KYB details research, development and manufacturing

KYB offers an insight into how its research, development and manufacturing processes ensure ranges can be expanded quickly, providing the UK aftermarket with original equipment (OE) standard components every time.

Q. What factors are key to aftermarket success in the new to range sector?

KYB: “The main reason for KYB is due to KYB’s strong OE presence with many leading vehicle manufacturers worldwide, including Audi, BMW, Toyota, and Citroën – and that’s just naming a few. In fact, one in five of all cars leaving production lines worldwide are fitted with KYB shock absorbers. This means that when it comes to introducing new applications to the European aftermarket, we can develop them at a quicker pace using the knowledge we have from manufacturing the original parts.

“We are also constantly investing in improving research & development to ensure that the speed at which we can introduce new applications only gets better over the coming years.”

Q. What exactly is involved in the research & development of shock absorbers, to ensure that they are moved from production line to factors’ shelves as quickly as possible?

KYB: “We’re a global corporation, so the development of new to range shock absorbers is heavily dependent upon dedicated product management teams across the world working together seamlessly.

“First of all, the product is designed by our engineering teams mainly in Japan and Spain, and then sent for thorough testing at KYB’s purpose-built test track in Kashio, Japan (above). Built in 2011, the facility features several dedicated test tracks, designed specifically for the development and testing of suspension & steering components. This includes a huge circular test track with a radius of 345ft and a camber of 0.5%, a 550m straight track with 15 lanes and 22 different road surfaces, and a handling and comfort test track – a course over 1km long that winds through a Japanese forest. The whole area is over 580,000m2, which is the equivalent of approximately 64 football pitches.

“There’s also a research & development building where further testing takes place and results are analysed. Having this huge purpose-built facility has significantly reduced lead times for both OE and aftermarket product development.

“The final stage of development is the vehicle fitting test, which ensures that the on-vehicle performance of all new applications is fully evaluated before being approved and made ready for the European aftermarket. KYB Europe Aftermarket has a 700m2 fitting and testing centre in France, which includes two lifts and a full range of garage equipment, including the latest 3D geometry check equipment.”

Q. What happens once the product has been approved and manufactured?

KYB: “KYB has multiple factories across the globe, four of which are based right here in Europe. From our factories, over 1 million shock absorbers are manufactured every single week. The manufacturing process itself is highly automated – operators start the process by adding the raw components and then they are not touched again until they are manually removed from the end of the production line. Once removed, manual checks are then conducted to ensure optimum quality.

“From here, product makes it way to our 10 branches across Europe where over 4.5 million pieces of KYB stock is stored and distributed. KYB UK is fortunate to have its own warehouse based near Manchester, in Warrington. This means that orders can be packed and sent to customers from the moment they are ordered and delivered the very next day.”