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Our Manufacturing Process

Our Monozukuri Process Our Monozukuri Process

The manufacture of JATCO’s automatic transmissions involves a variety of processes, ranging from raw material processes to machining, assembly, and inspection. Within these processes, we promote our "Diversity Line"-a production line where our diversity of people are flourishing—and we challenge ourselves to develop efficient and innovative production technologies that take advantage of IoT and AI, as well as robotic process automation (RPA).

Diversity Line

This "Diversity Line" is designed to enable opportunities for jobs with a reduced workload, allowing women to choose to work while performing household chores and childcare. Our goal is to create workplaces in which all people, including the elderly and disabled, can energetically participate.

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Taking on Next Generation Production Technology Challenges

We are also tackling the challenge of next-generation production technologies, now focusing on the adoption of assembly line automation and the use of a Vanguard system for automatic aerial transport of components. Such technologies will lead to higher productivity and lower costs.

次世代に向けた生産技術への挑戦
Die making
Maintenance
Prototype manufacturing
Forging
Forging
Casting
Casting
Machining
Machining
Heat Treatment
Heat Treatment
Assembly
Assembly
Customers
Automakers
Inspection
Logistics inside the plant

Forging

The process of "adding force to change the shape of objects" is referred to as plasticity forming. Among plasticity forming methods, "forging" in which parts are made by pressing materials into a mold using strong force, possesses the attribute of producing highly durable parts.

Steel material

Steel material

Cylindrical steel pieces

Cutting

Cutting

Material is cut to length

Heating

Heating

Heating prior to forging

Forging

Forging

Stamping to shape

Magnetic Particle Testing

Magnetic Particle Testing

Inspection for scratches, cracks

Exterior check

Exterior check

Shipping

Shipping

Casting

Parts with complex shapes are created in the casting process by pouring melted aluminum alloy into a die.

Ingot

Ingot

Aluminum ingot

Melting

Melting

The ingots are melted

Casting

Casting

High pressure die casting

Finishing

Finishing

Removal of excess parts

Shot blasting

Shot blasting

Blasting with zinc balls

Exterior check

Exterior check

Shipping

Shipping

Machining

The process whereby roughly shaped materials formed through forging and casting are ground down with an edged tool. They are made into higher precision shapes, their surfaces are smoothed, and holes are bored, among other processes. The processing of soft parts before heat treatment is called "raw machining," the processing of hard parts after heat treatment is called "finish machining."

Gear Machining

Materials

Materials

Insertion of the forged material

Rough processing

Rough processing

Machining prior to heat treatment

Teeth cutting

Teeth cutting

Forming the teeth shape

Heat Treatment

Heat Treatment

Improves material strength

Finishing

Finishing

Polishing to improve dimensional precision

Cleaning

Cleaning

Removal of foreign matter prior to assembly

Exterior check

Exterior check

Shipping

Shipping

Case Machining

Materials

Materials

Insertion of the forged material

Machining

Machining

Milling

Cleaning

Cleaning

Removal of foreign matter prior to assembly

Leak test

Leak test

Checks airtightness

Exterior check

Exterior check

Shipping

Shipping

Pulley Machining

Materials

Materials

Insertion of the forged material

Rough processing

Rough processing

Machining prior to heat treatment

Heat treatment

Heat treatment

Improves material strength

Finishing

Finishing

Polishing to improve dimensional precision

Cleaning

Cleaning

Removal of foreign matter prior to assembly

Exterior check

Exterior check

Shipping

Shipping

Heat Treatment

A heat treatment process in which metal is heated to produce hardness and toughness. Various types of furnaces are utilized according to the roles and characteristics of parts.

Pre-cleaning

Pre-cleaning

Cleaning before heating

Heating and carburizing

Heating and carburizing

Carburizing in the kiln

Quenching

Quenching

Rapid cooling using oil

Post-cleaning

Post-cleaning

Cleaning prior to tempering

Tempering

Tempering

Reheating and air cooling

Shot blasting

Shot blasting

Blasting with iron balls

Warp correction

Warp correction

Exterior check and warp correction

Shipping

Shipping

Assembly

The transmission is assembled using parts which have been produced both internally through processes until this point, and purchased parts delivered by suppliers. The clutch pack and control valve are assembled on the sub-line, then supplied to the main line. The output of this process is the product which is shipped to the customer.

Case

Case

Pulley

Pulley

Gear

Gear

Housing

Housing

Control valve

Control valve

Oil pan

Oil pan

Final test

Final test

Power performance check

Shipping

Shipping

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