What is factor4? Developed by Amory B. Robbins et al. in 1995, factor4 is the idea that the balance between wealth and the global environment can be established again. By halving the use of resources and doubling the productivity, it will be possible to quadruplicate the resource productivity. Matsui strongly supports the concept of "halving resource use and doubling wealth", thus decided to contribute to this mission for its main client, the molding factory. The core philosphy is "Matsui in search of rapport", with the aim of achieving a "rapport" both with the environment and with the customers´ wealth. The factor4 in molding factories Factories have mainly aimed to improve labor productivity (how to increase production with a small number of people). However, from now on, the focus is on improving resource productivity, namely on how to increase production with less resources. Many achievements are possible: reduce wastage of resources and energy, lower the rate of defective products, increase the productivity efficiency, expand the added value of molded products, and quadruplicate the resource productivity. In general, there are three main voices: 1) diminish resource and energy consume; 2) improve producitivty; 3) increase added value. There might be more than one method or product to figure a problem out. For us it´s important the first important step is to find the root cause of the issue, and then propose the solution combination to try by working together with our customers. We keep evolving and adapting to the environment, as to look for new partners and solutions. In 2016, Matsui opened factor4 tech-studios to raise awareness on our efforts to achieve the "factor4 in molding factories" mission. Tech Studio is a faciltiy based on generations of experience: it includes what everyone who´s involved in plastic molding wants to know, such as the waste hidden in molding sites, the points to observe, and the actual effects of when solutions are applied, offering a full-of-surprises experience. In 2011, Matsui invited worlwide companies that could agree with the "factor4 in molding factories" and established the Association for Greenmolding Solutions (AGMS). AGMS has expanded at global level in USA, Italy, the Netherlands, China (also Hong Kong and Taiwan), and is made up of 15 societies, whose various technologies complement one another. Therefore, Matsui has established a system that permits to propose a broad range of solutions to achieve the "factor4 molding factory". The factor4 Tech-Studios The factor4 tech-studios are based in the city of Hirakata, in the Osaka Prefecture, and consist of five spaces in three buildings. The visit is elaborated around the concept that "if there is a problem, there is a solution" and starts from the main entrance room, where music and images help the guests visualize the concept. The facility also offers seminar rooms, where 20 to 30 people at time can deepen their technical understanding. In many cases, visitors propose their own theme to be analyzed. Matsui is continuously updating the contents of the exhibition so that guests can return for a useful experience again and again. Studio 1 From the main entrance room, visitors will access a molding demonstration area where it´s possible to see pressurized hot water type, steam type, and heat-&-cool molding. Moreover, customers can bring their own molds and materials to carry out experiments based on their unique aims and needs. The first zone focuses on the cut of resources. Here visitors can observe the functioning of some specific items: energy-saving, space-saving, low-noise crushing hybrid machines; a dumpling rolling machine that can reuse dumplings that are thrown away every time they get changed; a dryer for biodegradable plastic as a seasonal item. The second area is dedicated to the increase of productivity. Matsui offers solutions to overcome challenges linked with many production factors, such as contamination issues, or problems caused by gases, or troubles with coloring of molded products. For example, here guests can see an on-machine subtraction blender and static mixer that eliminates the trouble of color unevenness. The third sector deals with the increase of added value. The machine part of the exhibition is a foam molding that achieves improved dimensional accuracy and weight reduction of molded products, especially recyclable physical foam molding equipment using MuCell®, displayed together with some samples. Visitors can also observe a R&M® molding, which offers a combination of physical foaming and heat-&-cool molding. Studio 2 The second studio presents an area for "improvement of surface quality and value". Here guests are offered a hands-on experience: it´s possible to observe measures for efficiently heating and cooling molds and also touch the experimental equipment used. Another analyzed feature is the resolution of troubles caused by water quality, as there´s a detailed explanation regarding the management of cooling water: this step is essential for the stable continuation of heat-&-cool molding. The products offered are simple and efficacious; they involve filterless filters, filtration equipment, ionization equipment, hybrid chillers, and next-generation cooling towers that can maintain the initial water quality of the entire cooling system of the factory for a long time. Studio 3 This section consists of a facility entirely dedicated to testing. Guests can observe experiments regarding different aspects, such as long-distance transportation, compounding, drying, crushing, operation and performance confirmation before delivery. It´s important to note that, depending on the content of the test, it may not be possible to observe the proceeding. Do you want to see the factor4 Tech Studios yourselves? Have a virtual tour!
