Technical Expertise
The “Three Pillars” Underpinning Technology
Yamato Steel’s production processes, operational capability, and engineers that support its technological
expertise.
This solid foundation underpins our technology.
Production Process
Decarbonized Steelmaking
Yamato Steel is engaged in the electric furnace steelmaking,
which involves melting and refining scrap iron that has reached the end of its useful life,
by using heat from electricity and transforming it into new steel products.
As a leader in the steel industry,
we are dedicated to reducing carbon emissions through this sustainable production method.
Steelmaking Process
Steel Rolling Process
Operational Capability
One of the Most Advanced Facilities in Japan
01
Melting in a 130-ton DC Electric Furnace
Yamato Steel was the first in Japan to introduce the latest state-of-the-art scrap preheating device (SSP) with a top-mounted furnace. This innovation enables energy-saving and efficient melting of iron scrap to while maintaining high productivity.
Operational Capability
One of the Most Advanced Facilities in Japan
02
Manufacture of a wide variety of products on a single line.
Our manufacturing capacity of various sizes (from H150×150 to H900×300), including H-beams, steel sheet piles, I-beams, channel steel, and shipbuilding steel. We are the only company in Japan that operates such a flexible production system.
Operational Capability
One of the Most Advanced Facilities in Japan
03
One of the Japan's Largest Large-Scale Facilities
Our large-scale facilities are capable of manufacturing cast steel products weighing up to 40 tons and heavy industrial products weighing up to 70 tons. We have a proven track record in manufacturing a wide range of cast steel products for ships and industrial machineries, as well as stern frames. Furthermore, all of our workers hold ship classification qualifications, ensuring the highest level of quality and compliance with ship classification society standards.
Engineers
Those Who Shape the Future
The Accumulation of High-Quality Experience Creates a Decisive Advantage
- Melting Section,
- Melting Department
- K.M
Profile
Joined the company in 2009. After working in the Steel Manufacturing Division, which is engaged in the operation of continuous casting machines and electric furnaces. He was seconded to the Nucor-Yamato Steel Company, a U.S. group company, for 5 years. After returning to Japan, he applied the knowledge gained overseas, where he was in charge of operational improvements in the steel manufacturing process and the introduction of the latest equipment.
Many Young Employees Gain Overseas Experience
At Yamato Kogyo Group, a global steel manufacturer, Yamato Steel sends employees overseas as
engineer support staff to group companies’ factories. There, they participate in a variety of
projects and return to Japan with a broad range of experience and insight.
I believe that this kind of hands-on overseas experience is closely connected to Yamato Steel’s
operational strength. Many of these overseas factories have been operating for more than 30 years
and have developed their own unique expertise and strengths not found in Japan. By working on-site
overseas, seconded employees to learn directly from these environments and bring back valuable ideas
to improve operations upon their return to Japan. Additionally, gaining access to the latest
insights from the global market on-site is another major advantage.
Leaders with Extensive On-Site Knowledge Manage the Process
Yamato Steel’s strength lies in its ability to offer a wide variety of products – all from a single
line. And with surprisingly fast delivery! How is this possible with just one line? One reason is
that Yamato Steel operates a wide range of large and small continuous casting machines, optimized to
quickly produce high- quality products. Steel melted in the electric furnace is solidified in these
casting machines to form rolling stock. Since the quality of this material directly affects the
quality of the final rolled product, it is critically important.
Naturally, if the equipment is not in good condition, operations are affected. That is why, we place
strong emphasis on diligent maintenance and thorough management. What we value most is listening to
the voices and opinions of those working on the manufacturing floor. Daily communication with
on-site experts is crucial to fully understanding the real-time situation. This enables us to give
precise instructions quickly and respond flexibly to sudden customer requests or orders involving
small lots and a wide variety of products.
The Growth of Each Individual Powers Yamato Steel’s Innovation
Our company is a place where engineers are encouraged to try many different things. As for myself, I was involved in equipment installation and other tasks right after joining the company, and I have been able to gain a wealth of experience that I likely would not have had anywhere else. I think that one of the unique features of our company is that we can implement ideas for operational improvements right away. We test them in real operations, and if they succeed, we put them into practice. Through this process of trial and error, I feel that my skills are steadily being refined. Furthermore, by expanding my perspective through overseas experience and applying what I have learned, I hope to contribute to the development of the core manufacturing plant as a future leader. I am truly fortunate to be in an environment where I can always take on new challenges. With this mindset, I aim to perfect the creation of high-quality products in the upstream process of steelmaking, ensuring customer satisfaction.
Major Investment: Challenging the Complete Renewal of the Rolling Line
- Rolling Section,
- Rolling Department
- Y.H
Profile
Joined the company in 2010. From his 3rd year to the 5th year, he was dispatched to South Korea where he was provided technical support in areas including steelmaking, rolling, and the environmental management. He currently works at a rolling factory where his responsibilities include planning rolling methods, supervising workers, and designing rolls for new products. He is also involved in a project for renewing the rolling line, which is scheduled for completion in 2028.
World-Class Technology: Multi-Product Manufacturing on a Single Line
Our rolling department’s greatest strength is its ability to manufacture a full lineup of H-beams. There is probably no other plant in the world with facilities of the same scale capable of manufacturing large products with a width of 900 mm. Given the compact scale of the facility relative to the products, maintaining high manufacturing precision becomes more difficult as product size increases. I think that Yamato Steel’s greatest strength advantage lies in its ability to manufacture products by maximizing the use of its rolling mill adjustment technology. Of course, we will continue to work on improving quality. Rolled products can show significant variations in dimensional accuracy – not just due to rolling mill control but also, because of various factors, such as multiple equipment conditions and temperatures exceeding 1000°C. Therefore, we repeatedly analyze multiple factors and make improvements each time. As a result of that analysis, I feel a great sense of fulfillment when my ideas lead to concrete results. Dimensional accuracy is improving year by year, and we have received positive feedback from our customers.
Promoting IoT Through Equipment Upgrades to Further Enhance Quality
Our company can deliver the products our customers want in small lots, with short delivery times,
and at low cost using electric furnaces. In addition to these strengths, a large-scale project
called the “Complete Renewal of the Rolling Line” is currently underway with the aim of further
improving quality and safety. The company plans to invest hundreds of billions of yen in this effort
and introduce state-of-the-art equipment. The project I am personally overseeing is well over 10
billion yen.
There are many things that we plan to do once the new equipment is in its place - one of the most
important being - the promotion of IoT. For example, it is not possible to equip state-of-the-art
sensors in our current old rolling mills, but with the updated rolling mills, it will be possible to
quantify all movements and extract them as detailed data. This will allow us to monitor the
condition of the products during the manufacturing process with a high degree of accuracy. In
addition to improved quality, productivity will also increase significantly. With the aim of
completing the project in 2028, I would like us to take on various other challenges as well.
Transferring Japanese Expertise Overseas, Then Bringing It Back
Changing the rolling mill means more than just upgrading equipment; it also means improving the operation method. Since work processes on site will change significantly, one of our key future challenge will be training the workforce. Now, as one of the project leaders, I am trying to acquire a wide range of expertise, including human resource development. I would also like apply this knowledge to improve our overseas group companies. Several overseas factories are already scheduled for upgrades, so I would like to become an indispensable person who can jump in at any time! Our goal is to share the know-how developed at Japan’s core manufacturing plant with our global locations—and then bring the insights gained overseas back to Japan. Creating this cycle will inevitably lead to high customer satisfaction.
Crafting Massive Ship Sterns with an Integrated System: The Ultimate Challenge
- Cast Steel Section,
- Heavy Industry Department
- J.K
Profile
Joined the company in 2005. Acquired advanced manufacturing skills in cast steel products at the Heavy Industry Department that manufactures parts of the vessel’s stern (such as stanchions and rudder horns). Currently, he is in charge of managing the manufacturing process of cast steel products, evaluating and introducing the latest equipment, and training young skilled workers.
Comprehensive Capability: From Steel Casting to Machining and Fabrication
In the Heavy Industries Department, where I work, we mainly handle the production of ship stern sections. In particular, we hold a leading domestic market share in stern blocks, known as “stern frames.” It is quite rare for manufacturers like us to have the ability to manage every step of the process – from producing large cast steel parts to machining and fabricating – all within a single factory. I think that gives our company a significant competitive advantage. In other words, the steel castings we produce are machined and assembled on site into components for massive vessels. Naturally, this allows us to shorten delivery times and offers significant cost benefits. Due to these advantages that are unique to our company, we receive many bulk orders for steel casting and fabricated structures.
Continuous Improvement in Hardware and Software to Remain the Top Choice
Each of our shipyard clients expects high quality, technical expertise, and flexible responses from us. I believe our ability to consistently deliver on these fronts is what earned us ongoing orders and relationships of deep trust. In terms of hardware, we have equipment capable of producing cast steel products up to 40 tons and rare processing machines that can handle huge components up to 8 meters in height. In terms of software, our bending processing skills are highly regarded in the industry. Another of our strengths is the ability to offer technical collaboration from the design stage. Customers value our ability to review their drawings in advance and provide suggestions on cost-efficient design options. Hearing them say, “We’d like to consult with you again,” is incredibly rewarding for us.
Our goal is to build a state-of-the-art workplace while also training the next generation of steelmakers
In addition to my administrative duties, I am focused on developing young staff. As the number of young skilled workers increases due to the current generational shift, the challenge now is how to effectively pass down the skills and experience of our senior employees. With the goal of developing each employee into a “multi-skilled worker,” we are creating a unique system that incorporates each skill into manuals. By mastering a wide range of techniques, we are each able to respond flexibly to detailed requests from customers. That is the kind of skilled workforce we want to create. Of course, it is important not only to learn from the skills and experience of our seniors, but also to keep up with developments in technology and equipment. We aim to create a workplace that is safer than that of our competitors and is equipped with state-of-the-art equipment and technology.
