Aisin AI Co., Ltd. Business Report up until FY ended Mar. 2016
Recent Years
Toyota's Restructuring of Powertrain Businesses
-In September 30, 2015, Toyota Motor Corporation, Aisin Seiki Co., Ltd., and its subsidiary Aisin AI Co., Ltd., have made a further agreement regarding the consolidation of development and production of manual transmissions under Aisin AI. The development of manual transmissions for mass-produced vehicles will be consolidated at Aisin AI by the end of 2016. Toyota's manual transmission production functions in Japan will be transferred to Aisin AI's plant in Japan around February 2016. Outside Japan, Aisin Seiki plans to acquire a stake in Toyota's subsidiaries, Toyota Autoparts Philippines Inc. and Toyota Kirloskar Auto Parts Private Ltd. in India in January 2016 and July 2016, respectively, to strengthen its competitiveness. (From an article in the Nikkan Jidosha Shimbun on October 1, 2015)
-In November 2014, Toyota Motor Corporation announced that it will consolidate its development and production operations for diesel engines, manual transmissions, and brake systems into its main suppliers within the Toyota Group. Development and production of diesel engines will be integrated into Toyota Industries Corporation, while that of manual transmissions will be integrated into Aisin AI Co., Ltd., starting in 2016. Production of brake systems and components, which is now handled at Denso Corporation and Aisin Seiki Co., Ltd. in central Japan, will be consolidated into a new plant of Advics Co., Ltd. in the Aisin Group. The new plant is scheduled to be established in Handa, Aichi Prefecture around January 2016. The integration of the powertrain businesses will enable the Toyota Group to improve its development capability in each field and to allocate its management resources more efficiently, especially to the area of next-generation safety and environmental technologies. (From an article in the Nikkan Jidosha Shimbun on November 29, 2014)
Contracts
BMW
-In April 2015, the Company received its first order from BMW AG of Germany for 6-speed manual transmissions (MTs) for front-wheel drive (FWD) vehicles. This is the first business between the Japanese supplier and the German automaker. In November 2014, Aisin AI started supplying an improved version of its BG6 MT for the BMW 2 Series Active Tourer. The BG6 was initially commercialized in 2005. The Company made various improvements on the BG6, and achieved world top level light and comfortable shift feeling by improving the smoothness of shifting. Vibrations and noise of the MT were also reduced by optimizing the design of the transmission case. The product is being produced at Aisin AI's main plant in Nishio City, Aichi Prefecture, Japan and supplied to BMW's vehicle assembly plant outside Japan. (From an article in the Nikkan Jidosha Shimbun on April 6, 2015)
Subaru
-From 2012, a 6-speed manual transmission built by the Company is being mounted on the Subaru "BRZ", which was launched in the same year.
Toyota
-From 2012, a six-speed manual transmission built by the Company is being mounted on the Toyota "86", which was launched the same year.
-In July 2011, the Company announced that its medium-capacity FR transfer, which is being built in Thailand, was being mounted on the "Hilus Vigo".
-In February 2011, the Company has developed high torque capacity 6-speed transmission for RWD SA6 and front counter gear FA1 that are installed on the Toyota "Lexus LFA". In addition to the realizing the highest torque capacity (480Nm+) in the Company's existing models, SA6 and FA1 brings considerable lightweight toward torque comparing to the Company's usual product. (From a press release on February 16, 2011)
-In May 2009, the Company announced that it has been awarded a contract from Toyota to supply a new 6-speed manual transmission for Toyota's front-wheel drive vehicles produced in Europe. The Company has since begun production of this transmission. The Company plans to produce about 5,000 of these transmissions a month for the time being, which will be used in Toyota's "Urban Cruiser (sold as the Ist in Japan)", the "Corolla", and the "Auris". (From an article in the Nikkan Jidosha Shimbun on May 12, 2009)
-In January 2009, the Company announced that its new middle torque capacity 6-speed manual transmission for front-wheel drive vehicles is being installed in Toyota's new "Avensis" being sold in the European market. The new transmission was jointly developed with Toyota Motor Corporation. Production of the new transmission got under way at the Kira Plant at the end of August 2008. (From an article in the Nikkan Jidosha Shimbun on Jan. 30, 2009)
-In 2008, the Company was awarded a contract to supply transfers for the "Hilux Vigo", Toyota Motor's pickup truck.
Recent Development Outside Japan
-In April 2014, the Company, Aisin Seiki Co., Ltd. and Advics Co., Ltd. will expand production in Brazil. Aisin AI and Advics will establish their own manufacturing subsidiaries at the site of Aisin Seiki's production base in Itu, Sao Paulo. Aisin AI will commence production of manual transmissions in August 2014 while Advics will start manufacturing brake parts in October 2015. Aisin Seiki itself will add another new plant at the same site to start producing engine parts by February 2016. Combined capital investment of these three group companies will amount to JPY 4.1 billion. (From an article in the Nikkan Jidosha Shimbun on April 23, 2014)
-In July 2015, the Company announced that it has developed a new high-torque-capacity 6-speed manual transmission for rear-wheel drive it calls "AC6." The transmission is jointly developed with Toyota. Aisin AI started producing the transmission at Aisin AI (Thailand) Co., Ltd. for Toyota's Innovative International Multi-purpose Vehicles (IMVs). (From a press release on July 22, 2015)
-In 2011, the Company said it has started production of a power transfer device for all-wheel drive vehicles at its subsidiary in Thailand. This is the Company's first overseas production of power transfer machines. The production facility in Thailand will produce and supply 130,000 medium-capacity transfer devices for Toyota's "Hilux Vigo." The second plant of Aisin AI (Thailand) has commenced production of medium capacity "TV2" transfer devices for front and rear wheels. The transfer is a device that distributes power from the engine to front and rear wheels through the transmission. Aisin AI (Thailand), which has already been producing manual transmissions for the "Hilux Vigo", has now embarked on production of this product requested by Toyota. (From an article in the Nikkan Jidosha Shimbun on July 15, 2011)
-In 2009, The Company announced its manufacturing subsidiary in Thailand will build a new plant.
Recent Development in Japan
Production of more than 20 million manual transmissions and power transfer devices in Japan
-In 2011, the Company, a specialized manufacturer of manual transmissions in the Aisin Seiki Group, has announced that it has produced more than 20 million manual transmissions and power transfer devices in Japan ever since it was formed. The Company has been supplying its products to 16 automakers at home and abroad, including Toyota Motor Corporation. Aisin AI was established from a spun-off unit of Aisin Seiki's Shiroyama Plant on July 1, 1991. (From an article in the Nikkan Jidosha Shimbun on July 1, 2011)
Production of the 15 millionth manual transmission
-In July 2010, the Company announced that the domestic production of its manual transmissions reached 15 million units. The Company currently delivers MTs to 11 companies in Japan, including Toyota, in addition to five overseas clients. The Company expects its MT production volume for FY2010 to be around one million units. (From a press release on July 20, 2010)
Strengthening production infrastructure
-In January 2008, the Company completed its Kira Plant in Kira-cho, Hazu-gun, Aichi Prefecture.
Awards
-In March 2014, the Company announced that it has received the "Quality Achievement Award" from Isuzu Motors Limited. (From a press release on March 28, 2014)
-In March 2014, the Company announced that it has received "Certificate of Appreciation" from Toyota Motor East Japan, Inc. (From a press release on March 20, 2014)
In March 2014, the Company received the Best Award of Quality Control from Hino Motors, Ltd. (From a press release on March 5, 2014)
-In March 2013,the Company announced that it has received the "Quality Achievement Award" from Isuzu Motors Limited. (From a press release on March 28, 2013)
-In July 2011, the Company announced that it has received the "Excellent Quality Award" from Mitsubishi Motors. (From a press release on July 5, 2011)
-In March 2011, the Company received the Best Award of Quality Control from Hino Motors, Ltd. (From a press release on March 3, 2011)
-In February 2011, the Company received the Technology & Development Award from Toyota Motor Corporation. This award is in recognition for the development of Front Reduction FA1 and High Torque Capacity FR 6-speed Transaxle SA6 for the "Lexus LFA". (From a press release on March 1, 2011)
R&D Facilities
| Name | Location |
| Technical center | Aichi Pref., Japan |
Product Development
Electric four-wheel drive (4WD) unit
-In January 2016, Aisin Seiki Co., Ltd. announced that they jointly developed a new electric four-wheel drive (4WD) unit together with two other Aisin Group companies and Toyota Motor Corporation. The unit was used in the new Prius that was launched by Toyota in December 2015. In addition to being smaller than those made by competitors, it achieves improved performance by utilizing features such as a magnet-less induction motor that suppresses drag loss from magnetic force. Aisin Seiki oversaw all aspects of the 4WD unit design, Aisin AW Co., Ltd. handled the motor, and Aisin AI Co., Ltd. worked on parts like the gears and differentials. The new electronic 4WD unit is the first new product jointly developed by Group companies. The new unit is also Aisin's first electronic 4WD unit. (From an article in the Nikkan Jidosha Shimbun on January 22, 2016)
Automated manual transmission
-At the 2011 JSAE Automotive Engineering Exposition, the Company exhibited its medium torque capacity 6-speed Automated Manual Transmissions (AMTs) for front-engine, front wheel-drive vehicles. The AMT is an advanced version of manual transmissions, being equipped with an automated clutch system and an auto shift system. A driver can choose to let the system shift on its own depending on the engine speed and accelerator pedal position, or to shift gears manually without using a clutch. The AMT is used on models including the Toyota Yaris and the Suzuki Swift.
Small and middle torque capacity 6-speed manual transmission for front-wheel drive vehicles
-In May 2009, the Company announced that it has been awarded a contract from Toyota to supply a new 6-speed manual transmission for Toyota's front-wheel drive vehicles produced in Europe. The Company has since begun production of this transmission. The transmission is a low and middle torque capacity unit for 1.3 to 1.5-liter class engines. While the torque capacity of this transmission was increased 8 percent compared with that of existing products, the overall length was made 11 percent shorter, thus making it easier to install. The Company plans to produce about 5,000 of these transmissions a month for the time being, which will be used in Toyota's "Urban Cruiser" (sold as the "Ist" in Japan), the "Corolla", and the "Auris". The casing pattern has been optimized by applying CAE analytic technology, and the shift control cover has been eliminated. Also, the case design has been changed, becoming two pieces instead of three, which reduces weight and makes it more compact. Installation of an oil separator helps reduce oil stirring resistance during rotation and improves efficiency in torque conversion. (From an article in the Nikkan Jidosha Shimbun on May 12, 2009)
Middle torque capacity 6-speed manual transmission for front-wheel drive vehicles
-In January 2009, the Company announced that its new middle torque capacity 6-speed manual transmission for front-wheel drive vehicles is being installed in Toyota's new "Avensis" being sold in the European market. The new transmission was jointly developed with Toyota Motor Corporation. This transmission, which is used in a gasoline engine version of the "Avensis", was made lighter and more compact by eliminating the shift control knob cover and changing the case design, making it two pieces instead of three. The installation of an oil separator has increased power transmission efficiency also. A more efficient shift layout has reduced the amount of load exerted when gears are shifted, and also achieved making the feel smoother and lighter when gears are shifted. Production of the new transmission got under way at the Kira Plant at the end of August 2008. (From an article in the Nikkan Jidosha Shimbun on Jan. 30, 2009)
Investment in Japan
-In January 2008, the Company completed its Kira Plant in Kira-cho, Hazu-gun, Aichi Prefecture. The new facility is the Company's second plant to specialize in the production of manual transmissions for front-wheel-drive vehicles. The 10 billion yen project is expected to increase the Company's domestic production capacity for manual transmissions by 50 percent by 2010. Today, the Company is capable of producing 1.6 million manual transmissions and transfers per year in Japan. (From a press release on Jan. 16, 2008)
Investment Outside Japan
-In 2008, the Company announced its manufacturing subsidiary in Thailand will build a new plant to make transfers for the "Hilux Vigo", Toyota Motor's pickup truck. The new plant is scheduled to be completed in May 2009. The Thai subsidiary is Aisin AI (Thailand) Co., Ltd. in Chachengsao, which has manufactured manual transmissions for the "Hilux Vigo". Having received new orders for transfers, the Company decided to add a new plant on the adjacent site of the existing plant. Total investment will be about 2 billion yen. This will enhance the Company's annual production capacity to 800,000 units, from its current level of 300,000. (From an article in the Nikkan Jidosha Shimbun on May 23, 2008)