OUTLOOKTechnological Innovation Capturing Market Changes
M. IDOThe environment surrounding manufacturing is changing significantly and JTEKT, which produces mothermachines (machine tools) as its flagship products, must respond to this change in order to secure its survival.
Particularly significant changes are the shift to electric vehicles and the reduction of the working population. In
this paper, we will introduce our production equipment and processing methods enabling us to produce small,lightweight, high precision parts for EVs. We will also provide examples of smart technology for equipment andfactories, as well as 3D metal molding technology as responses to the reduction of the working population.
Key Words: EV shift, working population, skiving, IoE, additive manufacturing

1. Introduction

2. Response to the EV Shift of Automobiles

The environment surrounding industry is facing majorchange. On a global scale, examples of such change are
the shift towards electric vehicles in response to global
warming and monozukuri responding to a diversificationof user needs. Meanwhile, within Japan, a rapid decline
in the working population including the retirement ofskilled technicians is a matter of urgency. Amidst sucha situation, various initiatives are being launched on
the monozukuri shop floor, such as introduction of IoT(Internet of Things), utilization of AI and line automation.
Moreover, even in regards to machining methods, in linewith the practical realization of 3D molding technology,
there are increasing expectations on equipment utilizing
additive manufacturing as well as the conventionalremoval technology. At JTEKT, parallel to maintaining
and improving the competitiveness of our strength −equipment for engine manufacturing − we are taking on
new initiatives responding to various changes, represented
by the shift towards EVs of automobiles.
This paper will introduce machining methods andmachining technologies contributing to the higher
accuracy of parts in response to the EV shift and shift
towards compact, lightweight and quiet products.
This paper will also introduce examples of JTEKT’s
original IoE (Internet of Everything) initiatives tailoredto manufacturing shop floors facing a declining working
population and additive manufacturing leveraging 3D
metal lamination molding technology.

It is expected that the number of automobiles produced
will continue increasing in the future, however in termsof the drive unit, there is a shift away from combustion
engines alone and towards utilization of electric motors.
It is predicted that vehicles such as hybrid vehicles(HV) which use an internal-combustion engine andbattery/motor in combination, plug-in hybrid vehicles(PHV), electric vehicles (EV) and fuel cell vehicles(FCV) will increase in number in line with technologicaladvancement (Fig. 1).
The parts and production equipment utilized as aresult of this EV shift are required to have the below
characteristics.
(1) Compact and lightweight for longer battery travel
distance(2) Higher accuracy to support quietness and highefficiency(3) Equipment suitable for engine downsizing
For all of the three above-mentioned items, it isimportant to consider space productivity (productivityindicator in relation to equipment footprint). Automakers
must secure sufficient space for engine production, inaddition to production of those products related to theEV shift, such as motors and batteries, and can minimize
investment cost of increasing plant capacity by using
equipment with high space productivity.
In light of this, the following section introduces
concrete initiatives involving machine tools to meet therequirements of (1) and (2) above.

16JTEKT ENGINEERING JOURNAL English Edition No. 1016E (2019)

Incomplete tooth portion

No. of passenger vehicles sold, 1 mill units−Technological Innovation Capturing Market Changes−

200
FCV
150

EVPHV

100Less incomplete tooth portion

HV50
GAS
02000

2010

2020

2030

Hobbing
2040

Skiving

2050 Year

Fig. 3 Characteristics ① of skiving

Source: IEA_ETP “World Automobile Sales Forecast” 2012

Fig. 1 Prediction of shift to electric vehicles

2. 1 Downsizing of Parts through Skiving
As Fig. 2 shows, skiving is a gear processing method
using the relative speed generated when the tool andworkpiece are tilted relative to one another and rotatedsimultaneously. People have known about this processing
method itself since long ago, however the synchronizationof high-speed and high-accuracy tools and workpieces
required to obtain cutting speed was essentially madepossible by advancements in CNC servo technology
in recent years. Another factor behind the practicalrealization of skiving is that appropriate design for tool
shape to suit the gear tooth profile has become easy toachieve.
With skiving, it is possible to obtain workpiece shapes
not previously possible with conventional processing
methods. As Fig. 3 shows, with the conventional hobbing
technology, there was a large incomplete tooth portionand this made downsizing of parts difficult, however withthe application of skiving, the incomplete tooth portionis reduced, therefore parts can be made compact andlightweight. In the same way, Fig. 4 shows how skiving
eliminates the need for the undercut, which was necessary
with the conventional methods of gear shaping andbroaching, which helps to improve part strength and has
the additional benefit of reducing part weight.

Intersecting angle u
Tool
Workpiece

Workpiece
cutting speed V2

3-5mm
undercut

No undercut neededGear shaper

SkivingFig. 4 Characteristics ② of skiving

JTEKT developed and commercialized the Gear
Skiving Center as a processing machine that performs
skiving.
The Gear Skiving Center also features the functionsof a machining center and is capable of automatic toolchange. Furthermore, the principle of skiving requires
high rigidity, therefore we have increased mechanicalrigidity by shortening the stress path from the machining
point to the guide.
Due to the Gear Skiving Center’s ability to turn andindex the workpiece, as well as to perform automatic
tool change, it is possible to integrate six conventional
processing methods into just two, as shown in Fig. 5. This
type of process integration achieves efficient operationof equipment to suit varying-type/varying-volume
production as well as higher precision of coaxiality andpositioning through single-chuck machining.
As described above, skiving makes it possible toachieve efficient equipment operation through processintegration, enabling of compact, lightweight and highaccuracy parts, as well as cost reduction. This makes it aneffective method for machining gears used in many EVs,etc.

Actual cutting
speed V3
Tool cutting speed V1Feed direction

Fig. 2 Principle of skiving

JTEKT ENGINEERING JOURNAL English Edition No. 1016E (2019)17

−Technological Innovation Capturing Market Changes−

Process

Turning 1

Turning 2

Hobbing

Lathe

Lathe

Hobbing
machineShapingChamfering

Drilling

Conventional
Equipment

Turning 1

Gear shaper Special-purpose Special-purpose
machinemachine

5 processes-in-one

Process
New technology
Equipment
Lathe
Skiving tool

Gear Skiving CenterFig. 5 Example of ring gear process integration

2. 2 Response to High-Accuracy Grinding/Compact Parts
In line with an increase in EV production, theproduction of lithium-ion batteries is also increasing. Of
the equipment used for lithium-ion battery production,
coating machines and presses use many high-accuracy
rolls and these rolls must be grinded at a high accuracy
in the unit of microns (shape accuracy, mirror finishing).
Currently, production depends on skilled workers withadvanced grinding skills, however in response to increase
production, expectations are growing regarding equipment
able to produce high-accuracy rolls without the need todepend on worker skill.
In order to meet shape accuracy needs, JTEKT isdeveloping and launching a cylindrical grinder featuring
a thorough low heat displacement design and lowvibration design, as well as functions such as automatic
determination of grinding conditions. Furthermore, thevarious companies of the JTEKT Group are collaborating
on initiatives to develop CBN/diamond wheels andgrinding technologies (Fig. 6) aimed at securing highquality grinding surfaces, such as mirror finishing.
Through these comprehensive development efforts, we
aim to offer customers a grinder capable of easily mass
producing high-accuracy rolls without relying on skilledworkers.
Apart from roll production, higher accuracy grinding
technology has a broad application scope, including
reduction of noise and vibration generated from vehicle
drive parts, as well as improved part accuracy that leads
to better fuel economy, therefore JTEKT wishes toconstantly evolve it as a fundamental technology throughwhich we can differentiate ourselves from others in theindustry.
Meanwhile, from the perspective of our 5-year midterm management plan and our “Beyond” mid-term plan
which considers a further 5 years into the future, the18

50 000×100

Surface roughness: 20 nmRa (0.02 µm)
Wheel used: SA#80

Roundness: 0.07 µm

Fig. 6 Example of high-accuracy roll fully-automated mirror
finishpopularization of EVs is predicted leading to a gradualdecrease in the demand for grinders used in machining
engines, which has been the backbone of JTEKT’s
grinder business to date, therefore we must develop newmarkets. JTEKT offers a lineup of compact crankshaft
grinders for the robot and compressor markets, forwhich demand is expected to grow in the future. To date,based on our camshaft grinder for automobiles which
possesses a profile grinding function, we have proposed
installing tooling for the eccentric portion of the compact
crankshaft, however, now there is a need to improveaccuracy of surface roughness, dimensions and roundness,
as well as to make the equipment more compact in orderto suit the dimensions of compact crankshafts. For thecompact crankshaft grinder, we have deployed compact,
high-accuracy technology such as shown in Fig. 7, andsucceeded in improving grinding accuracy at the sametime as reducing space and improving productivity. This
makes it possible to meet requests for space productivity
improvement by customers who need to secure space inpreparation for increased production.

JTEKT ENGINEERING JOURNAL English Edition No. 1016E (2019)

−Technological Innovation Capturing Market Changes−[High accuracy/compact]
High filtering compact coolant system⇒Surface roughness: 0.1 µmRa or lessScratch-freeApprox. 38% lessmachine space[High accuracy]
Stabilization of wheelhead movement accuracy⇒Roundness: 1 µm
[High accuracy/compact]
Wheel spindle (static pressure technology)‫ޓ‬compact/energy-saving

WheelheadWheel[High accuracy]
Low thermal displacement through‫ޓ‬heat management technology⇒Dimensional accuracy: ±u2 µm
Headstock

Spindle head

Machine plan viewFig. 7 Deployment of technology achieving both compact/
high-accuracy and good productivity

3. 1 “Factory Smartification and Machine
Smartification” Leveraging IoE

3. Response to Decline in Working
Population
In Japan, due to the declining birthrate and aging
population, it is predicted that the working population in
2025 will decrease by 17% compared to 1990 (Fig. 8),
and the issue will arise of personnel shortages on theproduction shop floor. In Japan, the manufacturingindustry has survived due to offering products with highadded value, such as high quality and high performance,compared to low cost products imported from overseas.
The source of this added value is the existence of skilledworkers with abundant experience. The true problem ofa decline in working population is the shortage of skilledworkers, therefore there is a need to produce results withlimited resources.
So that we may thoroughly eradicate the “sevenwastes” lurking in production sites which prevent added(1 000 people)
14 000Working population ratio

value creation, and engage in efficient monozukuri withlimited resources, JTEKT presents the proposals of“Factory Smartification” and “Machine Smartification”
leveraging IoE from the perspective of a manufacturer
with both an auto parts business and a machine tools
business.
[Proposals in response to a declining working population]
1. Shortage of production personnel⇒Factory smartification, improved productivity,
automation
2. Shortage of skilled workers who create high added
value⇒Machine smartification: Digitalization, knowledge
acquisition＊①Over-processing waste ②Inventory waste③Overproduction waste ④Waiting waste⑤Motion waste ⑥Transport waste ⑦Defect waste

Firstly, “Factory Smartification” is whereby, evenon the monozukuri shop floor, there is a need to “haveproduction lines that are trouble-free” and “haveproduction lines that do not stop” in order to “improveproductivity.” To achieve this, JTEKT not only considers
IoT, which is about connecting “things”, it also
considers “connection of everything”, including people
and services, and, calling this as “IoE” or “Internet ofEverything”, we propose four IoE solutions. In regards
to the introduction of IoE, we have defined the four steps
shown in Fig. 9 and offer the optimal solutions for eachstep.
Step 1, the “Connection” solution, proposes a PLC,TOYOPUC Plus, that connects the various control
equipment in a factory, then the “Visualization” solutionof Step 2, proposes a PLC, TOYOPUC-Hawkeye, that(%)
80.0

65 or over

70.0

12 00060.0

10 00015 or over,under 65

8 000

50.0
40.0

6 000
30.0
4 000
2 000
020.0

Aging ratio

10.0

Under 150.0

1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 2045 2050 2055 2060 Year

(Source: Ministry of Finance)

Fig. 8 Predicted decline in working population

JTEKT ENGINEERING JOURNAL English Edition No. 1016E (2019)19−Technological Innovation Capturing Market Changes−finds the weaknesses in a factory based on the collected
information in order to make improvements, and for a
production management system which primarily uses
andons, enables customers the freedom to make any
combination of equipment, visualized content and time
periods that they wish.
The “Value” solution of Step 3 proposes TOYOPUCAAA, an edge-type analysis module that analyzes datafrom various sensors mounted on equipment, so that
customers can do something to prevent their equipment
breaking down before it is too late. The “Chain” solutionof Step 4 proposes data utilization not only within one’scompany, but with suppliers, group companies andcustomers, by broadening the scope.
Next, “Machine Smartification” uses the data collection,accumulation, display, analysis and determination
functions of the “Value” solution (Step 3) mentioned
above, to make a machine capable of autonomously andautomatically detecting abnormalities in terms of machine
maintenance and machined workpiece quality, as well as
the optimization of machining status.
In order to realize machine smartification, modelIntroduction step
1. Connect things
2. Connect information
3. Make improvements
4. Broaden the scope

based analysis technology of the machine and machining
statuses and utilization of AI for statuses and conditions
that are difficult to analyze using models. The “SmartCutting” introduced in the next section is a technologythat makes it possible for even non-experienced workers
to obtain chatter-free machining conditions, which willlead to “Machine Smartification” in the future enabling
the significant reduction of time required for trial
machining − a process which relies on skilled workers.

3. 2 Smart Cutting
When using long tools for deep boring of metal, etc.,
there is a high potential for chattering to occur due totool distortion. To prevent chattering, the conventional
approach was to perform trial machining first andselect the machining conditions (spindle RPM) wherechattering did not occur. However, the scope of optimal
machining conditions in which chattering does not occur
is extremely narrow, and a significantly high number ofman-hours by a skilled worker was required to complete
this task. As such, we developed JTEKT Smart Cutting
technology, which enables anyone to easily find theIoE solution
Connection solutionVisualization solution
Value solution
Chain solution

Step 4

Increase income by
improving productivity

veEvolStep 4

Step 3
Want to take action before equipment stops“Visualization” of signs using quality IoE and maintenance IoE

Broaden the “scope”

Step 3Make “improvements”

Step 2
Want to know how to increase productivity
Statistical “visualization” of equipment weaknesses with a moving monitor

Step 2Connect “information”

Step 1Connect “things”
Connect

Connect with suppliers, groupcompanies and customers

Step 1Visualization

Value

Want to know what is happening now“Visualization” of current line status with an Andon

Chain

4 IoE solutions

Fig. 9 The four steps
Accuracyevaluation

Machining

Hammering & measurement/analysis

OKGood part

Profile error/surface
roughness indicator

Roughness indicator

Instantly obtains chattering-free,high accuracy optimal machining conditions (spindle RPM)

0
Profile error
3 000

4 000

5 000 6 000 7 000 8 000−
Spindle RPM, min 1

9 000

10 000Fig. 10 JTEKT Smart Cutting

20JTEKT ENGINEERING JOURNAL English Edition No. 1016E (2019)

−Technological Innovation Capturing Market Changes−

Die cast mold repairs

Sensor housing

Slide core ofrepaired portion

Before repair

Groove machining Laser metal padding

Finishing

Reduction of mold repair lead-time

No. molded, ×1 000 units

Fig. 11 Mold repairs using laser cladding
454035302520151050

Production results
Appearance/product accuracy
No abnormalities

Production plan

Operating time

Fig. 12 Aluminum die cast-Repaired mold forming countevaluation

functions responding to various needs other than moldmaintenance, and that the applications of this technology
used in combination with removal technology could
expand further in the future.
Mold repairs using laser cladding are performed onmolds for manufacturing JTEKT products and 20 000
molds to date have been repaired using this method.
With laser cladding mold repairs, there is no abnormal
wear, cracks and so forth, and good product accuracy ismaintained (Fig. 12).

5. Conclusion
optimal machining conditions by measuring the dynamic
characteristics of tools including the spindle throughhammering. This technology is expected to reduce manhours of skilled workers.

4. 3D Metal Molding Technology
Many people associate “3D printer” with 3D metal
molding technology. This term was first used to referto a device that utilized technologies such as a nozzle
and head on a printer to create layers of material
inexpensively and with low molding accuracy. In contrast,“Additive Manufacturing” (AM) is the term used for highperformance devices such as those which use resin andmetal materials to perform molding with good accuracy.
In the machine tools field, the 3D metal lamination
technology associated with AM is utilized to perform 3D
metal lamination molding. Two methods exist; “SelectiveLaser Melting” (SLM) involves spraying metal powderthen using a laser to create solid layers one at a time,and “Laser Metal Deposition” (LMD) involves using alaser to create solid layers from metal powder that haspooled on the layer surface. LMD is also known as laser
cladding, and JTEKT is developing this for the purposeof mold maintenance (Fig. 11). It is believed that thistechnology could be used for lamination of metal withJTEKT ENGINEERING JOURNAL English Edition No. 1016E (2019)

This paper has introduced JTEKT’s initiatives
in response to the EV shift and declining workingpopulation. We must continue our efforts in response
to environmental changes. JTEKT wishes to view suchchanges as business opportunities to achieve advanced
technology development and product development thatpredicts needs. To this end, we will hone our ability torespond nimbly and swiftly to environmental changes
from a customer perspective and aggressively engage
in initiatives for new technologies to bring aboutmonozukuri innovation.
*1 TOYOPUC is a registered trademark of JTEKTCorporation.

M. IDO**Managing Officer21