Aisin is active in automotive sector and offers a wide range of products covering nearly all components that comprise the manufacturing of a vehicle. Aisin is seeking to pursue excellence in production technology and acknowledges investing in digital transformation will allow to create an edge over competition.
For the tough and heavy assembly of powertrains, they have chosen Ansomat Operator Guidance as the operator helping hand, guiding them flawlessly through the assembly. Ansomat solution has been implemented at 11 workstations; each representing a different step in the assembly of a motor transmission.
Powertrain assembly involves numerous tightening operations, each requiring specific torque and angle settings, a predefined tightening sequence, and complete verification.
Manual tightening introduces the risk of:
Aisin required a solution that could control the entire tightening process while reducing operator workload and maintaining full production traceability.
Ansomat implemented its Process Control software across 11 transmission assembly stations, integrating ESTIC pulse tools with digital operator guidance and real-time process control.
Aisin selected ESTIC pulse tools because they combine the accuracy and traceability of intelligent DC tightening systems with exceptional operator ergonomics. Unlike conventional direct-drive nutrunners, pulse tools deliver torque through a series of controlled pulses, dramatically reducing reaction forces and virtually eliminating kickback. This allows operators to tighten high-torque fasteners comfortably by hand, without the need for bulky reaction arms or manipulators, resulting in greater flexibility, improved accessibility, and reduced operator fatigue. Despite the minimal reaction force, the tools still deliver highly accurate and repeatable tightening performance with full torque and angle verification.
The software continuously monitors every tightening operation and only allows operators to proceed once the correct bolt has been successfully tightened to specification.
The system automatically:
Rather than relying on operator experience, the assembly process itself controls every tightening step, ensuring every fastener is tightened in the correct sequence, to the correct specification, while eliminating common assembly errors and delivering complete traceability.
The Ansomat Controlled Tightening solution provides:
Every tightening result is linked to the individual product, creating a complete digital record for quality assurance and production reporting.
Implementing controlled tightening significantly improved Aisin's transmission assembly process.
Every fastener is tightened using the correct parameters, eliminating missed bolts, incorrect torque values and sequence errors.
Automated process control reduces decision-making for operators and streamlines assembly, resulting in shorter cycle times.
Operators simply follow the guided workflow while the software manages tightening parameters and validates every operation.
Every tightening cycle is automatically stored, providing full traceability for quality audits and production analysis.
New transmission variants and tightening strategies can be configured quickly without increasing assembly complexity.
By combining controlled tightening, digital process control and integrated tightening tools, Aisin significantly increased assembly efficiency while maintaining the highest quality standards.
The improved workflow enabled the production team to manufacture nearly twice as many transmissions per shift, while ensuring every tightening operation met specification and was fully traceable.
Manufacturers rely on Ansomat to ensure every critical tightening operation is completed correctly the first time.
By combining digital process control, operator guidance and intelligent tightening tools, manufacturers can:
Whether you manufacture powertrain components, electric vehicles, aerospace assemblies or other safety-critical products, Ansomat's Controlled Tightening solution helps eliminate tigh
