Lathe Operator’s work

The Star of Machining

The single-story factory is filled with the mixed scent of iron scrap and oil. Among the briskly moving lathe workers, Tomosada Fujimoto smiles and recalls, “Back in the day, we didn’t have a roof here, and snow would fall inside. We’d light a fire to keep warm.”

The workshop Kiren Royal houses various kinds of equipment, from a radial arm drilling press to a milling cutter to a vertical shaper. Those manual machines have been meticulously kept in good condition and used since the 1970s. Instead of giving a wordy explanation, Fujimoto grabs a handle and shows us how a lathe works. When a turning tool softly touches the surface of an iron block mounted on the rotating faceplate, it’s almost unbelievable to see a ribbon of hard metal peel away from the spinning workpiece.

Before readymade and disposable cutters became prevalent in the 1960s, machinists often crafted their own turning tools. Like blacksmiths, they heated pieces of metal with bellows and a coke-fueled fire, beating them repeatedly with a heavy hammer. The shine of the handmade, well-maintained tools symbolized their expertise and pride. Lathe work was, and hopefully is, considered the highlight of manufacturing.

Beyond Blueprints

Fujimoto’s first collaboration with Fuji Kouki was at the age of 20. His rugged hands have mastered the intricacies of milling different components ever since, such as cast iron lids, damper levers, and more. Take a grid-shaped base for a cooling tray, for example: “Its top surface is shaved 0.3 mm more than the bottom because the top swells when the tray catches hot roasted beans. The thermal expansion of iron must be accounted for to ensure perfect function and proper assembly.”

He adds, “Lathe workers often communicate with the designers to have appropriate allowances.” Even if assembling precisely milled parts is theoretically feasible, practical difficulties can arise when hand assembly workers need to tilt the components slightly, adjust angles, and fit them together. Lathe expertise involves predicting the subsequent process and considering factors not apparent in the blueprints.

It is most rewarding to achieve the very measurements I aim for. No matter how many years you dedicate to a component, repeating the identical measurement without adjustment is challenging. It’s gratifying to hear that the assembly goes smoothly.

So says Fujimoto, wiping sweat off and taking a break with a glass of juice. The physical and mental exertion to do the best signifies the core values of true craftsmanship.