AISIN boosts a sustainable and competitive node at its Mons plant in Belgium

On a recent press trip to various European media, AISIN, a multinational supplier of OE and aftermarket components under the Toyota umbrella, showcased its capabilities as a strategically located, sustainable and competitive node. Founded in 1997, the AISIN plant in Mons (Belgium) specialises in the reconditioning of automatic gearboxes and the manufacture of electronic products such as in-vehicle navigation systems. It is located close to the sea canal and has direct connections to the ports of Rotterdam, Antwerp and Zeebrugge. It serves a considerable number of car factories belonging to Audi, Stellantis, Toyota or Volvo, located within a radius of approximately 100 kilometres. The plant plays a key role in the Japanese multinational's European strategy.

The company says that AISIN Mons is the only factory in Europe that fully reconditions gearboxes on an OE production line. The process is aimed at guaranteeing performance equal or superior to that of a new gearbox. Every year, some 10,000 reconditioned gearboxes leave the Belgian factory. Today, the company has extended its activity to the overhaul of hydraulic distributors.

When it comes to gearbox reconditioning, AISIN Europe believes that it offers a revolutionary alternative solution: the complete industrial repair of gearboxes directly on a reconditioning line. ‘This reconditioning process allows gearboxes to be made as good as new using original parts and in compliance with the manufacturer's strict processes,’ explains Renaud de Meyer, AISIN's AT transmission specialist for the aftermarket. 

As soon as a gearbox arrives at the Belgian factory in Mons, a rigorous traceability process begins in which every step is documented. After a thorough initial check, if necessary, the gearbox is cleaned by shot blasting: a technique that uses stainless steel balls to remove all impurities. The gearbox is then completely dismantled by a technician. The nearly 1,000 parts that make up the gearbox are cleaned and inspected one by one. ‘Following strict quality criteria, we decide whether to reuse or replace each part,’ says Renaud de Meyer. The new or reconditioned parts are then reassembled with extreme precision, according to strict specifications’, confirmed by AISIN's engineers.

Since 2003, the Mons plant has also embarked on a process of diversification with the creation of an electronics production plant. In addition to its specialisation in navigation systems for Toyota, Lexus and Audi, it now produces specific electronic cards for gearbox management, in particular for Volkswagen. Building on this experience, a new activity will start in 2025 for the production of electronic cards for the management of cooling systems in electric cars.

‘Our objective, defined with regard to the vision of AISIN Europe and approved by our parent company in Japan, is to root the activities locally. This translates into a strong capacity to develop competencies internally and a real European rootedness. This dimension represents two key elements in the successive factory conversions,’ explains Jacques Fils, Operations Director of AISIN Europe in Mons.

In Europe, the company has plants in the UK and Turkey for bodywork components, as well as in the Czech Republic specialising in engine components. Fils says: ‘Unlike other European plants in the group that receive production lines designed in Japan directly from the parent company, here, we have developed most of the processes ourselves. In 2012, for example, we defined the reprogramming of BMW's gearbox software. The manufacturer wanted the new software to be in the gearboxes ten days after launch. This was impossible to achieve from the factories in Japan: transport would take too long! But we were able to deliver just-in-time to BMW. The experience was conclusive, with impeccable quality.

The privileged location of the Belgian factory is exploited in an extensive logistical deployment. The reconditioning and electronics production operations are complemented by logistics activities linked to the distribution of spare parts. To meet these needs, a 15,000 m2 warehouse was set up at the Mons plant in 2012. This warehouse, located on what was until 2023 a former gearbox distribution platform for Stellantis and BMW, has played a key role in the company's turnaround.

It is also a response to AISIN's decision to relocate its entire European reconditioning business to Mons. This strategy has made it possible to bring all Belgian operations back to a single site. Today, a team of 50 of the factory's total of 500 employees is actively working to ensure the supply of the necessary spare parts throughout Europe. Its mission is based on a strong catalogue with more than 11,000 references (transmissions, clutches, water pumps, brakes, etc.). Every day, 5,000 spare parts are shipped to the aftermarket and spare parts networks.

Adaptation and higher sustainability rates
 

As a key to the factory's continuity, Jacques Fils stresses that ‘the successive conversions are the result of our constant observation of the European market and its needs. It also reflects the agility and performance of our teams. We have relied on developers to digitise the company by reducing the activity of navigation programmes: the teams in charge of navigation test software have transferred their skills to quality control or supply chain automation software. But the philosophy of the factory remains the same: we work to extend the life of the vehicles’.

The Operations Director emphasises the dual European-Japanese aspect. ‘We develop partnerships with European companies. For example, the gearbox reprogramming activity is done in partnership with two Walloon companies, KST and Citius. The electronic card assembly lines, planned for 2025, will be done in collaboration with French and German companies. We are European, but we are proud of our Japanese roots. Japan brings us this culture of ‘100% quality’ and full dedication to customer service. It is our foundation, and we build on it with our European culture. It's what has given the group its reputation and why customers come to us.