The KITZ Group's manufacturing is based on the concept of delivering products when necessary and in the quantities required with better quality.

Integrated Production System That Provides Quality Control Starting from Castings

Based on integrated production, the KITZ Group positions castings (forge and foundry materials) that are valve materials as the core technology and produces them internally from castings. We have established an integrated production system in which our Group has its own casting facilities for the main valve materials such as bronze, casting iron, ductile, stainless steel and casting steel, thus putting in place a quality assurance system starting from materials. We also provide a wide variety of products in small quantities.

Production Method Based on KICS

What supports manufacturing operations based on the market-oriented concept is the production method according to the KITZ Innovative and Challenging System (KICS). KICS provides a mechanism of sending only good products to the subsequent process by producing each product one by one in a sequence of processes at the exact timing with which it can be sold. It also achieves the elimination of stagnation and waste in a series of processes from order receipt to production and delivery. Moreover, we strive to further reduce delivery times and reinforce production lines continuously by thoroughly implementing standard work and improving processes.

Toward a Manufacturing Workplace for Creating Added Value

KITZ is investing proactively in new production technologies and manufacturing processes, with the aim of achieving quality, prices, delivery periods and services that will guarantee the satisfaction of our customers. In addition to ongoing efforts in introducing robots to the manufacturing workplace, we are also applying and incorporating equipment management and image processing utilizing ICT and inspection methods leveraging sensor technologies. We are also seeking to improve and enhance our core technologies through the adoption of new casting methods and new materials research. Through these initiatives, we are driving the evolution of processes in the manufacturing workplace toward creating greater added value.

Pressure test of pneumatic actuators with sensors

KITZ Brand is Backed by Quality Management Systems

KITZ Corporation recognized the importance of conformance to the international standard on quality management systems earlier than anyone in the industry. In November 1989, KITZ became the first Japanese company to earn ISO 9001 certification. At present, all domestic and international production bases in the KITZ Group have been certified to this standard. In February 2019, our Group company, KITZ Engineering Service Co., Ltd., became the first in the Group to obtain certification for the scope of "valve maintenance" under the standard. Additionally, in July 2001, KITZ Corporation was certified, for the first time in the valve industry in Japan, in accordance with the Pressure Equipment Directive (PED) for CE marking required for European markets. KITZ plants in Taiwan, Thailand, China, Spain and Germany have now obtained PED certification as well.

In addition to these international quality standards, in Japan, KITZ Corporation is approved by the Minister of Economy, Trade and Industry as an authorized gas tester under the High Pressure Gas Safety Act. It supplies Japan Industrial Standards (JIS) certified products and complies with standards of the Japan Water Works Association (JWWA). KITZ plants in Japan and China are also certified to display the API Monogram of the American Petroleum Institute.

Global Production Network: Manufacturing Facilities Located in Optimum Locations

The KITZ Group is building a structure for undertaking production in the most suitable locations for its operations around the world.

Under this structure, we produce high value-added products in Japan, while Japan also plays a crucial role as the command center for our global manufacturing activities. The KITZ Group now has international factories in Thailand, Taiwan, China, Korea, India, Spain, Germany and Brazil.

New High-Frequency Induction Furnace in the Nagasaka Plant

In August 2020, a high-frequency induction furnace with a melting weight of 500kg was installed at the Nagasaka Plant. Previously, special material castings were produced by using the high-frequency furnace with a 1 ton melting capacity, but thanks to the installation of the new 500kg equipment, special material castings of smaller quantities can also be produced and we can shorten delivery times thanks to the reduced lead times. Additionally the more compact furnace is expected to reduce running costs and improve the percentage of defect-free, non-adjusted products.

Stainless Steel Valve Manufacturing Process

[1] Melting
Raw materials are melted in high-frequency electric furnaces.

[2] Ladling
Melted metal is ladled for pouring.

[3] Pouring
Melted metal is poured into a casting mold. The melted metal flows into the cavity between the upper mold, the lower mold and the core.

[4] Heat treatment (solution heat treatment)
Raw materials are quenched after having been heated up to 1,100°C. This process forms a uniform metallic structure and makes mechanical properties such as tensile strength and elongation higher and ensures corrosion resistance.

[5] Acid pickling
Pickling castings in acid solution removes impurities such as oxidized scales on the casting surface caused by heat treatment and shot blasting. At the same time, a protective film is formed on the casting surface, enhancing corrosion resistance.

[6] Machining
Castings are cut, drilled and processed with machines.

[7] Assembly
Various parts and components are assembled to complete valves.

[8] Pressure tests
Valves are pressurized with air and/ or water and operated to verify that they satisfy the quality requirement.

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