50 YEARS OF HISTORY
At that time, because Totsu did not know about screws so much, his way of making holes in the center of screws was inefficient. Thus, he faced the problem that he could not mass-produce them.
After spending two years studying this, one day he came up with an idea of shaping simultaneously with punching. Trial production was successful, and manufacturing 200 Totsu Screws per minute became possible. As a result, he immediately solved the problem and started mass production.
Inspired by the development of Totsu Screw, he began to develop an "automatic screwdriver (later electric screwdriver)" that could automatically fasten screws while foreseeing the needs of the industry in the future.
Those days, air tools were popular for screw fastening, but there were problems such as the difficulty of setting torque, large impact noises when fastening, and oil and water falling with air. Thus, screws were tightened manually for precision equipment. His obsession “I want to make good things” finally produced a result – he had invented the M-type electric screwdriver. Thanks to the M-type, the production site started to use electric operation for screw fastening and the work hours were greatly reduced, improving production efficiency.
Because the battery did not cover the number of screws for a day, it was disregarded in Japan. However, Volkswagen thought of an idea and prepared a rack like a bookshelf to charge about 50 batteries at once, and they thought they could replace a battery immediately when it ran out.
The crosshead (Phillips) screw was invented by an engineer named Henry F. Phillips in the U.S. in 1935. It gradually became popular in the 1960s, and eventually overwhelmed the market. It became an essential screw for streamlining the production line. However, although it does not skid like a slotted screw, it causes popping out (called “cam out”) where the screwdriver escapes from the screw, so you must apply thrust from the top while fastening it. Therefore, we have developed a crosshead screw with a straight recess instead of a skew one to overcome the problem of popping out. Thus, the Totsupura® screw was born.
No matter how excellent the screwdriver’s accuracy becomes, if the screw quality remains poor, screw fastening errors will not be eliminated. The overwhelming stability of the Totsupla® screw drove the improvement of screw fastening quality.
When testing automation with conventional screws, the quality became unstable due to the problems including popping out and bit wear of crosshead screws. Regarding Hexalobular with a star-shaped recess, less thrust was required than for a crosshead screw, but wobbling caused poor workability, and robot operation often stopped. The solution to all these problems was Intrtorque®, which demonstrated the best performance in screw history.
Like our first invention, Totsu Screw, Intrtorque® had a circular recess in the star shape to solve a long-standing problem of wobble and improve stability.
As a result, lateral and diagonal fastening, which was said to be the most difficult process in automation, was solved. In addition, by reducing screw fastening errors caused by excessive thrust, bit wear, and wobble, significant cost reduction was realized. Intrtorque® will drastically change the future of the industry.
With conventional screwdrivers, it often relied on the experience and intuition of the worker to determine whether the screws were fastened correctly, and quality often depended on the skill of the worker. Therefore, inexperienced workers always had to be trained. In other words, it was assumed that screw fastening depended on human factors. To maintain efficient and stable screw fastening quality, it was necessary to promote automation and digitalization to eliminate human errors. The solution to these problems was JUKUREN®
It checks the number of pulses by reading the signal transmitted from the motor. This screwdriver determines that a screw is placed, which is visually indistinguishable, by the number of pulses. Thus, anyone can efficiently perform accurate screw fastening. This makes everyone a skilled worker.
Totsu Screw is the origin of HIOS. When the slotted screw was the mainstream, we improved it by providing a recess to the center of the slot on the head to prevent the screwdriver from slipping sideways. This enhanced usability and greatly improved work efficiency.
TOPICS
While developing Totsu Screw, we also started to improve bits. We developed a unique chucking system that picked up non-metallic screws without using air. This was effective in assembling precision electronic devices that were vulnerable to magnetism. Furthermore, we made the bit end into a chip shape so that we could replace only the chip when the tip was worn. This made it possible to save bits.
Illustration of automatic chucking system
Established a research laboratory in Oshiage, Sumida-ku, Tokyo.
Released the world's first industrial electric screwdriver, the M-type. In the era of high growth where air screwdrivers were prevailing, the M-type opened up the field for electrification of screwdrivers because torque was easily adjusted with a dial.
TOPICS
Prototype of M-1000
M-type, the first electric screwdriver.
You can set the torque precisely through current control by adjusting the dial to one of the four options. Furthermore, by connecting with a power transformer, it was designed to reduce the operating voltage from 100V to 26V or less (low voltage) considering the safety of workers. In addition, the M-type was quieter and easier to carry than an air screwdriver because it was compact and lightweight. At that time, most of the assembly of precision parts was outsourced to home workers. Even if a housewife with no special skill fastened screws, she could fasten them with constant torque and assemble high-quality products.
Finished product
M-type electric screwdriver and power transformer
We devised an epoch-making system that used a combination of products we had developed earlier (e.g., Totsu Screw, automatic chucking bit, and M-type driver) to securely catch a screw with one chucking, which dramatically improved the efficiency of screw fastening.
We thought that this system was as good as a “Hole In One Shot” for golf, and named it HIOSYSTEM after taking the initial letters of the words. We later adopted HIOS as the company name. “O” in the corporate logo was designed to symbolize the shape of a Totsu Screw.
We started full-scale sales of screws and electric screwdrivers under HIOS brand in Akasaka, Minato-ku, Tokyo.
Corporate Logo
First catalog under the HIOS brand
Catalog to introduce HIOSYSTEM
We released Totsu-tite featuring benefits of Taptite (with the unique rice-ball shaped (triangle) shaft design manufactured and sold by Nitto Seiko) and Totsu Screw.
The internal substrate of electronic equipment began to shift from metal material to synthetic resin. However, the conventional air screwdriver had some problems and was unusable. It was difficult to control the torque accurately and the rotation speed was high, causing frictional heat in the resin screw to melt it.
On the other hand, the M-type screwdriver had precise torque control and slow rotation speed, demonstrating its superiority. Thus, it encouraged more synthetic resin to be used for camera bodies and allowed calculators to be thinner.
M-6000 with larger torque joined the product family according to customers’ demands.
Low-voltage design highlights "safe & secure" even if children touch it. Since the foundation of the company, we have focused on the development of environmentally friendly products and are working to improve screw fastening quality.
Mr. Totsu himself shot the photos with his daughter as a model.
[SEIKOSHA (now SEIKO)]
High precision oscillator clock, VIBRON
We were awarded the "Efficient System Development Award" from SEIKOSHA (now SEIKO) for Totsu Screw and the M-type screwdriver, both of which remarkably improved work at assembly sites. It was rather unusual for them to give such an award to a supplier.
[NATIONAL (now PANASONIC)]
For assembling TV components
This was the world's smallest IC TV TR-001; a compact monochrome TV with a 1.5-inch CRT that was exhibited at the Osaka Expo. It was one of the items stored in the time capsule at the Osaka Expo.
[SONY] For assembling radio-cassette players
SONY released the radio-cassette player "Teleco CF-1610", which changed the internal substrate from metal to synthetic resin for the first time in the world.
[NINTENDO] Game & Watch
NINTENDO's first portable game machine in Japan, "Game & Watch".
Totsu Screws were used also in children's toys.
We introduced an auto clutch screwdriver for the first time in the industry. It was widely used in assembly of industrial products in the age of “light, thin, short and small”, and it has become an extreme long-seller.
CL-6500
It was a new clutch system in which we applied the deceleration of the planetary gear mechanism and the combined function of the clutch. It enabled accurate and automatic torque control.
Screw fastening method in the precision field with a screw diameter of 3 mm or less started the full-scale shift from air to electric. The electric screwdriver market was expanding to cover the precision assembly of cameras, video players, watches, computers, etc. Meanwhile, our CL-type became the number one in the adoption rate at precision assembly lines.
Screwdrivers were assembled in our office in Akasaka, Tokyo.
Inspecting the screwdriver's torque.
Developed rechargeable torque tester. Setting and controlling fastening torque became possible.
HD-50
Released the world's first handheld rechargeable screwdriver. Volkswagen, an overseas automobile maker, swiftly adopted the F-type, which had high power and accurate torque control, in their assembly line. Then others followed: BMW, Mercedes-Benz, Chrysler, and aircraft manufacturers in the U.S.
TOPICS
Most of the electric screwdrivers at the time had cables. However, in response to the development of the rechargeable battery, we took the chance to develop a handy-type rechargeable electric screwdriver equipped with our original “plane-touch” system. Combined with high workability due to “no cable”, it greatly contributed to efficiency improvement at production lines. At the time of release, it was highly appraised overseas rather than domestically and was adopted by major European automobile manufacturers one after another.
We received a letter of gratitude from Sanyo Electric Co., Ltd., which developed the battery, because HIOS electric screwdrivers opened a new field of use for their products. This was a testimony of the product development capabilities of HIOS anticipating the needs of manufacturers and always staying one step ahead.
JAF MATE magazine, 1992: a photo of a woman assembling a car using the F-9000 at a Chrysler factory.
10th Anniversary
In commemoration of the 10th anniversary of our foundation, we released a unique rechargeable ratchet & clutch driver that temporarily fastened with the motor power and manually fastened the last twist. Compact and lightweight, achieving 6 times faster screw fastening and removal than manual operation! Ideal for maintenance work.
Mascot character,
Drucky
Released the first automatic clutch screwdriver in the industry. It was widely used in assembly of industrial products in the age of “light, thin, short and small”, and has become a long-standing long-seller.
A Creative Product
Released a unique electric feather duster that utilized the rotational force of the electric screwdriver motor. It became popular as a groundbreaking item because it removed dust gently and quickly and cleaned gaps.
We first invented an electric screwdriver with the whole controller built in the main body and without a transformer. The screwdriver could be used directly with AC100V.
This series allowed a numerical input of fastening torque in grams. Released a screwdriver for automatic machines requiring high accuracy of torque. Furthermore, ahead of the times, it had a function to judge pass/fail of screw fastening.
Released a specially developed screwdriver for automatic machines. Demonstrated its effectiveness in labor-saving and automation of screw fastening. It is still a long-selling product.
20th Anniversary
The reciprocating mechanism was to feed a screw to the tip of the bit with air, and the next screw was automatically fed as soon as the first screw fastening was finished. This greatly improved work efficiency as an automatic feeding system for screw fastening.
Released a unique automation screw fastening robot with a rotating table. It was highly recognized for its effectiveness in high-mix low-volume productions.
Following the ACL Series, we pursued better work efficiency and developed a screwdriver that could operate at higher speeds.
With the advent of the era of diversified compact personal computers, we utilized our years of technology and experience to release a screwdriver that absorbed the impact of fastening.
The 100-data-memory function expanded the recording and management of fastening data and the series supported the systemization of production control with multiple functions. It is still regularly used as a standard device at production sites around the world.
Following the rotary-type screw fastening robot, we developed a robot in the XY axis direction. Since you can design the working range of the robot freely through simple teaching and easy operation, it was extensively used.
This enabled prevention of popping out (the bit escaped from a screw, called “cam out”), a problem with conventional crosshead screws, and achieved stable screw fastening quality. As a result, the operator was relieved from stress owing to the reduction of damage to components due to popping out as well as thrust force. In addition, it enabled reliable screw removal during maintenance and recycling for eco-friendly manufacturing.
TOPICS
2001: The 6th Best Venture Business Owner Award "Governor of Chiba Prefecture’s Special Award" and "The Best Venture Business Owner Award"
Sponsored by: Chiba Prefecture Industry Persons’ Club
2001: The Japan Society of Mechanical Engineers, Kanto Branch Award "Technology Award"
Sponsored by: The Japan Society of Mechanical Engineers
2003: The 1st Manufacturing Parts Award "The Best Brand of Japan Award"
Sponsored by: The Nikkan Kogyo Shimbun Ltd.
2004: The 30th Invention Grand Prize "Invention Award, Ikeda’s Special Award"
Sponsored by: The Japan Society of Mechanical Engineers & The Nikkan Kogyo Shimbun Ltd.
2006: The Scientific and Engineering Award “Technical Award” by the Minister of Education, Culture, Sports, Science and Technology
Sponsored by: The Ministry of Education, Culture, Sports, Science and Technology of Japan
2007: National Medal of Honor in Spring “Medal with Yellow Ribbon"
Sponsored by: The Ministry of Education, Culture, Sports, Science and Technology of Japan
The newspaper advertisement indicated the importance of the "screw" and won the "43rd Japan Industrial Advertising Award" (the second section of the newspaper division, "Encouragement Award") sponsored by Nikkan Kogyo Shimbun. It is quite a simple design with the word “screw” handwritten by Totsu in the center.
30th Anniversary
Developed an environmentally friendly brushless driver. Since there was no emission of carbon particles, the torque accuracy and durability were significantly improved, resulting in more stable quality control.
Utilizing an old newspaper advertisement (sepia-toned newspaper) in 1973 about labor-saving for screw fastening and environmental improvement, we displayed our latest brushless driver that inherited this excellent tradition.
Powder of carbon particles adhered to the inside of the driver to make it black. This will cause performance degradation.
The inside is clean to keep performance stable and improve durability.
Powder of carbon particles adhered to the inside of the driver to make it black. This will cause performance degradation.
The inside is clean to keep performance stable and improve durability.
This series supported a one-man production system to eliminate equipment costs and waste. It was effective because it could be used flexibly for product assembly and disassembly (recycling) anywhere and fasten a maximum of approximately 4,000 screws when fully charged. We provided two types: a portable type with a screwdriver mounted on the waist and a stationary type that was attached to a cart or automatic transport system.
Released a power supply unit with a counter function to prevent workers from skipping (careless error).
This prevented cam out because each “wing” of the fan-shaped recess contour is wide and the hole is straight. It was extremely effective for automation.
Pass/fail judgment was made for each screw fastening, and all fastening data was stored on a PC. Enabled detailed quality control of screw fastening.
2010: The Super Manufacturing Pars Award "Machine Parts Award" Category
Sponsored by: Chiba Prefecture Sangyojin Club
2011: Recognized as the 1st Chiba Prefecture “Chiba Monozukuri Certified Product”
Sponsored by: Industrial Development Section, Commercial and Industrial Labor Relations Division, Chiba Prefecture
2013: Commendation for "Remarkable Industrial Technology in 9 Prefectures Award"
Recommendation: Chiba Prefecture
Sponsored by: The governors of Tokyo, Saitama, Chiba, Kanagawa prefectures and mayors of cities
This was a screwdriver for automatic machines spun-out from the PG Series which could judge pass/fail for each screw fastening.
By providing a guide function on the tip of the bit, mating became smooth. Easy to fasten even for beginners.
A guide & lock function was provided on the tip of the bit to prevent wobbling during mating, which significantly improved workability. Thus, it can provide screw fastening with stable quality even for automation that requires high precision.
TOPICS
2018: "Super" Manufacturing Parts Award "Machine and Robot Parts Award"
Awarded Part: INTRTORQUE
Sponsored by: Monozukuri Nippon Conference / Nikkan Kogyo Shimbun Ltd.
2018: The Assembly Show “NEW PRODUCT Awards”
Awarded Part: INTRTORQUE
Location: Chicago, U.S.
40th Anniversary
Self-maintenance became possible owing to unitizing internal parts. We launched this series as a global standard for the future.
This brushless screwdriver for automatic machines was extremely durable with stable torque accuracy and could be mounted on XY robots. As a result, it had a great effect on automation and streamlining of assembly lines.
This series eliminated the need for an external counter by integrating the counter with the screwdriver. The screwdriver itself became able to detect screw fastening errors.
Distal display shows pass/fail of the work in real time.
JUKUREN’s product logo
This series can detect an error by counting the number of motor rotation pulses. Even an inexperienced worker can perform a fastening task like a skilled worker. We named this series "JUKUREN (skilled worker)" because the tool itself becomes a worker.
TOPICS
2014: Recognized as the 2nd Chiba Prefecture “Chiba Monozukuri Certified Product”
Sponsored by: Industrial Development Section, Commercial and Industrial Labor Relations Division, Chiba Prefecture
2014: Received Small-and-Medium-Sized Company Award at the "57th Top 10 New Product Award"
Sponsored by: Nikkan Kogyo Shimbun Ltd.
By connecting an external input/output cable, it became possible to work with external devices.
We ran a full-page advertisement to commemorate receiving The Small-and-Medium-Sized Company Award at the "57th Top 10 New Product Award” sponsored by Nikkan Kogyo Shimbun Ltd.
Released "JUKUREN Zero One" series for beginners that did not require any troublesome setting work. The slogan is "A beginner can be a skilled worker in just 30 seconds."
This was the decentral unit of BLG-BC2 Series. We collected screw fastening data from factories around the world in the cloud to manage them in an integrated manner. Monitoring production status from a remote location in real-time, you can make an analysis and introduce countermeasures.
By mounting an AC servo motor, multiple screw-fastening conditions (torque value, rotation speed, etc.) can be externally changed from one screwdriver. Contributes to cost reduction without having to install multiple automatic machines.
Two models, low torque type and high torque type, were newly added.
Established a research laboratory in Oshiage, Sumida-ku, Tokyo.
Totsu screw, an improved slotted screw
Developed the world's first current-controlled industrial electric screwdriver for the precision industry.
Totsu, who had skillful hands, liked working on cars and motorcycles because his father was running a gas station. A slotted screwdriver was required to adjust car carburetors, but when he used the screwdriver to turn slotted-head screws, slipping always occurred. He felt the inconvenience with this repeated failure and started thinking "Is there any way to prevent the screwdriver from slipping off from the screw’s groove?" Thus, the story of Totsu Screw started.
Started manufacturing and sales of industrial electric screwdrivers and special screws (Totsu Screws) in Akasaka, Minato-ku, Tokyo. Decided Mitsubishi Corporation as the general distributor and started full-scale sales of HIOS brand products.
Corporate logo
First catalog for
the HIOS brand
M-type screwdriver as
the first electric
screwdriver
Totsu, engaged
in R&D
With the birth of the M-type screwdriver, the precision industry in Japan switched screw tightening from hand to electric earlier than overseas companies. As a result, precision and high quality as well as streamlining of work were realized thanks to accurate torque control by the dial system. This way, the precision industry in Japan was highly evaluated abroad.
Totsu himself went overseas and fully engaged in sales activity. Starting from Taiwan, launched sales operation in Hong Kong, the U.S., and Europe.
Catalog for overseas sales
In the first half of the 1970s, we ran a wrap advertisement for our M-type screwdriver on the City Bus in Hong Kong. Actively worked on promotion not only in Japan but also overseas through distributors.
Participated in exhibitions through distributors in Asia, America, and Europe.
10th Anniversary
It was thought in the industry that the screwdriver's warranty period should be 6 months, but we took the occasion of the 10th anniversary of our foundation to extend it to 2 years. Furthermore, we enhanced the after-sales service and provided a speedy repair service (3 days after arrival at our head office), which was the best in the industry.
The departments of development & design, sales & marketing, manufacturing, and repair service were in the head office in Akasaka, Tokyo.
The repair of the air driver required a rather long time of 1-2 weeks. However, because of the electric screwdriver's simple structure and the express courier service (it had just started in Japan), it was possible for us to smoothly arrange items to be repaired all over the country by providing a speedy repair service. The production and sales of electric screwdrivers then were 3,500 to 4,000 units per month, and we gained an 80% market share of electric screwdrivers. We responded directly to the users’ needs with high-mix low-volume production and prepared a product lineup consisting of 61 models including electric screwdrivers and other tools.
Refurbished the factory to make it the head office and factory.
Showroom
20th Anniversary
30th Anniversary
Business Description: Manufacturing of HIOS products (electric screwdrivers, power supply devices, torque meters, screw tightening robots, rechargeable screwdrivers), assembly and processing of electronic components, high-density mounting (lead-free), and EMS (electronics manufacturing service). EMS covered quartz-cut electronic equipment for semiconductor manufacturing equipment by utilizing the laser processing machine.
Appearance of
the factory
Screwdriver
assembly line
Screwdriver
inspection
Surface
mounter
Laser
process
Laser process/
shower plate
Business Description: Manufacturing of screws for precision machines (M1.0 to M2.6), coarse screws and tapping screws as well as JIS standard products and special products.
Appearance of
new screw factory
Header
Rolling
Business Description: Maintenance of HIOS electric screwdrivers, maintenance and calibration service of HIOS torque meters, and technical services of HIOS products, and import/export business.
Business Description: Manufacturing and sale of various screws (those compatible with JCIS standard and JIS standard, Totsupla® Screws, etc.) and products with header processed, and sale of metal parts such as washers, nuts, rivets, springs, and pins.
Supports 4 languages: Japanese / English / Chinese / Korean
40th Anniversary
A spiral staircase at the entrance symbolizes the company. It implies an imaginary screw that is being fastened from the sky by an electric screwdriver, the symbol of HIOS.
New showroom opened, and products from the past to the present are displayed there.