Tokyo Foundry Group

High quality assurance system

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Strict process control to produce “ultimate high quality”

We have built technology and management system cultivated by casting of automobile parts that always require strict conditions of quality, by making full use of technology such as AI, robots and IoT.
We achieved high quality assurance compliant with IATF 16949:2016.

Commitment to high quality

  • 01High Quality

    Clarify the grounds for casting conditions to produce high quality (IATF 16949:2016)

    IATF 16949:2016
  • 02High Quality

    Prove three elements of high-quality castings (materials, porosities, shapes)

    High quality castings / Materials:materials as standardized / Porosities:no casting defects / Shapes:dimensions as drawn
  • 03High Quality

    Record quality for each process to enable to trace.

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High quality assurance from process design term to mass production term

IATF 16949:2016 (European standards higher than ISO) Process design term:define mass production management standard / Mass production term:conduct ingredient analysis, temperature control, and dimension control to prove by traceability

Please refer to scroll horizontally.

Process design term

01Design, simulation, prototype

  • Flow and solidification analysis on 3D model is conducted before casting to understand defects such as porosities in advance to reflect them in the mold design.
    Test casting under wider range of manufacturing conditions is conducted to confirm robustness. Defects in test products are inspected by X-ray CT metrology. We detect the optimum conditions for mass production by repeating cycles of these processes.

  • Sampling inspection by “three-dimensional measurement + robot”
    Sampling inspection by “three-dimensional measurement + robot”
  • Nondestructive inspection by X-ray CT metrology
    Nondestructive inspection by X-ray CT metrology
Mass production term

02Material management

  • When materials are received, we internally analyze the components by analysis robots. Patrol analysis is conducted every three hours when melting as well as vacuum gas test to determine if there is any problem.
    We conduct multiple checks such as appearance inspection, cutting color check after finishing process to inspect quality before/after casting.

  • Automatic analysis by robots
    *Played at double speed

03Mold temperature

  • Precise temperature control is performed by monitoring temperature data of eight locations (four points each top and bottom) inside the mold by LCD monitor with good visibility.
    Temperature data is saved as a CSV file every 5 seconds.
    We constantly monitor mold temperature to prevent casting defects.

  • On-site LCD monitor
    On-site LCD monitor

04Dimensional control

  • Dimension is guaranteed by sampling inspection by 3D measuring machines and robots. In addition, the shape of products and molds are inspected by contactless inspection by using a 3D scanner. Automated measurement can achieve much better efficiency and accuracy than manual measurement which was common in the past.

  • Sampling inspection by “three-dimensional measurement + robot”
    *Played at double speed
  • Measure products and molds by 3D scanner
    Measure products and molds by 3D scanner


  • QR code is printed on our products to show the manufacturing data (Manufactured date/manufacturing line/worker’s name/mold temperature during casting/material analysis information/leakage inspection information). This enables to trace accurate process records for accurate feedback.

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