JATCO Ltd ||| Production Processes |||


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Automatic transmissions and CVTs (Continuously Variable Transmissions) are created as the cystallization of multiple technologies.
Producing automatic transmissions and CVTs, which are extremely complex and precise, reflecting the prescribed design quality requires micron-unit processing and assembly precision in the gears, shafts and all other individual components and parts.
We produce optimal automatic transmissions and CVTs based on our own unique manufacturing style through the various individual processes from acceptance to shipment.

* Click each chart for details.

Each automatic transmission and CVT consists of a total of some 500-1,200 parts. We procure about 70% of these from outside cooperating companies.
They are supplied to the departments that require the delivered products only in the required quantity in a timely manner.

		Prototype parts and initial samples delivered by cooperating manufacturers are measured based on design drawings, are subjected to physical and chemical inspections and the quality is guaranteed.

		Cases for automatic transmissions and CVTs and other items are produced by injecting or pressure feeding molten aluminum into metal molds.

When designing the molds, optimal design is implemented through CAE simulation.


Simulation		Product

Rough unfinished gears, pulleys and other parts are produced by pressing steel material with the application of heat or at normal room temperature.Unit length reductions and part cost reductions are promoted by unitizing park gears and pulleys for new-generation mid-size belt CVTs.

With this flow forming method, the shape of the metal mold is transferred to plate material sandwiched between by rotating the mold and material and moving the formation rollers around the periphery of the mold.

Rough cast and forged parts and steel are finished into products formed in compliance with standards using automatic NC lathes, gear-cutting machines, grinding machines, machining centers, special automatic processors and other high-precision machine tools.

Automated line		Transfer machine


The process from rough parts to finished products is implemented consistently on automated production lines.		All processes including the attachment, removal and shipment of processed parts are fully automatic.

Automatic NC lathe		Gear-cutting machine


Rough and finished processed parts are rotated and bite is applied to assure their precision.		Gears are cut using a variety of gear cutters.

Shaving		Grinding machine


The teeth of a rough cut gear are finished.		Grinding is implemented by rotating both parts and honing wheels to assure the precision to the prescribed dimension.

Measurement instrument		Drill press


Machined parts are automatically measured and verified to assure that they meet the required standards.		Drills are used to make screw holes in the parts.

In order to boost the hardness of the parts for higher strength, and to improve wear resistance, heat and cold are applied under various conditions taking advantage of the transformation characteristics of steel.

Quenching		Tempering


The material is hardened by applying heat and then rapidly cooling using oil.		Quenched parts are successively heated and cooled to improve their toughness.

Finish inspection
		They are finished by shot blasting in order to eliminate scale (ferric oxide) resulting from processing and heat treatment and pressing is implemented to correct bending. External inspections, magnaflux inspections and other inspections are subsequently conducted, the quality is guaranteed and finished products of excellent quality are sent off for the next process.

		Vacuum carburizing furnaces are used as a way of significantly reducing the heat treatment time of pulleys, the most important component of the belt CVT, and realize stable quality.

		Heat treated parts are finished to a high level of precision by grinding, etc. Dry hobbing, which eliminates the need to use grinding oil during machining, is also used taking the environment into account.

		This is a task in which parts that are machined and cleaned are assembled in advance into units in order to promote the effective implementation of main assembly line operations. Pulleys, oil pumps, control valves, planetary gears, clutch packs, etc., are assembled.

		Tailored to customer requirements, machined parts and subassemblies are assembled into automatic transmissions and CVTs.

		All of the assembled automatic transmissions and CVTs are subjected individually to performance testing. Speed performance, operability, gear noise and so forth undergo stringent testing and the quality is guaranteed.

		Automatic transmissions and CVTs that pass the final testing are mounted with external parts and prepared for shipment. They are finally cleaned and sent off to the shipping dock.

		Once all of the assembly and inspection tasks are completed, parts that successfully pass the inspections are shipped off to automaker plants.