Making 144 million screws alone with a 60-year-old machine
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- Опубликовано: 26 сен 2024
- Company Asai screw factory
This is a screw factory in Japan where the president alone has continued from receiving orders to manufacturing, sales, and shipping for 55 years.
The factory has a very high profit margin with fully automated mass production of screws and no employees.
Produces 144,000,000 bottles annually.
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I'll bet that machine was 60 years old when he got it 30 years ago. It is amazing how well made older machinery was. I took a machining class. In the shop was a HUGE metal lathe that could turn things 7' long and 4 or 5 feet in diameter. It was made in 1932 and you can still get all new bearings for it and it is still as accurate as any lathe made today.
My dad used to make lathes, much bigger than you saw, but nothing like the biggest. The biggest I know of can work 25m length and 7m diameter, but probably not at the same time. Waldrich Siegen Profi Turn H, if I spelled it right.
@@cageordie Yes, good point, the one I worked with could do a long length or a wide diameter but not both at the same time.
There are ship yards making diesel (bunker oil actually) engines with crank shafts a hundred feet long or longer which means a HUGE lathe has to be involved.
Might have been a Monarch or American.
@cageordie there used to be a business called triggs mfg in city of commerce calif they had lathes that machined the metal o rings for rocket engines some were fifteen twenty feet or more in diameter they had to use a lift to load stock onto machine and also a catcher to get part as it was machined off was there when a operator failed to place his catcher...beheaded
@Brian some longer parts thread isn't cut its rolled between two mandrels some hot rolled others cold rolled
I just love the japanese with their appreciation for high quality. Please never give that up
Hello from Tokyo! Thanks for your comment!
Neat little shop. Sadly it looks like when the owner retires these machines will end up in the scrap yard because you don't have any young people learning how to work and maintain them. Would have been interesting to see some of the actions like heading screws and rolling the threads at a slower pace to see how it's actually done in the machine.
Hello from Tokyo! Thanks for your comment!
It is a pity that there is no successor. The president's son used to work there, but he quit.
Hear ya have 47 years setting up different types screw machines and did prototype machining now no one wants to get hands dirty retire soon to my home workshop maybe when I pass grandson will take my machines
Why would you manually do something that a factory can do to better precision and on orders of magnitude greater volume
@@wazaagbreak-head6039 The fact that he operates with a significant profit margin demonstrates the why someone would continue to use these old machines.
The fact that you think this is what making screws manually looks like shows you don't know much about it. These screw machines are all automatic, hence why a single guy can produce millions of screws all by himself. And I'm sure his screws are more than accurate enough.
@@wazaagbreak-head6039screws are still made this way today. Screws are not made in CNC machines. But screws can be made much cheaper from another place not far from this gentleman’s home…. I would proudly buy this man’s fasteners for my shop.
My cousin would love working there 'cause he just screws around all day anyway.
Amazing guy! I love that he has a belt holder for his micrometer! 😊
Reminds me of a screw shop I used to work in. We made every kind of screw, nut anything up to 1". We ran 8 Davenport screw machines, and they were old, noisy and nasty, but they were accurate. I miss it sometimes, just me and the machines.
Yea ran those most of jobs we bid on weren't for parts was for chips...the brass
As I said, crappy UNC luckily nobody use outside NA.
0:52 There's something so cool about carrying a micrometer in a holster on your belt. Sort of like the machinist version of a gunslinger. "You're a thousandth out of spec! You're under arrest!"
Wow, watching this video sure takes me back to the old days. That’s a mini cold heading shop, a lot of machines for one man to work, impressive.
Hello from Tokyo! Thanks for your comment. Yes, the president said that it is fully automatic and efficient.
That’s a fantastic little shop
I used to make these parts on B&S "00" screw machines. Sure would like to know more about this process!
Hello from Tokyo! Thanks for your comment! I'd be happy to entertain you with other videos as well.
Had my hand caught in a B&S screw machine. That was 40 years ago. I am still machining. Have 2 lathes, and 2 mills in my garage. Screw machines are on another level. Maybe now I could master one.
@Wild E. Coyote well fairly easy any brownie or cva..index davenport Acme just the matter of concept..been setting up 45 years sad to see the old dinosaurs phased out...most of reason is no longer tax deductible...cnc are but screw Mach is cheaper overall
@@miguelcastaneda7257 There's still things that good old screw machines and purpose built machines can do faster and more economical than modern CNC's. I worked @ John Deere as an electrical maintenance tech. about 10 years ago and they had a number of purpose built machines 40+ years old that they were still running because nothing modern could compete. Interestingly, they were still running a big old Warner & Swasey NC turret lathe (converted to CNC) made in the 70's because nothing modern could remove as much material/hr as that old behemoth. The increased productivity offset any tax benefits of replacing it. They had a lot of really cool, unique equipment there. Unfortunately, between the ridiculous union politics and Deere treating everybody like they're 5 years old, I couldn't take it and found a better job.
@Marc's Eclectic Stuff true at work I finally convinced them to blank out parts on brown and sharp screw machines they can run four five hundred a day then cnc do the burnishing making two hundred or more versus previous doing it all cnc lucky get fifty a day ...screw Mach only specialized tool is form everything else pershiable tooling drill cut off tool cams are pick up am on cncs now but did set up and reapair for forty plus years
He's obviously holding up the custom of high Japanese quality, too bad we've lost all our screw shops to China in the US
Not all of them.
I know of one in stl
Rockford IL had a bunch when I was growing up
The US and Chinese trying to "screw" each other
Mill-Max has a large captive screw machine shop on Long Island, NY. They make all sorts of connector pins for electronics.
Nice to see things that last. Quietly working away. Much success to to this company
Молодцы!!! А у нас России не делают даже гвозди!!! Господин Титов (советник Путина) Говорит: Мы все купим!!!
Now I know why Japan was a formidable opponent in WW2 and why my Japanese products are such great quality. Many thanks..
After the war when they were occupied by the U.S. we helped them get back on the road to economic stability by teaching them SPC (Statistical Process Control). They embraced and improved it. Changing tooling just before it fails saves you a lot of scrap.
Don't know which is better, the actions of the machine, the operators skill or the sounds. They are all great.
this guy is a bolt lord, but hiring 1 employee would be the smartest decision of his life
Hello from Tokyo! Thanks for your comment!
That's one option, too. I think so.
Very nice precision work
When I’m 60 I want to be him, so cool ☀️
The thing about these 1 man band workshops that always makes me nervous is if he had an accident. With no apprentice or someone in the office, it could be several hours before he's found, if he did manage to knock himself unconcious. In our workshop we have a rule that no one is to work alone. All it takes is a single trip and to smack your head on something and you're in serious trouble if theres no one else around to get help.
Despite that worry, A very cool little shop! But all this skill will eventually get lost to time if no one younger is learning these skills and able to continue on when this guy retires.
Hello from Tokyo! Thanks for your comment.
I agree with you.
But the president said that one person is comfortable and good.
A good old Craftsman's skills and machinery are always so nice to watch.
I would like to see how the threads were rolled. I assume not cut.
7:50 Look at how the hands of a Japanese patron look.
And then think about how the "patrons" look in Europe and America.
Well done Mr. Asai! All respect from Romania!
Thanks for the comment! I will let President Asai know!
SOMEBODY, PLEASE GET THIS MAN A MEDAL!
Кустарщина. А ещё Япония. Я думал у них там всё высоком технологическом уровне.
Para cerrar el taller innediatamente. No pasa una minima inspeccion de condiciones de trabajo. Es raro que no le falte parte de un dedo o haya perdido el oido
대단합니다
Did a few days of electrical work in a shop that had maybe a dozen Brown & Sharpe screw machines years ago. Owner told me the machines were over 20 years old and run 24/5. Worst thing due to oil mist oil was on everything that you touched. They would shut down one week a year and to clean oil buildup. One time they were making cheap screwdriver handles. In less then 5 seconds they cut out a channel for your finger, drilled a deep hole for screwdriver blade and beveled cut off edge.
Greetings from Reno, Nevada, USA
Thank you! From Tokyo
No computer to be found anywhere in that shop. Bliss.....
Hello from Tokyo! Thanks for your comment! I'd be happy to entertain you with other videos as well.
Respect to a factory where president works too!
昔の機械は 潤滑油の製造元変わるだけでも正常に動かなくなるから本当に大変
そうそう、いい仕事してくれるけどクセが強いんだよね！
いや、ダブルヘッダーなんて何でも動くしこれくらいの線経ならホイール手で動かしてもねじ造れるぞww
知ったかぶりやな
昔の機械というより、油の問題だね。
今は測定器の性能が向上してるから同じ粘度の潤滑油作りやすい。
@@菌悪玉-c8s
潤滑油の妄想始めたのはコメ主やろ？
この機械はそんなに繊細じゃねーよ。
Great Job kids today cant run 5 machines at once but this guy is rocken n rollin !
社の機械室に、太平洋戦争直前にドイツから来たケッパーという歯切盤が2台ありました。使えるのはたった1人で歯車の設計図を見ながら計算尺で使うギヤを決めての作業、1台に100枚のギヤが。昭和の時代はフル運転だったそうですけど、だんだんと数値制御の世になって歯切盤の出る幕もなくなったし職人さんもお年で処分する事になりました。
最後に切ってくれたはすば歯車は、今も会長室に飾られています。
コメントありがとうございます！今では貴重な歯切盤なんですね、素晴らしい
Nice open electrical box.
Got his Mitutoyo micrometer on his belt 🫡
How does he get anything done? He just screws around all day 😅
The president said that it is fully automatic and easy. However, he said that he would like to turn this factory into a museum in the future because there is no successor.
There used to be 850,000 of these small operators in Japan.
wow.
I worked at a book making plant they had some equipment that was over 110 years old and that was 26 years ago. Old German equipment lasts.
It does it in 1 step? That’s crazy.
Any of these mass produced screws and bolts often come with made in China flat pack assembly products and often the screws are deformed or have no notches for screwdrivers to engage with. I have a whole collection of these from over the years.
I had a buddy that had a business that rebuilt headers in the Rockford, Il. area from about 1965 till 2000. In the 40's ,50's and 60's Rockford's nickname was Screw city for all the screw machine Co's that were there. That's 1940's etc. if this post is still out there 200 years from now. Every year there is a Screw City Beer Fest.
Used to make tooling for the fastener industry. Those old machines are solid and overbuilt and rebuilt when they need to be .
The old Machines . Righteously built !
Great video luv machines that make things.I guess this is the epitomy of a one man shop and why a mask when your all by yourself I was wondering. Maybe some hazardous dust in the air from the process possibly. Those machines were made well in a different day & age when they made with tremendous durability & high quality ........
Oil mist.
@@rkgaustin9043 That makes sense..
I ran bolt makers at a fastener company that ditched their vintage National and Nedschroef machines for cheap Chinese machines that ran a couple ppm more. The old machines could head, trim, point and roll threads with each stroke of the ram. The new machines were strictly cold headers, so they had to add secondary work to parts. Guess what happened.
Made in Japan❤👍🇯🇵
AWESOME Machine👍👍👍
Hello from Tokyo! Thanks for your comment!
Excellent
5:29 he sticks his hands in the washer like it's nothing. I would think he would have some kind of tool for that. That tough old man could probably sand drywall with his palms
Grande !!!
Its a well oiled machine and slick operation 💰💰💰💰
thanks man !
Cool.
All we have left in the US is screwballs.
Thanks for the comment!
You forget highballs and speedballs.
A good example is in the case of machine maintenance. If preventive maintenance, scheduled maintenance and breakdown maintenance of those machines are carried out properly, this machine will work well even for hundred years. This gentleman seems to be dedicated to machine maintenance
The thing that I fail to understand is how the heads are done. Cold forging, I presume, but I think those are stainless steel screws, which makes me wonder. Anyway, those are nice quality screws. Great for cameras and precision equipment.
Fascinating process. But that endless-loop/endlessly repetitious music bed gets absolutely mind-numbing after about as many repetitions as screws being made here. (OK, a bit of an exaggeration, but still...) Why is it deemed mandatory to stick music behind every friggin' video that gets posted? Has absolutely nothing to do with the subject at hand.
Hello from Tokyo! Thanks for your comment! Thank you for giving me your precious time.
At 6:06, that pivot screw looks very loose.
I wonder how his hearing is holding out, with all the clanging metal.
keep them old machines lubed up and they're good to go for many a screw
Hello from Tokyo! Thanks for your comment.
The president said that maintenance is easy. You are right 👍
Glad the Chinese didn’t get all the old machines. Hard to imagine but modern machines are lighting faster.
I used to live next door to a small company that made specialty screws, aptly called "Specials, Inc." - but they went bankrupt and the building was abandoned, with the ancient equipment still in it. The roof leaked, and the whole place started falling apart - a shame, really.
집에 있는 40년전 재봉틀은 아직도 내 옷을 수선해 주고 있어요
Boleh ikut kerja,saya biasa ngoprasikan mesin Heading
If only Jeff bezos didn’t start Amazon sand sell books
This is exactly where I imagined he would be
Outstanding
Looked like many computer screws until toward the end.
Hello from Tokyo! Thanks for your comment.
Near the beginning also, looks like small screws for 2.5"/ODD/floppy/etc.
Nice info, thanks :)
Corre riegos, trabajando solo.😮
Тот, кто писал заголовок, понятия не имеет, как выглядят шурупы. Это ВИНТ, а не шуруп!
I WISH GOOD HEALTH TO THAT GENTLEMAN. BRAVO BRAVISSIMO REGARDS FROM AN OLD GREEK CRAFTSMAN FROM ATHENS GREECE
This guy is playing Factorio IRL
Old style mechine
But beat qual👍🇯🇵
real goals
It looks and sounds like Willy Wonka's inventing room Willy Wonka & the Chocolate Factory.
I wanted to see the threading operation...no joy.
Alles vollautomatisch, auf den neusten Stand der Technik. ! .
Der Präsident dieser Fabrik sagte, dass sie rentabel ist, weil sie voll automatisiert ist und keine Arbeitskosten erfordert.
Yey, there 60 years isn't that old!!!!
Hello from Tokyo! Thanks for your comment!
🙂А самое интересное -как изготавливается головка шурупа и шлиц на ней, как изготавливается резьбовая часть -утаили!
And the most interesting thing is how the screw head and the slot on it are made, how the threaded part is made - they hid it!
Шлиц прошивкой, резьба накаткой. Загуглите: «резьбонакатной станок»
?? 1,000,000 screws will take about 11 days continuous to produce ?? Or 5.5 days ?
yes 💪
WHAT A MAN !
Hello from Tokyo! Thanks for your comment!
Hebatnya 👍👍
Hello from Tokyo! Thanks for your comment!
昔の機械は本当に凄いのよ。
なかなか壊れないし、職人がいれば修理もできる。
今の機械も悪くないけど、壊れたら基本終わり。
テスラ車なんてほぼ総取っ替え、こういうのは気に入らない。
When I was young I worked in a production machine shop, I SET UP and ran two Automatic Screw machines (oldest made in the 1940's), AND two CNC lathes ... simultaneously! :) The owner used to call me "The Multi-Spindle Man" :) these old machines remind me of the days back then :)
Super
oh , ja , wenn man bedenkt was hier schrauben kosten , zb , spaxschrauben im sonderpreis baumarkt , pro kilo 5 euro , was bekommt der hersteller
한국에도 60년전에는 90% 가 일본이 남기고간 공작기계임. 공작기계 기술자는 거의 일본인 기술자에게 기술을 익혔다.
공부가 되었습니다. 댓글 감사합니다!
小さいネジは番線から作るのかぁ(ﾟдﾟ)！
Where were the old machines made ?????
Hello from Tokyo! Thanks for your comment!
This machine is made in Japan.
400 тыщ за день ну ну. Визуальный осмотр.про мерила что нибудь слышал. И какие 7 станков. 4 процесса. Высадка.накатка.мойка.гальваника. и это один за день ниччо не попутали. И ещё у мужика хороший сбыт.или это один заводик на всю японию😊
Invest in some ear muffs my friend but great video
Hello from Tokyo! thank you for the advice.
Great work,
How much cost of machine for small scale business
Hello from Tokyo! Thanks for your comment! According to the president, he bought one for $4,000 60 years ago. Maintenance of the machine is also easy, just apply oil and replace consumable parts.
He said it was a machine with good cost and performance.
Is it family business? Is that man the owner of these tools?
El 99% del video muestrav la fabricación de PERNOS (y no ''tornillos).... Solo al final se muestran muy fugazmente solamente dos tornillos, uno muy corto y el otro largo, coloquialmente llamados ''roscalatas''
¡Hola desde Tokio! ¡Gracias por tu comentario!
Rien d exceptionnel....😊
В России давно бы налогами и штрафами придушили.
excuse me sir, i made a mistake in my order. i only needed 144 screws, NOT 144 million. sorry about that. ;) my bad.
Так вот на каких винтах собраны все китайские и не только телевизоры
Привет из Токио! Спасибо за ваш комментарий!
Sugoi !!!
arigatou!! Hello from Tokyo! Thanks for your comment!
Hello from Honolulu 😊🌞
You are most welcome !
Dōitashimashite😊
Have a wonderful day.
У дядьки микрометр сломан, видимо точность станков на такой высоте))
И руки в масле по локти, а он этими пальцами на кнопки жмёт. Коробки грязные таскают руками, никакой механизации, по колено в масле работают. Никакой техники безопасности и гигиены труда. ))))
@@RobertoCarlos-m1i, if he is happy doing his work which he has been doing for so many years, I don't see any problem. Your comment just reflect your state of mind.
@@RobertoCarlos-m1i, try to learn the meaning of the word savage.
Плахой начальник, в нашей стране начальнику с курорта даже думать не надо!
HE IS SO NICE TO WEAR MASK 😷 SO THE POOR METAL SCREWS WON'T CATCH COVID-19... 😏