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10.02.2023

ESI Group

For Nissin Kogyo, ESI ProCAST is an Indispensable Tool for Assuring Production Quality

Nissin Kogyo Co. Ltd., established in 1953, develops, manufactures, and sells brake equipment for two- and four-wheeled vehicles. Honda Motor Co., Ltd. and Toyota Motor Corporation are among their largest customers. One of their main challenges is meeting crucial demands of such OEMs, including reducing the weight by using lightweight aluminum as an alternative without sacrificing performance and durability.

Brakes are the primary safety device of an automobile and at the same time are often visible and must be aesthetically pleasing. They typically experience temperatures of 200° - 300°C as a consequence of friction during braking and must function well under the adverse environments of dirt, water, snow and salt. The challenge for many manufacturers, such as Nissin Kogyo, is to deliver, in the shortest time, optimal designs that meet the stringent requirements of automotiveOEMs. The level of defects Nissin Kogyo experienced in their product lines was too high and was delaying deliveries to their customers. With increase in production and product diversification, the problems amplified.

Their main task was to produce a “quality casting” (right size, shape, weight, strength) without internal defects and with a good after-machining surface finish. At the same time, the manufacturing process had to be designed to provide the highest possible yield. Nissin Kogyo realized that their success depended on understanding the casting process inside the mold cavity.

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