During the manufacturing phase, Amada promotes to realize a clean factory through the accomplishment of zero-emission factory.
By applying the new Nitrotherm spray system based on nitrogen gas, paint transfer efficiency improved dramatically at the Fujinomiya Works. As the heated ionized nitrogen lowers the paint viscosity, much less diluting solvents are necessary.
Following the introduction of this new technology, paint usage was reduced by 27%, VOC emissions by 35% and paint sludge (industrial waste) by 25%.
The water-soluble cutting fluids used previously by AMT caused odor and sludge problems, making it necessary to change the cutting fluids once every six months, but since they operate with alkali ionized water, they are able to prevent the decay of cutting fluids, as well as the particularly unpleasant odors at processing stations.
This also prevents the adherence of dirt to machine interiors, lengthens the time between cutting fluid changes and results in a substantial reduction of waste fluid emission.
The use of wooden pallets for the delivery of castings is now prohibited at AMT. Instead, reusable resin pallets and palletainers(metal-cage-type containers) are used.
All pallets and palletainers are numbered, and managed by the persons in charge of material reception, who directly check the materials each time upon delivery.
We have also developed an assembled material handling system that can be used repeatedly for sheet metal delivery. Thanks to this system, we succeeded in achieving our "zero wooden pallets" and "zero plastic sheets" goal in the packaging material field.
Our specific activities conducted by these zero-emission factories is "exit control", which aims at "producing no waste". We do this by finding recycling options for waste. In the "entrance control" activity, we are promoting the use of returnable cases and packaging material reduction.
As a result, Fujinomiya Works and Isehara Works have achieved the zero-emission standard in May 2008 and March 2009, respectively.
Clean Factory is an environmentally-friendly factory that reduces the environmental load generated by production. It includes zero-emission (reduction of waste) as well as energy-saving efforts to prevent global warming, reduction of CO2 emission, and reduction of VOC used in factories. The Third Factory at Fujinomiya Works is the world's largest assembly plant for laser machines, and it is fit to be called a Clean Factory.