further driven by establishment of ROKUGO BASE, a business start-up support facility, and Techno FRONT Morigasaki, a factory apartment complex.

 

As small factories can barely take time to train their own personnel, the chronic shortage of labor is also a major issue.

In order to help them with this problem, OTA-KOREN holds manufacturing seminars to foster the next generation and provide support to help them acquire the skills essential for proposal type co-creation. OTA-KOREN cooperates with the municipal authority to hold seminars for new recruits as well. We hope that they will connect with one another as fellow workers in small factories in Ota City and that co-creation will be born from the younger generation.

 

The people involved in manufacturing in Ota City are all strongly committed to developing the industry as an entire community. We will continue to back up co-creation for its further development by accepting not only existing companies but also a wide range of venture companies including those from overseas in the future.”

 

・Click here for the details of OTA-KOREN.

 Click here for the details of hosted seminars.

* The seminars are targeted for those who live or work in Ota City.

 

Click here for the details of ROKUGO BASE, a business start-up support facility.

 

Now that we understood well about the origin and characteristics of manufacturing in Ota City, let’s move on to the two examples of co-creation in Ota City that we just talked about.

Co-creation example 1: Autonomous mobile transport robot, Mighty-D3

Piezo Sonic Co., Ltd.



Mr. Kohei Tada, Representative of Piezo Sonic Co., Ltd.
Piezo Sonic Co., Ltd. is a developer and manufacturer of Piezo Sonic Motors, rotary ultrasonic motors that use piezoelectric ceramics as the drive source, and operates out of Techno FRONT Morigasaki.

“We manufacture thin, powerful, and quiet motors. Since magnetism or coils are not used, these motors can be used in medical equipment that generates intense magnetic fields, such as MRI machines, and in precise transport equipment,” says Mr. Kohei Tada, Representative of Piezo Sonic.

“Products made with ordinary motors cannot maintain their state unless they are energized, and the moment the power is turned off, the motor loses its power. To prevent this, electric power is generally used for braking and control so that the motor can stop, whereas Piezo Sonic Motors can maintain position through friction, so it does not require electricity to stop and is superior in energy conservation.”

Mr. Tada used to be involved in the development of a lunar surface exploration robot, and the Piezo Sonic Motors were originally developed for use in space exploration robots meant to function well in a vacuum environment like space, or in areas lacking power.

According to Mr. Tada, manufacturers capable of mass-producing rotary ultrasonic motors that use piezoelectric ceramics in their mechanisms have not appeared in the past 20 years. He also mentioned that this type of motor is very difficult to develop and manufacture, meaning that even a small company has a chance to obtain a significant share of this niche field.


Ultrasonic motors, Piezo Sonic Motors
“Although we have 3D printers and metalworking machines to quickly create prototypes, in general, we ask external partner manufacturers to do the resin processing and metalworking. We also develop control software to create devices that utilize the motors, but since it is difficult to complete everything in-house, we often cooperate with other companies for development.”

When Piezo Sonic is requested to develop a product, they get involved from the conceptual design stage, including the purpose of the product. Mr. Tada oversees the entire development and manufacturing, and proposes ideas from a consultative view.

“Each customer has different needs for the products they want to make, such as products that require special mechanisms, products that require particular attention to design, and products that require software development including communication. Therefore, we make proposals while envisioning which possible partner companies we can collaborate with for each project.”

Piezo Sonic does not just decide that they can do it on their own; they understand the importance of relying on each professional in order to create a product accurately in a short time. Mr. Tada observes a policy of taking advantage of the location, Ota City, and if there is someone who knows more than he does, he will honestly rely on them.
Piezo Sonic was founded in Setagaya City, but Mr. Tada chose to set up its office in Ota City because he was attracted by the fact that there are many professionals that can be counted on as collaboration partners.

Mr. Tada says, “These are tiny details, but numerical problems such as the appropriate number of screws or the thickness of a cable can be quickly derived from calculations. However, in reality, it may not go according to what has been calculated. This is the difficulty of manufacturing. There are definitely situations where knowledge learned through experience is required in manufacturing. In an environment like the one found in Ota City, top notch professionals advise you candidly, so I’m very grateful.”


Autonomous mobile transport robot, Mighty-D3, developed through co-creation

As a result of co-creation, an autonomous mobile transport robot, Mighty-D3, was developed with Piezo Sonic Motors.
Mighty-D3 is a type of robot called AMRs (autonomous mobile robots), which autonomously drives itself to its destination using a camera and sensor. One of its characteristic capabilities is that it can operate inside as well as outside. This robot can be used for home delivery, logistics in factories, and contactless/non-face-to-face guidance in hospitals and condominiums. The development started by using the grant program from the Ota City Industrial Promotion Organization in 2018, and within only three years of development, the production of the commercial model became possible.

“During the development of the Mighty series, we consulted with Technology Link Co., Ltd. in Kamata regarding the strength of the suspension which supports the main frame. Their advice based on experience regarding bearing selection and the size and number of screws was truly helpful.
As for the body design, we consulted with FACTUS DESIGN INCORPORATED, which operates from the fourth floor within the same building as us, Techno FRONT Morigasaki. FACTUS DESIGN did a wonderful job of designing of course, but they also worked with us to create a design that took into account the usage and movement of the product. I myself want to deliver products that are useful when people actually use them, while putting the customers’ needs first, so I very much relate to FACTUS DESIGN’s attitude toward their work. If it weren’t for partners like Technology Link and FACTUS DESIGN, it would’ve taken longer and cost more for the development of the Mighty series, and most likely the release would have experienced significant delays.”


The plaque in the back is for the GOOD DESIGN AWARD. The awards in front are (from left to right) for CES 2022 Innovation Award, 5G New Business Award, and New Products/Technology Contest for Ota City Small/Medium-sized Businesses. Piezo Sonic’s technology is highly acclaimed domestically and internationally.
Piezo Sonic Co., Ltd. Main Office
Address
Techno FRONT Morigasaki 507, 4-6-15 Omori-minami, Ota-ku
TEL
03-6379-6020
Mail
info@piezo-sonic.com
Link to their motor business
Link to their consulting development/robotics business

Up next is FACTUS DESIGN INCORPORATED, which was in charge of the body design of Mighty-D3.

FACTUS DESIGN INCORPORATED


FACTUS DESIGN INCORPORATED handles industrial designs. Mr. Bunshu Hachiro, the representative, started his career as a designer at a watch manufacturer.
“In designing watches, various materials from metal to leather, and even cloth are used. We try to incorporate these different materials in our industrial designs and make proposals that are entirely original to us that cannot be conceived by other companies.”


Mr. Bunshu Hachiro, Representative of FACTUS DESIGN INCORPORATED (right) and Minako, the designer and his wife (left)
Mr. Hachiro considers the ability to mass-produce a product as part of the basis for his designs.
“There are many genres in design. For example, automotive manufacturers design the exterior overview first as the styling design. Next, another designer creates detailed design drawings and blueprints based on that design into a form that can be molded in 3D. With these phases, a design turns into a product. However, handing this styling design to a manufacturing factory without an environment such as what you find in an automotive manufacturer, they would just say, ‘So the design looks great, but how do we turn this into a product?’”

This is where Mr. Hachiro’s idea of co-creation is born.
“There are many examples of designs that people liked when they were seen on a flat surface, but they could not be realized as a product. Therefore, we envision and propose a form that can be mass-produced from the initial design phase.”
FACTUS DESIGN has a metalworking factory on the premises, and they take care of the production in-house if the order is a small lot. If a customer requests the design in shape, they sometimes produce a sample to show them.




A number of beautiful products sold by FACTUS DESIGN’s original brand, FACTRON
The major reason as to why FACTUS DESIGN moved to Ota City is because the Tokyo Office of IWAMA Co., Ltd. is in Techno FRONT Morigasaki.

“We use IWAMA’s metalworking machines. Techno FRONT Morigasaki is a very solid building with robust facilities, which means loud noises do not cause problems for the neighbors. In addition to that, having IWAMA Co., Ltd. in the same building is a great benefit for us.”

Mr. Hachiro mentioned that he has been involved in the Mighty-D3 project since the beginning.
“Since it is an autonomous mobile robot, the first thing we made sure of as far as the design goes was that whoever sees the robot can tell that it is something that moves when they see it for the first time, and that the front and back can be distinguished. We figured that being able to tell which way it would move at a first glance would be an important safety measure.”

“We believe that Mr. Tada will continue to be one of the leading people for creating new technologies, so we definitely want to work with him for any other co-creation opportunities,” says Mr. Hachiro.
FACTUS DESIGN INCORPORATED
Address
Techno FRONT Morigasaki 401, 4-6-15 Omori-minami, Ota-ku
TEL
03-6715-1362
Mail
info@factus.co.jp

Mighty-D3, an autonomous mobile transport robot created through mutual respect towards each other’s technologies and co-creation, won the CES 2022 Innovation Award in the Drones & Unmanned Systems category at CES 2022 (the world’s largest technology trade show).


Mr. Tada (left) and Mr. and Mrs. Hachiro (right) confirm further co-creation in the future.

What is Techno FRONT Morigasaki?


Address: 4-6-15 Omori-minami, Ota-ku

Techno FRONT Morigasaki is a factory apartment complex built and opened by Ota City in May 2008 to improve the operating environment for factories and contribute to the revitalization of local industry.

In order to promote co-creation within the factory apartment complex, the first and second floors are designed with high floor loads and high ceilings to accommodate processing factories that operate machine tools, while the upper floors are compact enough to accommodate R&D offices.

Contact:  Industrial Promotion Division, Ota City
TEL 03-5744-1376
HP https://www.city.ota.tokyo.jp/sangyo/kogyo/sangyou_sien_shisetsu/fctfm.html

Co-creation example 2: 10x speed 3D printer, G-ZERO

Gutenberg + Kyokuto Seiki Co.,Ltd + Yasuhisa Koki Bio Mechanics Co., Ltd., and others



10x speed 3D printer, G-ZERO
The 3D printer G-ZERO (GUTENBERG ZERO) was unveiled at the Ota City Industrial Plaza PiO in October 2021. G-ZERO has attracted attention in the industry for achieving 10 times faster molding speed compared to commercially available 3D printers.

Conceived by Mr. Lee Seungjoo, President of Gutenberg, this product was created through the co-creation of Kyokuto Seiki Co.,Ltd, Yasuhisa Koki Bio Mechanics Co., Ltd. (both in Ota City), and Q-ho Metal Works in Osaka.

Gutenberg has an office on the premises of Kyokuto Seiki Co.,Ltd
Mr. Ryosuke Suzuki, President of Kyokutou Seiki Seisakusho, who was struck by Mr. Lee’s enthusiasm for taking on the challenge of manufacturing, provided him with not only the equipment but also a vacant space within the company premises, saying that Mr. Suzuki can also introduce Mr. Lee to the industry network of Ota City.

For G-ZERO, Gutenberg was primarily responsible for the design, and Yasuhisa Koki was in charge of prototype design. After Q-ho Metal Works joined the production team due to the experience in manufacturing 3D printers and fine molding, 3DXs was formed. The detailed parts were created by various manufacturing companies in Ota City.


Everyone in the production team, 3DXs
Ms. Nishikawa, Director of OTA-KOREN, who knows how the development came about, looks back on things.
“The speed from the creation of the first prototype to the commercialization of the product was just very fast. Mr. Lee’s idea was realized in no time with the technology of each company. When they consulted us with the request to hold a presentation to reveal the product, we of course cooperated in full force.”

The reveal presentations were full on both days. Although due to the pandemic, the presentations were held on a reservation-basis, the number of visitors far exceeded the number of reservations, and they were amazed at the speed at which the G-ZERO sculpted items in front of their eyes.
Sales of G-ZERO began in February 2022 through the sales channels of each of the four companies.


We have just showcased two examples of co-creation within Ota City.

Through tireless efforts, inquisitiveness, and strong ties of co-creation among local associates, we are confident that groundbreaking products will continue to be delivered to the world.

Extra Information
Ordering consultation service


The Ota City Industrial Promotion Organization offers an order consultation service in which a professional coordinator listens to you and introduces, for free of charge, companies in the city that have reliable technology to those who are looking for subcontractors for processing and manufacturing.
The organization accepts consultations from companies as well as individuals, and every year they handle nearly 1,000 cases from all over the country.

HP
https://www.pio-ota.jp/trade-expansion/trading-consultation/jyuhachuu-soudan.html
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