Customer Feedback

As a leading manufacturer of cores* for casting, Taisei Shell Corporation holds the top market share in Japan. The company has been committed to pursuing high quality and has earned the trust of casting companies, including manufacturers of automotive parts, who regard Taisei Shell as the best choice for challenging cores. Asahi Yukizai has been a key partner in this endeavor, supplying the "Resin Coated Sand" (RCS) casting sand product to Taisei Shell for over 40 years, thereby supporting the company’s continuous improvement in core making. We interviewed Mr. Toshitaka Ozawa, President about the impact of Asahi Yukizai's RCS on their operations. He emphasized that "excellent RCS is one of the indispensable elements for producing high-quality cores.

*A core is a mold inserted into the casting mold to form the cavity in castings that have an internal cavity.

Proposing the Right RCS to Solve Problems

We established our Shimane Plant in 1977 to engage in full-scale core manufacturing. At that time, we had little knowledge of Resin Coated Sand (RCS), but through trial and error, we gradually increased our collaboration with casting companies by aiming for higher-quality cores. Concurrently, the demands from these companies grew more diverse, leading to requests for cores with a higher degree of complexity. In casting, various issues can arise, ranging from accuracy in dimensions and surface finish to defects caused by gas emissions. When casting problems occur, cores are often the first to be inspected. Although not always at fault, we have consistently strived to produce cores that meet our customers' requirements to the fullest extent possible.

Initially, the Shimane Plant sourced RCS from a local supplier. However, when issues with the RCS arose, we faced limitations because we could only use products offered by that supplier. This changed when we encountered Asahi Yukizai. Upon consulting with Asahi Yukizai about a problem, they suggested an RCS specifically improved for our needs, which provided a solution. As the number of complex requests from casting companies grew, so did our consultations with Asahi Yukizai, leading to an increase in business volume.

Dual Support in Products and Services Leads to Quality Improvement

Currently, over 90% of the RCS used by our company is sourced from Asahi Yukizai. Their RCS comes in a wide variety of grades, tailored to the resin coating the sand. Each grade offers superior characteristics, such as enhanced mold strength and fusion point compatibility-traits that usually contradict. Additionally, they provide improved dimensional accuracy through low expansion and fewer defects due to reduced expansion rates. When issues arose, swift resolutions were achieved by adjusting the blend ratios of these grades. This responsiveness is possible because Asahi Yukizai is the sole RCS manufacturer in Japan that oversees the entire process from resin development. Their dedication to meeting our demands for higher quality cores has resulted in a diverse RCS lineup.

The research-driven approach of Asahi Yukizai's staff, who regularly visit our office to collaborate with our team on problem-solving, is particularly reassuring. In the casting industry, including core production, quality is influenced by a myriad of factors such as materials, production methods, and environmental conditions like temperature and humidity. High-quality core production is beyond reach if pursued in isolation. Asahi Yukizai's ongoing research and development in casting, from the perspective of an RCS manufacturer, have significantly enhanced our core quality. The synergy between Asahi Yukizai's product and service support and our technological advancements enables us to fulfill a broad spectrum of customer needs.

Building Customer Trust Hand in Hand with Asahi Yukizai

When our Shimane Plant was founded, we were a modest operation with just 5 employees. Today, our team has expanded to 140, including temporary staff. This growth was made possible through our close collaboration with Asahi Yukizai, meeting our customers' needs and building trust over the years. We hold Asahi Yukizai in high regard, feeling a connection akin to that of a group company, despite no direct capital ties.

The complexities of casting are vast and not fully understood by us yet. Unveiling these complexities is key to producing high-quality cores. Now more than ever, exchanging and sharing information with Asahi Yukizai, a company with a global footprint, is crucial. It's important to actively discuss the myriad of casting challenges faced both in Japan and internationally. By continuing to research collaboratively, we can contribute not only to our company’s growth but also to the broader development of the casting industry. Moving forward, we are committed to uniting our efforts to craft superior cores and address various casting challenges together.