Reterra Inc.

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Reterra Inc. is one of the world’s most experienced manufacturers
using the aluminum squeeze casting process.

Japanese Page

ISO9001 received

ISO14001 received

2015/04/01: Web site renewed.

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Company Profile

Ryokami Headquarters

Ryokami Plant

Chichibu Plant

Chichibu Plant II

Name of Corporation:

Reterra Inc.

Address

Ryokami Headquarters [map showing location]
2703 Ryokamisusuki, Ogano-machi, Chichibu-gun, Saitama Prefecture 368-0201, Japan

Production Facilities:

Ryokami Plant [map showing location]

2703 Ryokamisusuki, Ogano-machi, Chichibu-gun, Saitama Prefecture 368-0201, Japan

Chichibu Plant [map showing location]

9 Midorigaoka, Chichibu-city, Saitama Prefecture 368-0067, Japan

Chichibu Plant II [map showing location]

29-2 Midorigaoka, Chichibu-city, Saitama Prefecture 368-0067, Japan

Foundation

March 1977[click to see timeline]

Representative

Hiroyuki Akiyama, Representative Director and President

Capital

90 million yen

Shareholders

F-TECH INC. (85%; listed on the First Section of the Tokyo Stock Exchange), UBE MACHINERY CORPORATION, LTD. (10%), and ALCONIX Corporation (5%; listed on the First Section of the Tokyo Stock Exchange)

Number of Employees:

236 (as of April 1, 2022)

Sales

3,944,000,000 yen (for fiscal year ending March 2021)

Main business

Manufacture and sale of aluminum and zinc castings

Main customers

Aisin Co., ; AISIN KEIKINZOKU Co. Ltd.;ALCONIX CORPORATION; Bosch Corporation; F-TECH INC.; GKN Driveline Japan Ltd.; Hitachi Astemo, Ltd.; Komatsu Ltd.; Knorr-Bremse Commercial Vehicle Systems Japan Ltd.; KYB Corporation; MITSUBISHI FUSO TRUCK & BUS CORPORATION; NEC Corporation; SUZUKI MOTOR CORPORATION
(in alphabetical order; capital letters according to company preference)

Message from the Company President

Hiroyuki Akiyama, Representative Director and President

Reterra Inc. was founded in 1977 in Tokorozawa, Saitama Prefecture, not far from Tokyo.
Right from the time of our establishment we employed vacuum casting methods, which were not commonly used at the time. This helped us produce castings that have consistently high interior quality.
We were also one of the early users of squeeze casting, a special process giving us an enviable reputation among customers as “Do-it-right Squeeze Casting Reterra.” In 2007, the Ministry of Economy, Trade and Industry listed us among Japan’s 300 most dynamic manufacturers.
We have made our experience in the field a positive force not only for squeeze casting but also for general die-casting, supplying products that exhibit excellent interior quality.
To respond accurately to customer requirements for such high quality products and supply them at a more reasonable cost, we conduct research into the development of special methods and materials, all the while building on our experience.
The motor vehicle industry is our main source of orders. Its growing need for lighter products is encouraging them to consider switching from steel to aluminum components, thereby using more castings. This has resulted in a range of different requirements for casting quality and advanced products.
We will continue to satisfy these customer requirements by applying the technologies and experience we have gained over the years, and by proactively promoting new developments.
We are also shifting to manufacturing our own molds (after many years preparing for this step), and are promoting our business overseas.
Reterra is ready to respond positively to your various aluminum die-casting requirements.

Employee Welfare

softball tournament

Reterra employees work at our facilities in the Chichibu district, an area of Japan known for its beautiful wooded mountains and valleys.
Here they bolster our efforts to continually improve casting techniques and create products that lead the industry. Their zeal and diligence are a source of strength for the company, and one reason why customers trust us.
When it comes to employee welfare, Reterra’s philosophy is “Respect and honor our workers.”

Employee Welfare Facilities

Employees can use the following rest and recreation facilities during the consecutive holidays in April and May, New Year’s holidays, other long vacation periods, and at other times during the year.
Kanagata Kawaji-so Lodge: Kawaji-onsen, Tochigi Prefecture
Kanagata Hakone-so Lodge: Kowakidani, Hakone-machi, Kanagawa Prefecture
Kanagata Akakura-so Lodge: Myokokogen-machi, Niigata Prefecture
Laforet Club

Employee Holidays and Special Leave

Reterra employees enjoy 120 days off during the year: Saturdays and Sundays; New Year’s holidays; consecutive holidays in April/May; summer vacation; paid annual leave (4 days after 3 months of employment, 6 days after 6 months of employment, and an increasing number of days, up to a maximum of 20, as the number of years of continual employment increases); special leave (for marriage, birth, other personal events, and disaster recovery); child-care days; family member care days

Insurance

Health insurance (Metal Mold Industry Health Insurance Co-operative of Japan); employee pension plan; employment insurance; workmen’s compensation insurance

Training and Education Programs

Group training for new employees, echelon-specific education programs, skill-specific training, preparation for trade skills qualification test, study sessions and training, etc.

Other Company Support for Employees

Company housing, asset building savings plan, retirement allowance, periodic health checkups, rest and recreation facilities (Laforet Club membership, health insurance fund resort, etc.)

Online Announcements

No announcements at present.

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Products

Let your mouse hover over any of these items to learn more.

Engine components

Reterra’s products for engines, transmissions, steering systems and suspension systems are used in a wide variety of applications.
We meet customer requirements with the latest advanced technologies, prioritizing products made using squeeze casting methods that provide excellent air tightness and durability.
[Click on any of the photos for information on manufacturing method and special features]

Cylinder head

Oil filter

Oil pan

Engine Support

Transmission components

Oil pump

Clutch

Case

Steering system components

Rack housing

Column EPS

Hydraulic pressure PS

Air conditioning system components

Cylinder

Head

Heat sink

Brake components

Cap

Vacuum pump

Suspension system components

Sub-frame

Mount

Differential components

The differential case

The differential mount

Electronically controlled coupling

Hydraulic device parts

Our hydraulic device parts, which are primarily for structural devices, are used in products where air tightness and durability are especially important.
Quality is ensured first and foremost through the squeeze casting method, when high pressure is applied during the forming stage until hardening.
[Click on any of the photos for information on manufacturing method and special features]

Control valve

Gear pump

Piston pump

Other components

We also supply products for sectors other than the automotive sector, where high strength and air tightness are important.
[Click on any of the photos for information on manufacturing method and special features]

Rotor

Swivel

Manifold

Tank

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Reterra’s Integrated Production System

Fast turn-around times, low cost, consistently high quality - all ensured through our in-house integrated production system

Reterra’s integrated, start-to-finish production system begins with development and extends from die-casting to downstream processes (heat treatment, machining and finishing).
Thanks to our die-casting experience, which is among the most masterful in the world, we have the expertise needed to respond accurately to customer needs.

Die-Casting

At Reterrra, customers select the die-casting method that best suits their needs, since we employ a wide range of casting methods, from common high pressure die-casting (HPDC) to low pressure die-casting, insert die-casting, squeeze die-casting, nanocasting (semi-solidification casting), and various special methods.

Amount of gas pockets remaining in aluminum castings

Special features of the low pressure die-casting method

Reducing pressure inside the mold cavities makes it possible to boost running more than what can be achieved during an ordinary casting method, while also reducing gas entrainment.

Other methods

Click on any of the items for information on other die-casting methods

Heat Treating Technology

Our heat treatment process offers the strength that cannot be achieved by regular die-casting methods and the lightness and high durability required for automotive parts.
Our advanced heat treatment techniques and full range of machinery make it possible to manufacture products that offer higher quality and greater reliability.
Automation at Reterra plants permits T5, T6 and other heat treatment methods.

Machinery

We have installed an excellent line of processing machines and keep creating new added value, in order to satisfy the advanced requirements of our customers and supply high-quality products with extra added value.
One of our goals is to accurately anticipate the products that will be in demand in these changing times. This is one way to ensure our future growth.

Leak testing

We conduct leak tests at our facilities when customers require high quality performance.

Assembly

Reterra’s assembly processes for automotive parts and household appliances have improved its integrated production system even more.
These advances help customers reduce their costs. In addition, our proprietary technologies maintain high quality, and as time passes we will continue investing in even more advanced factory equipment to meet the requirements of customers in various industrial sectors.

Treatment device production

Reterra manufactures treatment devices within our facilities.
The expertise we have gained over time is useful in our design and production, and we install new factory equipment on a regular basis. As a result, we can manufacture products that have complicated specs and respond accurately to varied customer requirements.

Development System

Our 3D modeling, strength analyses and casting simulations are all useful when exploring options for optimum product shape, casting and mold structure, and when manufacturing the molds.
The object here is to ensure high quality, mass-produced items, quality assurance during mass production, and consistent reliability.

We are proactive in developing new techniques.
Feel free to contact us to learn more about our innovative manufacturing processes that look forward, rather than back.

Development of New Techniques

With a view to promoting new techniques, we conduct research in new manufacturing methods. Our research applies the technical expertise we have gained during production using various known die-casting methods.
Using our technical expertise in squeeze casting, our development projects use die-casting machinery designed specifically for research purposes, to develop slow filling (laminar flow filling) die-casting methods, to explore metal gauging possibilities (base thickness: 3mm), and more.
That machinery for research purposes includes equipment capable of conducting trials testing pore-free die-casting methods and nanocasting (semi-solidification casting) methods.
And, by using a smaller melting/holding furnace, we are able to test manufacture materials that have properties different from those ordinarily seen.

To respond accurately to customers’ varied needs, we continue conducting research and development projects, pursuing new techniques and technologies that will yield products satisfying their requirements.

Production Facility

Die-casting machinery	Squeeze casting machines (350 to 800 tons)	14
	High pressure die-casting machines (250 to 850 tons)	11
	Semi-solidification casting machine (670t)	1
Heat treatment equipment	Solution heat treating furnaces	3
Heat treatment equipment	Aging furnaces	4
Shot equipment	Hanger shot blasting machines	7
Shot equipment	Apron shot blasting machines	3
Press equipment	Presses (5 to 80 tons)	11
Machining equipment	Machining centers	7
	NC lathes	8
	Tapping centers	6
CAD	CATIA V5	1
	CADPACK	4
	NC CAD	2
	UG-NX	1

Measurement and inspection devices	3D measuring instruments	3
	Contour shape measuring instrument	1
	Roundness measuring instrument	1
	Surface roughness measuring instruments	2
	X-ray equipment	2
	Electric discharge luminescence analysis machine	1
	Flow analysis system	1
	Tensile tester	1
	Universal tester	1
	Portable fatigue testing machines	1
	Metallurgical microscopes	2
	Leak testers	5

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Quality Control

Slogan: Establishment of in-process assurance system

Reterra takes its status as a casting manufacturer very seriously, placing extra importance on management systems that ensure our products are always manufactured to high quality standards.
Our customers have every confidence in the high performance levels of our products, achieved through the accuracy of our inspection systems (which are incorporated within our own start-to-finish production system), and through processes which are designed to ensure quality through strict controls governed by quality control sheets and inspection specifications.
Our quality control system is based on a stringent quality assurance system and worker dedication. It leads the industry.

Measuring Instruments

Emission spectrophotometric analyzer

Roundness measuring instrument

Metallurgical microscope

3D measuring instrument

Emission spectrophotometric analyzer

Before beginning a casting process we examine the composition of the molten aluminum, then adjust the composition to customer requirements.
Using the emission spectrophotometric analyzer to control the composition of the molten metal, we ensure proper casting at stable flow rates, and achieve physical strength and other quality requirements.

Roundness measuring instrument

Rotating components must have precision roundness.
Measurements verify whether the required level of roundness has been achieved.

Metallurgical microscope

A metallurgical microscope is used to verify the precision of the casting surface and polished surfaces.

3D measuring instrument

The instrument examines the geometric shape of the product to ensure it meets multi-dimensional requirements for precision in coaxiality, concentricity, flatness, straightness, etc.

Quality Improvement Activities

At Reterra, employees work together to make further quality improvements.
For example, we organize regularly scheduled in-house meetings where incident reports are presented, to instill in all employees an awareness of the need for improvements.
Everyone, from young employees to the company president, continues to pursue the goal of raising customer satisfaction.

Quality Control Circle activities within the company

Employees in each company department organize quality improvement circles and work together on a daily basis toward that aim.
Their activities are highly regarded by our corporate customers, and the STEPS Circle at our Chichibu Plant’s Second Casting Department recently won the Quality Improvement Plan Award.

ISO9001

Our company received ISO 9001 certification on December 13, 2003 as part of its pursuit of even higher quality.
We will continue to develop quality assurance systems that respond positively to customer needs.

Traceability

Reterra realizes that, as a manufacturer that wants to continue enjoying its reputation of dependability, it must raise its quality levels even higher and ensure efficiency in its operations.

Click here to view a chart showing key elements in our traceability system.

Here are some of the results!

- Employee know-how has been incorporated into the traceability system to develop all of our own applications.
- We’ve selected devices and equipment that can stand up to dust and other tough workplace conditions.
- We developed our own original printer safeguard racks and payment slip cases.

Here are some of the advantages!

- All products still on company premises, whether work in progress, replenishment products, finished products or products in inventory, can now be identified in real time.
- We’ve developed a No Late Delivery system.
- Inventory has been slashed by more than 40%.
- Production history can now be viewed, enhancing the traceability system. In addition, customer inquiries can now be answered promptly.

Issuance of forms identifying material on hand

Issuance of forms identifying castings on hand

Attachment of seal indicating Acceptable for Delivery

Awards

Certificate given in recognition of our innovative Saitama entrepreneurial spirit / Quality Improvement Award

Quality Improvement Award

Award for Excellence in Quality Improvement

Certificate listing Reterra among Japan’s 300 most dynamic manufacturers

Cost Improvement Award

Reterra has received awards from some of its corporate customers in recognition of our unflagging commitment to quality and dedication to continued improvement.

Striving for Harmony with the Environment

Reterra’s Environmental Protection Policies

In light of the fact that our production and processing of aluminum automotive components can have an environmental impact, we have developed an environment management system to protect the environment. Under this system, we implement improvements to prevent pollution on a regular basis and when changes in social awareness occur.
We abide by laws, ordinances, regulations, agreements and other requirements of an environmental conservation nature.
We promote efforts to reduce waste, increase recycling, and conserve resources and energy.
We ensure that our environmental protection policies are understood and accepted by all employees, including the employees of affiliated companies. We also require that collaborating companies understand, accept and implement the policies.
We strengthen ties with local communities, participate actively in their activities, and implement environmental conservation measures within our company premises.

The following are concrete examples of Reterra’s environmental protection efforts.

Strict Abidance with Waste Water Criteria

Training in Dealing with Emergency Situations

Safety and Environmental Protection Training

Business Continuity Planning (BCP)

The Three BCP Elements Reterra has adopted a Business Continuity Plan that is founded on the three elements illustrated to the left. The plan is designed to enable the company to get back into operation quickly after an untoward incident.

In February 2014, part of our BCP was proven effective when heavy snows caused damage in the Chichibu district, where our facilities are located. This website introduces the incident as a way to demonstrate an example of the need for a BCP.

Damage caused by heavy snows in February 2014, and subsequent reconstruction

Safety Confirmation System

We developed our own employee safety confirmation system.

Supplies Kept On Hand for an Emergency

If, after a disaster, employees and visitors are unable to return home, we have supplies on hand for them to use on our premises. The supplies include drinking water, food, simple toilet devices, and first aid kits.

Redundancy for Data and Communications Systems

All of our digital infrastructure, including the server for in-house IT systems and the email server for external communications, is redundant so that if one fails the other can be used.

Wireless Connections Between Buildings

During the February 2014 weather emergency, our wired LAN connection was cut and lightning caused other problems. Learning from this experience, as a backup we installed our own wireless communication system between buildings that are separated from each other.

Prevention of Possible Damage from Molten Metal

We’ve installed covers that form a protective perimeter on furnace openings to prevent molten metal from sloshing out and causing a fire during an earthquake.

Oil Leak Preparedness

We’ve installed emergency tool sets in the machining plant, and in multiple areas near processing areas, in readiness for a possible oil leak during a disaster or machine failure.

Sway Prevention

Sway prevention bars have been installed on the ceiling to prevent fluorescent light assemblies near the ceiling from swaying and falling during a severe earthquake.

Inquiries

Inquiries regarding products, sales, etc.

+ Telephone inquiries
+81-494-62-3024(Mr. Hiroyama, Sales Department)
+ Fax inquiries
+81-494-62-5659
Click here for email inquiries

Inquiries regarding general affairs, employment, etc.

+ Telephone inquiries
+81-494-79-1300(Mr. Moriya, General Affairs Department at Head Office)
+ Fax inquiries
+81-494-79-1305
Click here for email inquiries

Web site renewed.

Company Profile

Message from the Company President

Employee Welfare

Employee Welfare Facilities

Employee Holidays and Special Leave

Insurance

Training and Education Programs

Other Company Support for Employees

Online Announcements

Products

Engine components

Transmission components

Steering system components

Air conditioning system components

Brake components

Suspension system components

Differential components

Hydraulic device parts

Other components

Reterra’s Integrated Production System

Die-Casting

Special features of the low pressure die-casting method

Other methods

Heat Treating Technology

Machinery

Leak testing

Assembly

Treatment device production

Development System

Development of New Techniques

Production Facility

Quality Control

Measuring Instruments

Emission spectrophotometric analyzer

Roundness measuring instrument

Metallurgical microscope

3D measuring instrument

Quality Improvement Activities

Quality Control Circle activities within the company

ISO9001

Traceability

Here are some of the results!

Here are some of the advantages!

Awards

Reterra’s Environmental Protection Policies

Business Continuity Planning (BCP)

Safety Confirmation System

Supplies Kept On Hand for an Emergency

Redundancy for Data and Communications Systems

Wireless Connections Between Buildings

Prevention of Possible Damage from Molten Metal

Oil Leak Preparedness

Sway Prevention

Inquiries

Inquiries regarding products, sales, etc.

Inquiries regarding general affairs, employment, etc.