Company Profile of Miraial Co., Ltd.

Transcription

1 October 22, 2014 Company Profile of Miraial Co., Ltd. 1

2 General View of Miraial Group Space-saving and cost-saving (custom-made to automate a production line). Handling of special raw materials (LIM, transfer, BMC) Various sizes and applications. Marketed for electrical, car and health care industries, etc. Accurately materializes the product before mass-production by various machining methods. (3D printers, rapid prototyping, cutting, vacuum cast molding, simple metal molds, etc.) Size : 3,000-ton large products to small rice-grain-sized ones. Quantity : 1 pc. to mass-production of over 10,000 pcs. Raw materials : Super-engineering plastics, fluorine, original compound raw materials. 2

3 General View of Miraial Group Providing All the Solutions Required for Manufacturing 3 Design Single-piece test production (Machined product) Small- and mediumvolume production (Machined product) Metal mold production Evaluation (Physical properties and chemical analysis) Mass-produced molded product Molding machine production Miraial Sanjo Seiki Miyamoto molding Customer

4 Company Profile Established in: 1968 Listed on first section of Tokyo Exchange Market in 2012 Capital: 1.11 billion yen As of end of Jan Sales: Representative: 8.35 billion yen (consolidated) As of end of Jan Hideo Yamawaki No. of employees: 451 As of end of Jan Business outline: Main business bases: Subsidiary: Semiconductor-related products, other products Main office in Tokyo, Plant in Kumamoto Sanjo Seiki Co., Ltd. Miyamoto molding Co. Ltd. 4

5 History 1968 Established Kakizaki Seisakusho Co., Ltd Succeeded in development and commercialization for the first time in Japan of a PFA cassette for silicon wafer. Established the Kumamoto Office for expanding production of silicon wafer cassettes. Developed and marketed a 300 mm silicon wafer shipment container FOSB ahead of the rest of the world Changed the company name to Miraial Co., Ltd Listed on the JASDAQ Securities Exchange Made Sanjo Seiki Co., Ltd. a subsidiary 2007 Completed the No. 3 Sumiyoshi Plant for expanding FOSB production capabilities Listed on the second section of the Tokyo Stock Exchange Made Miyamoto Molding Co., Ltd. a wholly owned subsidiary 2012 Listed on the first section of the Tokyo Stock Exchange Started mega solar power generation Established a materials laboratory. 5

6 Main Products (Semiconductor-Related Business) Product Applications Customer Wafer manufacturer Device manufacturer Timing of use Production process Cassette Shipment from plant Carry-in to plant Inter-process carry-in and production process FOSB FOSB FOUP Cassette 6

7 Main Products (Semiconductor-Related Business) Product Lineup 200 mm or less In-process containers (In-plant transfer) Shipment containers (Inter-plant transfer) 300 mm Chemical treatment process Non-chemical treatment process Fluororesin Special PP, PBT, PEEK PC, PBT In-process container (In-plant transfer) Chemical treatment process Non-chemical treatment process (Inter-clean room transfer, etc.) Fluororesin Special PP, PBT PEEK FOUP Shipment containers (Inter-plant transfer) PC, PBT FOSB 450 mm FOSB (shipment container) + FOUP (in-process container) = MAC (shipment container + in-process container) Left: 450 mm MAC, Right: 300 mm FOSB 7

8 Miraial s Integrated Production System Raw material development Product design Metal mold design Metal mold production Inspection Evaluation Molding Shipment 8

9 Top-Level Global Market Share 1. High-cleanliness, high-quality and high-accuracy products demanded by the semiconductor industry 1) Development and molding of pure special-grade resin Resin containing less gas components, metallic compounds and ionic materials. Highly difficult molding with pure resin. 2) Inspection capable of maintaining high cleanliness, high quality and high accuracy Analysis at the µg (microgram) to ng (nanogram) level. 3) All the production processes have been turned into clean rooms. (Anticontamination measure) 4) Dimension accuracy for using the wafers in an automated line Position control in steps of 10 µm. 2. Customer-based support Silicon wafer manufacturers, device manufacturers 9

10 Integrated Production System Raw Material Development Our original raw materials have been jointly developed with a raw material manufacturer. Developing production and marketing of high-function, high-purity products As a breakdown of raw materials used, high-performance plastics account for over 90% (e.g., PEEK, PBT, PEE, PC, POE, PFA, PTFE). General-purpose plastic resins account for less than 10% (e.g., PP, PE, PS, PMMA, ABS). + Established the materials laboratory in 2013 to enhance our research and development system. 10

11 Integrated Production System Product Design & Metal Mold Design Efficient Design Utilizing 3D CAD/CAM and Analytical Software to Satisfy Strict Dimension Tolerance 11

12 Integrated Production System Metal Mold Production Capable of in-house production of various sizes of widely applicable metal molds. 12

13 Integrated Production System Molding Complete lineup of injection molding machines (from 30 to 3,000 tons) Precision molding technology for hard-to-cut, high-performance, highpurity plastics. Clean molding facility generating less dust and contamination. Prevents external contamination with a raw material transfer system combining all the processes of drying, supplying and injecting raw materials into the hopper. System management of the plant s internal environment, based on the concept of molding clean raw materials through a clean facility. (Class 100 to 10,000) 13

14 Integrated Production System Inspection Typical value of Class 500 Product assembly and inspection in a fully clean environment 14

15 Integrated Production System Evaluation (Various Evaluation Devices and Facilities) Able to evaluate various functions and raw materials 3D measuring machine MFR measuring instrument Surface resistance measuring instrument Submerged particle measuring instrument Vibration tester Charge plate monitor Drop tester 15

16 Integrated Production System Evaluation (Chemical Analysis) Cleanliness of the chemical laboratory = Class 100 to 1,000 Microanalysis of ions, metals and gases. IC (Ion chromatograph) ICP-MS (Eluted metal analysis) GC-MS (Gas chromatograph) Analysis results are fed back to improve the products. 16

17 Kumamoto Office/Sumiyoshi Plant (Completed in 2001) Role: Mass-production Points Production base for mainstream products (300 mm FOSB and FOUP). Facilities already introduced for producing the products for 450 mm wafers. Chemical laboratory provided to assure product quality. Mega solar panels installed on the overall rooftops of the plants. (Started selling electricity in Sep. 2013) Nos. 1 to 3 Plants, Total land area: 134,178 m 2 17

18 Production Base: Kumamoto Office/Tominohara Plant (Completed in 1984) Roles: Production of order-received goods; development of new products and new projects; research and development; metal mold design and production. Points Resin molding (engineering plastics such as fluororesin and PEEK, and general-purpose resins) Inspection system in a clean room environment. Laboratory for improving the existing products and developing original raw materials (Future Emergence Office) Nos. 1 to 3 Plants, Total land area: 14,850 m 2 18

19 Overview of Subsidiary Sanjo Seiki Co., Ltd. Business outline: Production and marketing of various vertical molding machines and metal molds President: Hideo Yamawaki No. of employees: 86 Main office: Tokyo, Plant: Yamaguchi (Hagi, Mine) Excellent chemistry with automated equipment. Space-saving vertical molding machine to realize a smart production plant. When it comes to molding machines, horizontal ones are the mainstream. Since vertical ones operate in the same direction as gravity, however, the metal mold is subject to a lighter burden, allowing a more even flow of raw materials at the time of molding. Sanjo s molding machines are good at handling special raw materials with LIM, BMC and transfer molding. 19

20 Overview of Subsidiary Miyamoto molding Co., Ltd. Business outline: Test production and modeling of plastics and metals President: Hisashi Maki No. of employees: 37 Main office/plant: Fukushima City, Fukushima Prefecture 3D printers, rapid prototyping, cutting, vacuum cast molding, simple metal molds, etc. Complicated geometries are reproduced by a variety of machining methods. Test production before mass-production. Properties added to the present products by raw material compounds (original raw materials + luminosity, metallicity, etc.). Material copy created by 3D scan. Lighter weight and lower material cost achieved by changing materials (going from metals to resins). Machining methods Machining 5-axis machining center Fused deposition modeling Rapid prototyping Simple metal molds Rapid prototyping machine Machining methods Metals Machining Wire electric discharge machining Fused deposition modeling machine Materials Aluminum, zinc ADC 12 SUS 303/304/316/430 Titanium Nickel Inconel Brass, copper Special steels 特殊 (NAK, SKS, SC, SKD) Resins Test production and modeling of functional parts Small lot production Machining methods Machining Vacuum cast molding Materials Super engineering plastics PPS, PEEK, PEL, PES Fluorine Engineering plastics, general purpose resins ABC, PMMA, PC, POM, PE, PBT, PA Rubber Materials Urethane Silicone Various kinds of elastomer Vacuum cast molding machine 20