By bringing installation technician expertise and monozukuri together, YKK AP is focusing on human resource and product development to enhance exterior product quality and streamline installation.

The exterior product category includes fences for property and road boundaries, decks installed in yards, carports to protect customers’ beloved vehicles, and balconies that provide spaces to dry laundry and relax. Exterior planning is part of building a home, but sometimes the construction process starts with planning the layout and other portions of the building, and the exterior is planned separately or put off until later. Despite this, exterior items are very important—they help maintain privacy, and exterior designs should harmonize with and be integrated into the building. And because people are spending more time at home due to the COVID-19 pandemic, demand is growing for attached yards and other exterior products to create enjoyable, private outdoor spaces.

While products like windows and doors are attached to the existing building frame, exterior products are installed in empty spaces. Technicians must have skills to install these in three dimensions, including length and height. Requirements differ at installation sites, such as lot shapes, elevation differences, and distances from adjoining properties. In some cases, installation requires advanced skills backed by ample experience. And because exterior items are exposed to wind and rain in harsh outdoor environments, they must be installed with a high level of quality to prevent flooding and other problems. YKK AP is focusing on both human resource development and product development in light of these unique environments and challenges.

Fewer exterior product installation technicians are learning their trade through a master-pupil relationship today, and more self-employed technicians are reaching their 60s and 70s without anyone to take over their business. Manufacturers cannot deliver products to users without opportunities and environments to train skilled technicians who can install their products on-site. YKK AP founded DO SPACE Ageo to develop installation technicians, improve their abilities, and help them pass on their advanced skills, with the aim of continued growth in the exterior product industry.

Along with planning, we believe it is important for technicians to learn from hands-on experience. Even with an intellectual understanding of the installation process, experience is necessary for learning how it feels to handle these products, including their actual size and weight. Two 20-kilogram material pieces may feel different according to their length and shape. By experiencing what it’s like to install these, students come to understand what is and what isn’t possible. Mistakes they make at the facility allow them to succeed at real job sites. The things they experience during their training become a foundation for confident on-site work.

Carports protect our customers’ beloved vehicles from dirt and deterioration by shielding them from the elements, including rain, snow, and the sun. Carports must be installed with a high level of quality to accomplish this job. One important point is the sealing process. The technician applies a paste sealant to the caps where parts are joined, which provides waterproof and water-blocking properties. Because this is done by hand, the finished quality depends greatly on the skills of the technician, and quality can easily vary for the same product. There are cases when water has leaked because the technician didn’t use enough sealant or didn’t apply it consistently. Leaks—which are actually the most common issue with carports—are usually problems with the sealing process. We began working to develop a sealing-less cap as a way to prevent leaks.

We finalized the sealing-less cap by solving each of these issues. We couldn’t have done it without cooperation from the Fabrication Technology Division that evaluated the new material’s performance, as well as the plant’s Equipment Design Division. Three divisions joined together to develop the material, parts, and manufacturing equipment. I believe this type of monozukuri can only be accomplished through the integrated production system that is YKK AP’s forte.