FCS Technology and Passion: A Transport System That Maximizes Factory Space

The History of the Company’s Founding

The founder of the company is Mr. Shuji Sano. The current representative, Mr. Takahiro Fukuzawa, is the son-in-law of Mr. Sano. In 1979, Mr. Sano established and founded Nihon Aeration Co., Ltd. in Osaka’s Nishi Ward, where he independently developed and sold bearing cleaning machines, dial loaders (transportation devices), and other industrial machinery. However, starting in 1984, he began developing the Flexible Carrier System (FCS) and shifted the company’s focus to the planning, development, and sales centered around FCS.

Mr. Sano had previously worked at Seibu Jidokiki Co., Ltd., where he was involved in the production and sales of machinery used in a process called “superfinishing,” a critical step in the metal grinding process. As the company’s products played an essential role in the high-precision industry, many of its clients and partners were not only equipped with advanced technologies but also faced unique challenges. Leveraging the knowledge gained from these experiences, Mr. Sano developed the innovative idea that led to the creation of FCS in 1984. By consistently listening to user feedback and improving the product, FCS gradually gained recognition, culminating in the company’s name change to JFCS Co., Ltd. in 2005.

In 2018, after bearing the heavy responsibilities of leadership for nearly 40 years, Mr. Sano handed the business over to Mr. Takahiro Fukuzawa.

The Birth and Evolution of the Next-Generation Transport System “FCS”

In 1984, the company embarked on the development of its FCS product line. “FCS,” short for Flexible Carrier System, is an innovative transport technology designed to make optimal use of limited factory space while achieving efficient three-dimensional transportation.

FCS’s three-dimensional transportation system connects two distant points within a factory or production line using proprietary guide rails, enabling carriers to traverse three-dimensional trajectories.The key feature is the ability to move workpieces quickly along flexible paths without interrupting the flow of the production line.

In the year development began, we were approached by a representative from the production technology department of a major manufacturing company, who asked if we could address a specific challenge. In response to this request, we engaged in joint development, and through repeated trial and error, we successfully created the prototype of a new transport system.

In general, transport systems are designed and built by combining individual linear actuators on a case-by-case basis. At the time, the concept of a carrier capable of traversing curved guide rails was groundbreaking, especially in fields handling precision machinery, where such technology posed significant challenges. Risks such as derailment of carriers, component detachment, and wear-and-tear issues deterred many companies from attempting similar developments. The requirement was for a system capable of complex, continuous motion that included both ascending and descending trajectories—an exceedingly difficult task.

For example, AGVs (automated guided vehicles) might seem effective, but achieving not only horizontal freedom but also secure, high-speed, continuous vertical movement posed a monumental challenge. Overcoming issues such as load capacity, travel speed, repeatability stability, and reliability in harsh production environments made the development even more daunting.

FCS employs a wire rope drive mechanism, enabling it to not only securely tow carriers but also to rapidly traverse three-dimensional trajectories, reaching destinations and returning in a short timeframe with remarkable precision.

Reliable High-Speed Operation Without Delays

It is capable of repeatable, stable high-speed operation without any risk of delays. Technologies involving rope-driven mechanisms, such as elevators and lifts, are well-known examples. However, in the realm of industrial machinery, transport devices like FCS that can precisely and rapidly navigate three-dimensional spaces remain relatively rare even today.

“In the beginning, we received many complaints about issues such as wire wear and breakage. However, by persistently listening to user feedback, conducting research, and making continuous improvements, we were able to elevate FCS to a level that truly withstands the demands of industrial machinery. Today, it is utilized across various production sites. Our main product now is the ‘FCS-H300,’ which not only enables high-speed and accurate transport of workpieces but also supports increased load capacity. Additionally, the longevity of the wire ropes has been extended year by year.

FCS is widely used in production lines for tasks such as inter-process transport in metalworking. For instance, in factories producing bearings, there are extremely long production lines connecting various processing equipment. FCS is used to link discharge points from one piece of equipment to supply points of the next in sequence, cross walkways, or even span across equipment.

While there are numerous transport devices such as belt conveyors, AGVs (Automated Guided Vehicles), AMRs (Autonomous Mobile Robots), gantry loaders, and handling robots, FCS often becomes the sole option in situations or under conditions where other solutions are challenging to implement. Due to its unique characteristics, FCS can also meet rare and highly specific demands that other systems cannot address, sometimes leading to unexpected new applications. In such cases, I find the product’s strengths, rarity, and even its inherent intrigue to be truly remarkable,” explained Mr. Fukuzawa.

From Architect to Business Leader: Fukuzawa’s Challenges and New Beginnings

Mr. Fukuzawa began his career as a first-class architect, having studied architectural design at a university and completing graduate school. After graduation, he worked for over ten years at an architectural design firm. His wife is also an architectural designer.

During his time at the firm, Mr. Fukuzawa was posted to China, where he spent seven years before marriage.

“At the time, it coincided with events like the Beijing Olympics and the Shanghai Expo, so I was able to observe China’s rapid development from within while genuinely enjoying my work in architectural design. However, after the major earthquake in Japan and the conclusion of some of the projects I was working on, I felt a strong desire to return to Japan and contribute to society there. That’s when I decided to return home. But the reality was not easy. For a while after starting out on my own, I had no work at all. While trying various things, I spent my days questioning what it was I truly wanted to do in a rapidly changing society,” he shared.

Regarding the process of taking over the business, Mr. Fukuzawa shared, “I had heard that my wife’s father’s company had excellent products, a solid financial standing, and growing sales. However, Mr. Sano, the then-president, had mentioned considering options like M&A as he grew older and faced the absence of a successor.”

“My wife, at that time, was deeply concerned about the future of her father’s company and the issue of succession,” Mr. Fukuzawa recalled. While listening to conversations about the company from time to time, he gradually developed an interest in the topic of business succession.

“I realized that this small company held rare technologies, valuable to the industry, and thought it would be a shame to lose them,” he explained.

Although the issue of business succession is often discussed as a common social problem in Japan, Mr. Fukuzawa admitted he had no particular interest in it initially. “But when I encountered the situation firsthand, I couldn’t help but feel that, for better or worse, I might be uniquely suited for this role,” he said.

One day, while discussing the topic with his wife in front of Mr. Sano, the latter unexpectedly remarked, “That’s an interesting idea. Why not give it a try? You could even incorporate some architecture-related projects.” His wife, the youngest of three sisters, showed the greatest interest in the company’s succession compared to her siblings. Despite Mr. Fukuzawa’s background in architecture, which was far removed from the field of manufacturing, he concluded, “This kind of opportunity is rare and too good to pass up, so I decided to take on the challenge.”

Upon joining the company, Mr. Fukuzawa initially considered incorporating architecture-related projects into the business while preserving its core operations, partly due to encouragement from Mr. Sano. However, as he became involved in the work, he found himself increasingly drawn to machinery design, development, and management itself.

“In the end, I’ve distanced myself significantly from architecture. That said, designing is something I’ve always done, even in architecture, and envisioning mechanical systems in motion isn’t difficult for me at all. Proposing and implementing machines that enhance the productivity of our clients’ factories gives me great satisfaction—it’s even thrilling at times. Honestly, I’ve found my perfect fit,” he concluded with a smile.

Overseas Expansion: JFCS’s Development and Future Challenges

JFCS has sales agents in countries such as South Korea and Thailand, promoting its overseas expansion. Particularly in South Korea, the agent has been active for over 20 years, and products are sometimes supplied to other countries like Mexico through this network.

“We aim to further enhance our products by adopting new materials and making upgrades, striving for continual improvement. By steadily refining our offerings based on customer needs, we ensure they can be used for the long term. Additionally, we plan to expand our international presence and increase our global market share,” Mr. Fukuzawa shared.

With its unique technology and flexible responses to customer needs, JFCS has built a strong position in the field of three-dimensional transport systems. However, challenges remain.

“Since our products are relatively rare, some factory managers simply appreciate FCS itself. This brings both satisfaction and joy but also significant responsibility. Honestly, our sales have been stagnating. The automotive industry, our largest customer base, is undergoing major changes, and the unpredictable global landscape makes it even harder to navigate. We face the challenge of figuring out how to sustain and grow in such circumstances,” he explained.

Despite these challenges, JFCS remains committed to overseas expansion and product improvements. These efforts are expected to pave the way for new opportunities in the future.