Manufacturing Today - July 2017 - 39

Ryobi Die Casting

Midwest

Indiana you have GM and we're close
to Ford and even some European Tier
I suppliers," Sano says.

Large-Scale Casting
Ryobi Die Casting is a wholly owned
subsidiary of Ryobi Ltd., a Japan-based company that was founded
in 1943. It has since grown to encompass 12 facilities around the world,
including six in Japan and others in
Northern Ireland, China, Thailand,
Mexico and the United States.
The American facility was established in 1985 when it began operating
in Shelbyville, Ind., located about 30
miles southeast of Indianapolis.
Like its parent company's other divisions, Ryobi Die Casting specializes in high-pressure aluminum parts.
Following the $97.5 million purchase
and equipping of a neighboring former plastics plant last year, the Indiana campus has grown to about 1
million square feet of manufacturing
space spread out over 100 acres and
six buildings.
With $450 million in annual revenues, Ryobi Die Casting makes up
a significant portion of Ryobi Ltd.'s
$2.3 billion in annual sales. Die casting itself makes up nearly half of
the parent company's revenue, with
power tools, builder's hardware and
printing equipment making up its
other major markets.
From its campus in Indiana, Ryobi
Die Casting supplies parts to clients in
the United States, Canada and Mexico
that include many large automotive
manufacturers and key suppliers.
Although focused on North America, Ryobi Die Casting can reach a truly
global market through its parent company. "A lot of our customers like Ryobi because we have a global presence,"
Sano says. "We do a lot of global coordination." Ryobi Die Casting facilities

ryobi die casting takes pride
in designing and producing
all of its dies in-house.

all over the world can aid each other.
There have been cases where Ryobi
Die Casting develops a die cast but its
sister company in Europe is awarded
the manufacturing program.
Similarly, Ryobi Die Casting prides
itself on designing and producing all
of its dies in-house; however, in some
cases, those designs are derived from
products at other Ryobi Ltd. facilities.
"We're a little bit independent, but
because we all provide feedback to
[Ryobi Ltd. in] Japan there's a shared
global knowledge," Sano explains.
To facilitate that cooperation, Ryobi facilities employ local expatriates
to cross language barriers. Ryobi Die
Casting's engineers will perform
technology reviews and hold meetings at 6 a.m. when their counterparts
in Japan are still working.
The resource sharing that goes on
between Ryobi Ltd.'s different locations allows the company to set up
new programs more quickly than its
competitors can. This can also often
result in improved quality because

new parts can benefit from the experience of past projects.
It is common for new casting programs to have faults or quality issues
when they are launched, but Ryobi
Die Casting can eliminate or lessen
those problems by drawing from a
global knowledge base. "We have the
capability and horsepower to solve
those issues quickly," Sano says.
Ryobi Die Casting continues to build
on those capabilities. In 2007, the company purchased a die casting plant in
Irapuato, Mexico, that has since grown
to 700 employees. The Indiana branch
wholly owns the facility.

Quality Commitment
"I think we're known for providing
quality products," Sano says, noting situations where a customer dual-sources parts from Ryobi Die Casting and another supplier and Ryobi
Die Casting offer a better first-timethrough yield.
Ryobi's reputation for delivering
quality on a large scale has made it
JULY 2017 manufacturing-today.com

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