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Auto Industry Analysis Report

Aug. 7, 2003 No.194


Hino Motor to Launch Local Production of Region-Exclusive Vehicles
to Enter the US and Chinese Markets on a Large Scale

Hino is promoting a complementary system in cooperation with Toyota
in the ASEAN region with a target local-content rate of 50%



  The following are the recent trends of Hino Motors (referred to here as Hino) which will enter the US medium-duty truck market on a large scale within 2003. Its sales volume decreased by 50% to 35,117 units in 1998 due to a sharp shrink of the medium-duty truck market in Japan and every other ASEAN country. However, some positive factors are helping these decreased sales to gradually recover. Included is the of 2t-class trucks like the Dutro, marketed through joint development with Toyota in 1999. The projected target volume of 72,530 units for FY2003 exceeds the result of 71,019 units for FY1997.

  Hino's long-term sales goal is 150,000 units worldwide in 2010, which is more than twice as much as the current sales volume. This will allow Hino to become one of the top five makers worldwide in the over 3t truck market. The sales goal in the US market, where Hino plans to enter, is 30,000 units in 2010, while results for 2002 were 1,695 units. The sales goal in the Chinese market, where Hino will start joint production with a promising partner, Chunlan Group, is 20,000 to 30,000 units in 2010. Hino also set its sales goal at 30,000 to 40,000 units in Asia including its core bases in the ASEAN region, Thailand and Indonesia, where Hino established separate manufacturing and sales business structures.

  An agreement of cooperation was formed between Hino and Scania in March 2002, however, no announcement has yet been made regarding any specific actions. Hino also formed an agreement of cooperation with Isuzu for the domestic bus business in January 2002 and set up a joint venture through their investment in October 2002 to start their business in October 2003.

■Hino's consolidated production and sales volumes (Units)
  1998JFY 1999JFY 2000JFY 2001JFY 2002JFY 2003JFY
Production Trucks/Buses 34,822 45,421 49,821 52,965 57,856 72,500
Commission Production
(Toyota brand)
165,937 135,459 140,734 141,045 191,743 186,100
Sales Trucks/Buses (Domestic)
Trucks/Buses (Overseas)
21,349
13,768
30,002
14,965
33,136
19,380
34,011
21,448
34,742
25,743
45,470
27,060
Trucks/Buses Total 35,117 44,967 52,516 55,459 60,485 72,530
Commission Production (Toyota brand) 165,937 135,459 140,734 141,045 191,743 186,130
Sources: Brief of Hino's Financial Statements,
Note: Figures for FY2003 are estimates announced by Hino.


■Breakdown of Hino's consolidated sales
  Sales units Sales(100 million yen)
00JFY 01JFY 02JFY 03JFY 00JFY 01JFY 02JFY 03JFY
Domestic sales Heavy Trucks
Medium Trucks
  10,328
11,625
10,571
12,070
14,480
14,340
  105,100
56,600
105,000
58,000
144,000
70,000
Sub-Total   21,953 22,641 28,820   161,700 163,000 214,000
Light Trucks
Buses
  10,033
2,025
10,032
2,069
14,530
2,120
  29,600
31,500
29,200
30,600
42,000
32,000
Total 33,136 34,011 34,742 45,470 227,819 222,794 222,717 288,000
Overseas Sales Total 19,380 21,448 25,743 27,060 60,749 74,730 88,120 86,000
Trucks/Buses Total 52,516 55,459 60,485 72,530 288,569 297,525 310,837 374,000
To
Toyota
CBU (Hilux)
KD (Dyna Series)
129,489
10,559
130,437
10,002
171,631
19,624
157,270
28,260
118,189
20,067
153,812
19,156
221,582
24,569
213,000
31,000
High Mobility Wheeled Vehicle 686 606 488 600 3,190 3,347 2,786 3,000
Parts for overseas production         50,154 55,618 57,913 58,000
Total 140,734 141,045 191,743 186,130 191,601 231,934 306,852 305,000
Spare
parts
Domestic Sales
Overseas Sales
        46,394
11,177
45,439
13,331
44,055
11,329
 
Total         57,572 58,770 55,384 57,000
Others Domestic Sales
Overseas Sales
To Toyota
        130,317
7,686
28,250
129,596
8,072
32,740
126,851
14,736
35,655
 
Total         166,254 170,410 177,243 174,000
Grand Total         703,998 758,640 850,317 910,000
Sources: Brief of Hino's Financial Statements,
Note 1. Figures for FY2003 are estimates announced by Hino.
2. The results of the engine sales included in "Others" are broken down as follows (on an unconsolidated basis).
  ■Hino's engine sales on an unconsolidated basis
  Sales units Sales(100millionYen)
99JFY 00JFY 01JFY 02JFY 99JFY 00JFY 01JFY 02JFY
Domestic Sales
Overseas Sales
6,831
2,439
6,578
1,478
5,429
2,022
4,960
1,803
4,816
1,598
4,519
948
3,835
2,120
3,503
2,221
Total 9,270 8,056 7,451 6,763 6,414 5,467 5,955 5,725

■The projected sales between 2003 and 2005 show a recovery to the same level as FY1997

  Hino set its projected sales goal between 2003 and 2005 in expectation of a significant increase of the domestic sales in FY2003 followed by a decrease in FY2004. These projections account for the effect of the NOx/PM regulations to be implemented in the metropolitan area in October 2003 and the reaction that they will receive. The projected overseas sales increase can be compared to those which were established in its three-year plan that was announced one year ago.

  The total sales volume including the domestic and overseas sales is set at 72,500 units, 74,000 units and 85,000 units from FY2003 to 2005 respectively. These volumes do not include the Toyota vehicles on a commissioned production basis. They are almost the same level as the period from FY1996 to 1997 when the medium-duty truck market had not yet significantly shrunken in Japan and other ASEAN countries. Hino's projected volume for FY2005, excluding that of its 2t-class light duty truck, the Dutro, marketed in 1999, is close to the results for FY1997.

■Outline of Hino's three-year medium term business plan (Units)
  2001JFY 2002JFY 2003JFY Plan
(Plan02⇒Plan03)
2004JFY Plan
(Plan02⇒Plan03)
2005JFY
Plan
Domestic
sales
Heavy Trucks
Medium Trucks
Light Trucks
Buses
10,290
11,801
10,095
2,008
10,655
12,031
10,120
2,051
11,900⇒14,480
11,900⇒14,340
14,300⇒14,530
2,290⇒2,120
13,200⇒11,700
12,600⇒13,500
16,700⇒12,800
2,370⇒2,200
12,300
14,900
14,000
2,300
Total 34,194 34,857 40,390⇒45,470 45,870⇒40,200 43,500
Domestic
Sales Share
Heavy Trucks
Medium Trucks
Light Trucks
Buses
28.1%
30.4%
10.5%
18.9%
28.2%
29.3%
10.6%
18.3%
30.5%⇒30.5%
30.5%⇒30.5%
13.0%⇒13.0%
21.4%⇒19.5%
31.7%⇒31.5%
31.4%⇒31.5%
14.0%⇒14.0%
22.2%⇒22.5%
32.0%
32.0%
15.0%
23.5%
Overseas sales 21,448 25,743 27,000⇒27,060 32,000⇒33,700 41,700
Commission Production (Toyota brand) 141,045 191,743 175,000⇒186,130 155,000⇒171,900 119,700
Unit (Engine) sales 7,451 6,763 6,300⇒6,800 20,400⇒15,500 21,100
FinancialData
(100million yen)
Consolidated sales 7,586 8,503 9,100 8,800 8,800
Non-consolidated sales 5,640 6,593 7,000 6,600 6,400
Consolidated
Operation Income
89 191 310 350 420
Operation Income Rates 1.2% 2.3% 3.4% 4.0% 4.8%
Source: Hino Motors mid-term business plan Medium Plan 2003 (announced on May 29, 2003)
Note: 1. Hino's three-year plan is being revised every year in view its long term goal for 2010.
The mid-term Plan 2002 ⇒ the mid-term Plan 2003 indicates differences between the projected figures announced in June 2002 and May 2003.
2. The mid-term Plan 2002 set the major future goals aimed at: Becoming a leader in the Japanese market. Becoming one of the top five commercial vehicle makers worldwide with an overseas sales goal of 100,000 units for 2010. Increasing profit, unit sales and market share.
The present crucial challenges are listed as follows:
(1) Development and launch of low emission vehicles.
(2) Reforming its completed vehicle business to focus on specially designed completed vehicles from chassis basis.
(3) Expanding its light truck business through cooperation with Toyota.
3. The mid-term Plan 2003 sets the goal of increased operating profit for all business segments with global production and a sales target of 150,000 units of 3t plus trucks for 2010. This will allow Hino to become one of the top five commercial vehicle makers worldwide. This target volume per year is broken down by region into 40,000-60,000 units for Japan, 30,000-40,000 units for Asia, and 20,000-30,000 units each in China and the US.
4. The mid-term Plan 2002 sets cost reduction targets of 30 to 50% for each item (by the time of a new model launch). This has been promoted as part of HCC21(Hino Cost Competitiveness) activities.
5. Its goals also include the reduction of the parts in use by 90% as well as the use of modules on a large scale and reducing the engine and driving-system parts to focus on limited types of front end and rear end modules. This will allow sharing of common parts independent of vehicle types and sizes. A new design using these modules will be introduced into heavy trucks to make full model-change modifications in the fall of 2003 as Japan's new short-term emission regulations will be applied to new models in 2004.
■Premise for the plan: Hino's estimates for the Japanese market. (Units)
  2002JFY 2003JFY 2004JFY 2005JFY
Heavy Trucks
Medium Trucks
37,722
41,013
47,500
47,000
37,000
43,000
38,500
46,500
Sub-Total 78,735 94,500 80,000 85,000
Light Trucks
Buses
95,214
10,820
112,000
10,900
91,000
9,800
93,500
9,800
Total 184,769 217,400 180,800 188,300

■Toyota will delegate development and production of its 1.5t to 2t-class light trucks to Hino around 2006
  Toyota decided to delegate the development and production of its light trucks to Hino, one of its group companies, around 2006 as a target period under its policy. Hino's president, Mr. Jagawa, revealed the company's mid-term business plan during a news conference on 29th May.
  Toyota's 2t-class light trucks, the Dyna and ToyoAce, had been developed and manufactured mainly by Hino under commission from Toyota since 1999. The results from the commissioned production by Hino was approximately 20,000 units in FY2002. The policy states that approximately 2,000 more 2t-class trucks, which are currently manufactured by Toyota Auto Body under commission from Toyota, and 1.5t-class trucks will also be contracted out to Hino for their development and production. The annual sales volume of Toyota's 1.5t-class trucks is approximately 20,000 units.
Source: Nihon Keizai Shinbun 03.5.30

■Hino's medium and light truck sales by payload (Units)
  1997 1998 1999 2000 2001 2002 02.1-6 03.1-6
Over 12t
9~12t
9,755
8,105
4,757
3,055
4,777
2,728
6,586
1,517
7,187
6
6,559
62
3,135
0
4,462
0
7~8t
5~6t
4,911
1,066
2,060
489
1,755
497
1,851
440
1,816
381
1,789
325
937
169
1,040
201
3~4t
Tractor
29,347
2,630
12,360
971
11,930
1,101
10,567
1,270
11,602
1,267
11,317
1,109
5,619
552
7,228
830
Medium Trucks Total 55,814 23,692 22,788 22,231 22,259 21,099 10,412 13,854
Ranger
Dutro
5,510 3,667 1,270
4,339
34
8,035
1
10,077
0
10,099
0
4,936
0
5,442
Light Truck Total 5,510 3,667 5,609 8,069 10,078 10,099 4,936 5,442
Grand Total 61,324 27,359 28,397 30,300 32,337 31,198 15,348 19,296
Dyna
Dyna/Toyoace
Toyoace
41,258

14,899
20,426

7,038
14,331
6,491
5,455
8,629
14,894
4,932
4,528
19,727
2,480
274
22,751
14
153
10,281
7
151
15,504
0
Toyota's light truck 56,157 27,464 26,277 28,455 26,735 23,039 10,441 15,655
Source: Japan Automobile Dealers Association (JADA)
Note: "Toyota's light truck" stands for only truck type, excluding RV, Van and 1-Box types.


■Hino may supply engines to Scania for its medium trucks and buses

  Hino formed an agreement of cooperation with Sweden Scania in March 2002, though no announcement has yet been made regarding any specific actions. It seems that many matters are still under review. However, it has been reported that there will be possible action such as:
  - Marketing the Scania vehicles in Japan, which had been discussed since the agreement was established.
  - Engine supplies to Scania for its medium trucks and buses
    (although Scania's model lineup is more focused on 16t plus heavy trucks).
  - Test sales of the Hino vehicles through Scania's sales network in Korea.

■Hino will produce 45,000 engines per year; a result from the engine supply to Nissan Diesel and Scania for medium vehicles
■Starting engine supplies to Scania for its medium vehicles in 2005.
  Scania will use Hino's V6-cylinder diesel engines with a 8L displacement for its medium trucks and buses. Hino's common rail system engines will be also used for vehicles where model changeovers are required to meet Europe's emission regulations that come into force 2005. The volume of Hino's engines to be supplied to Scania is expected to be at most 15,000 units per year.
  Hino will also start engine supplies to Nissan Diesel with 13,500 medium-class engines per year in 2004 when new models that will comply with Japan's new short-term emission regulations will be launched, according to the agreement in May 2001. The total engine production for medium vehicles is expected to be approximately 45,000 units per year. This includes those which mounted to the Hino models and those which supplied to Scania and Nissan Diesel. (Source: Hino Press Release 01.5.21 and Nikkan Jidosha Shinbun 03.1.21)
■Test sales of Hino's medium trucks through Scania's sales network in Korea.
  Hino will use the sales network of its partner, Scania, to start test sales of medium trucks under Hino's brand names in Korea in the fall of 2003. Vehicles used for test sales have simple equipment exclusive to the Korean market in order to reduce the cost. It will be the first time that Hino markets its vehicles in Korea. Hino schedules to broadly market them through Scania's sales network after implementing the test sales. (Nikkan Jidosha Shinbun 03.5.19)
■Setting up a taskforce to support domestic sales for the Scania vehicles.
  Scania Taskforce was established in the Hino Operation Department in June 2002 to promote actions including the preparation to launch the Scania vehicles in the Japanese market. Prior to this launch, the Scania vehicles will be launched under Hino brand names within 2003 in the project.
■Agreed on cooperation with Scania in March 2002.
  Hino and a heavy truck and bus maker in Sweden, Scania, signed an agreement of cooperation in March 2002. An agreement of cooperation does not include capital involvement such as cross-shareholding. The essentials of the agreement were announced as follows. (Source: Hino Press Release 02.3.25)
  (1) Aiming at establishing a long-term cooperative relationship for further mutual growth.
  (2) Enhancing product marketability and cost competitiveness through their mutual complementary
     system in products and sales regions.
  (3) Combining their environmental technologies and know-how to bring further advantages in the
     diesel engine area.
  (4) Present challenges to be reviewed.
      1. Complementary sales of Scania's tractors under the Hino brand name in the Japanese market.
      2. Jointly reviewing possible usage of Hino's 7 to 8L engines for Scania's products.
      3. Technology exchange in the engine emission technology area.


■Hino will start local production of hood engine type vehicles exclusive to the North American market in 2004 with a sales goal of 10,000 units for 2006

  Hino announced a detailed project to enter the US medium truck market on a large scale in May 2003. The vehicles exclusive to North America will be exported from Japan beginning in 2003, followed by local production in the US in 2004. The target sales are 10,000 units in 2006. This project is carried out based on cooperation with Toyota for production and a new alliance with the US Penske Group for sales. The models exclusive to North America have not yet been revealed. However, Hino's announcement made in 2002 stated that they would not be cab-over-engine types which were the same as Hino's existing models, but conventional types (hood-engine types), which are the mainstream in the US market.

■Hino enters the US market by introducing the vehicles exclusive to North America and the local production

=NAPS Project (NAPS: North American Project)
Introduction Launching the local assembly in 2004 to enhance cost competitiveness.
Product Vehicles exclusive to North America (introducing the conventional type which commands 90% of the US market)
Production Local production including local assembly and local parts procurement through Toyota's TABC, Inc.TABC Inc. is Toyota's production base in North America established in 1971 to manufacture truck boxes, catalytic converters and stamping parts
Sales volume 2,400 units for 2001 ⇒ 10,000 units for 2006: 30,000 units for 2010
Sales 40 billion yen for 2006: 110 billion yen for 2010
Source: Hino mid-term business plan Plan 2002 released on 2002.6.6

■Vehicles exclusive to North America will be marketed in 2003 followed by local production in the US in 2004 and sales of 10,000 units in 2006
  Hino restructured its sales joint venture with Mitsui, Hino Diesel Trucks (U.S.A.) Inc, through the alliance with the US Penske Automotive group in May 2003 to strengthen the sales system for the already-developed vehicles exclusive to North America in order to enter the US market on a large scale. The plan includes marketing of the vehicles exclusive to North America in 2003, shifting the production from Japan to a local production base in October 2004 and sales of 10,000 units in 2006. As part of the plan, the 4t-class medium trucks newly developed for the US market will be exported and sold in October 2003.
  The Penske group has established a record in the areas of the commercial vehicle lease and rental, passenger car sales and car racing in the US. This group has sales of US$11 billion and 32,000 employees worldwide on a consolidated basis, as well as a close relationship with Toyota for a long time.
■The outline of the alliance is described as follows:
1. Capital increase in Hino Diesel Trucks (USA) Inc and capital involvement by the Penske group: The capital in Hino Diesel Trucks (USA) Inc increased from US$8 million to 22 million. This capital increase allows the shareholdings to be broken down into Hino 50%, the Penske group 25%, Mitsui 12.5% and the US Mitsui 12.5%.
2. The areas to cooperate with the Penske group
  (1) Dealing with the Hino vehicles in the Penske group's lease and rental divisions.
(2) Setting up sales shops in areas where no sales shops exist.
(3) Bringing Penske's senior vice president of sales and marketing into Hino.
■The company name changed at the time of reorganization.
Hino Diesel Trucks (U.S.A.) Inc ⇒ Hino Motors Sales U.S.A. Inc
■Hino Motors International (U.S.A.) Inc. performing parts supply business for Latin America changed its name to Hino Motors Manufacturing U.S.A. Inc. with a capital increase from US$ 1.5 million to 7.5 million (Hino's wholly owned subsidiary). This company was restructured as a manufacturing company with the following operations.
  (1) Manufacturing components used for Toyota's local plants in a newly established plant.Total investment amounts to approximately 10 billion yen. The components to be manufactured include suspension-related parts for Toyota's light trucks (150,000 units of wheel shafts to support tires per year, which are currently produced in Hino's Hamura Plant in Japan), as well as undercarriages and hoods for Hino's medium trucks exclusive to the US market.
(2) Commission production for the vehicles exclusive to North America utilizing Toyota group's production base, TABC, in October 2004.
(3) Parts procurement for these vehicles.
Source: Hino Press Release (03.5.29) and Nihon Keizai Shinbun 03.5.17

  Hino's sales goal for the US market is 10,000 units for 2006, which is the same level that Isuzu achieved in imported car sales between 2000 and 2001. The target share in the medium truck market would be 4 to 5%. The long-term sales goal for 2010, that is 30,000 units, is equivalent to the recent sales results made by GM and DCX's subsidiary, Freightliner. That means Hino may become one of the top five commercial vehicle makers in the US market or could be one of the top three if it always its ultimate goal.

■New truck sales volume by GVW class in the US (Units)
  1997 1998 1999 2000 2001 2002 02.1-5 03.1-5
Class 1
Class 2
Class 3
5,084,800
1,712,043
52,804
5,263,152
2,035,637
102,497
5,707,182
2,365,664
122,408
5,965,085
2,421,451
116,594
6,090,543
2,507,702
101,499
6,068,352
2,564,745
80,042
2,447,851
1,029,547
32,240
2,481,180
1,024,582
34,632
Light Total 6,849,647 7,401,286 8,195,254 8,503,130 8,699,744 8,713,139 3,509,638 3,540,394
Class 4
Class 5
Class 6
Class 7
56,526
9,262
18,111
113,689
43,357
25,189
31,586
114,665
49,423
30,353
48,115
130,983
47,417
29,165
51,169
122,614
52,037
24,362
42,430
91,564
37,827
24,003
45,095
69,328
17,807
10,171
16,131
33,574
15,799
11,319
20,007
25,621
Medium Total 197,588 214,797 258,874 250,365 210,393 176,253 77,683 72,746
Heavy (Class 8) 178,551 209,483 262,316 211,553 139,614 146,031 53,814 50,252
Medium+Heavy 376,139 424,280 521,190 461,918 350,007 322,284 131,497 122,998
Domestic
Import
361,269
14,870
405,804
18,476
501,878
19,312
441,338
20,580
329,162
20,845
305,159
17,125
124,157
7,340
115,770
7,228
Source: Ward's Automotive Reports
■New Medium Duty/Heavy Duty truck sales in Canada (Units)
  1997 1998 1999 2000 2001 2002 02.1-5 03.1-5
Medium Duty
Heavy (Class 8)
7,123
27,163
7,511
29,094
15,124
30,984
14,058
27,905
12,525
18,495
11,598
20,341
4,846
7,240
4,775
8,167
Medium+Heavy 34,286 36,605 46,108 41,963 31,020 31,939 12,086 12,942
Source: Ward's Automotive Reports
Note: Truck classifications in the US and Canada are shown below.
■Truck classification by GVW (pounds)
Light-Duty Medium-Duty(=Hino's Market) Heavy-D.
Class 1 Class 2 Class 3 Class 4 Class 5 Class 6 Class 7 Class 8
≦6,000 6,001~
~10,000
10,001~
~14,000
14,001~
~16,000
16,001~
~19,500
19,501~
~26,000
26,001~
~33,000
33,001≦
~2.7t ~4.5t ~6.4t ~7.3t ~8.8t ~11.8t ~15.0t 15t~
Note: The bottom row indicates converted GVWs from pounds to tons. Class 4, the GVW of under 7.3t, is approximately equivalent to 3-4t vehicles in Japan's payload classification.

■New medium trucks (Class 4-7) sales volumes by makers in the US (Units)
  1997 1998 1999 2000 2001 2002 02.1-5 03.1-5
GM
Ford
34,102
64,583
34,607
60,064
42,574
73,193
41,490
68,068
36,127
55,452
29,757
46,783
14,141
21,509
10,736
18,456
Freightliner
Navistar
Paccar
20,086
61,949
2,082
34,168
64,231
2,180
47,782
69,617
3,463
46,265
67,211
4,000
41,117
52,647
4,076
33,866
44,517
5,097
14,312
18,678
2,137
15,521
19,252
2,313
Volvo
Mack
330
1,292
15
1,545
1
1,511
1,126 602 699 234 292
Hino
Isuzu (Domestic)
Isuzu (Import)
Mitsubishi Fuso
Nissan Diesel
1,102

6,797
3,102
2,163
1,453
1,742
8,216
3,494
3,082
1,564
3,134
9,367
3,800
2,868
1,984
3,098
10,075
3,343
2,279
1,500
3,867
9,726
3,115
1,665
1,695
2,556
6,690
2,959
1,634
672
1,074
2,951
1,285
690
744
836
2,599
1,402
595
Japanese 4 Brands Total 13,164 17,987 20,733 20,779 19,873 15,534 6,672 6,176
Others       1,426 499      
Total Medium Duty 197,588 214,797 258,874 250,365 210,393 176,253 77,683 72,746
Source: Ward's Automotive Reports
Note 1. Hino, Mitsubishi Fuso and Nissan Diesel included in four Japanese brands deal with imported cars only.
2. Freightliner includes a total of three makers (Freightliner, Stering and Western Star).
3. Paccar include a total of two makers (Kenworth and Peterbilt)
4. No sale results of heavy trucks (Class 8) was yielded in the four Japanese makers. Hino's medium truck sales by Class are shown below.
■Hino's new medium truck sales volumes by Class in the US and Canada (Units)
  1997 1998 1999 2000 2001 2002 02.1-5 03.1-5
Class4 (U.S.)
Class5 (U.S.)
Class6 (U.S.)
Class7 (U.S.)
199
322
483
98
260
417
584
162
270
412
684
198
375
448
879
282
309
326
669
196
319
320
830
226
152
116
302
102
143
165
348
88
Sales in U.S. 1,102 1,453 1,564 1,984 1,500 1,695 672 744
Sales in Canada - - - - 854 923 363 441
Source: Ward's Automotive Reports


■Hino aims to enter the Chinese market as well as the US market through developing exclusive heavy trucks

  It has been reported that Hino is scheduled to enter the Chinese market through developing low cost exclusive vehicles to launch production of 10t-class heavy trucks. Hino's projected sales goal of 150,000 units worldwide for 2010 includes 20,000 to 30,000 units to be sold in China. The news report in China states that the most promising joint venture partner is Chunlan Group, traditionally a home electrical appliance maker, which entered the automobile industry and now is scheduled to produce 100,000 heavy and medium trucks for the next 5 years.

  Making possible the joint production with Chunlan Group may allow a large scale production of heavy trucks even at the initial stage. Isuzu, which already established its production system for heavy, medium and light trucks and buses in China, set its production goal of heavy and medium trucks for 2004 at 20,000 units. Nissan diesel, which started heavy truck production in 1998, set its present goal at 4,000 units as well as its ultimate future goal at 10,000 units.

■Heavy truck production will be launched in China followed by full-scale bus production in 2004
■Producing engines for sale in 2004 and heavy trucks in 2005
  Hino will launch production of diesel engines in 2004 and heavy trucks in 2005 in China.
  Approximately 10,000 engines to be supplied to construction machinery makers will be produced annually in the first year through the joint venture with the leading electric machinery maker, Shanghai Electric Group. Diesel engines for trucks and industrial machinery are sharply growing in demand in China due to a boost in public works. A cost reduction of over 30% compared to the existing engines will be conducted to ensure cost competitiveness against local makers. The cost reduction of engines for local use will be reviewed at the design stage as there is a limit on simplifying the engine specifications.
  Approximately 20,000 heavy trucks will be initially produced per year through the joint venture between a home electrical appliance maker and Chunlan Group, with its truck division. (Nihon Keizai Shinbun 03.5.1 and Nikkan Jidosha Shinbun 03.2.12)
■Developing heavy trucks exclusive to the Chinese market with reduced price and cost by 50%
  Hino, taking 10t-class heavy truck production of approximately 20,000 to 30,000 units per year in China into consideration, will develop vehicles exclusive to the Chinese market with a substantial cost reduction. Hino aims at over 50% price and cost reduction compared to its existing models by reviewing the equipment and specifications together with using parts manufactured in China. (Nikkan Jidousha Shinbun 03.2.17)
■Developing light trucks exclusive to the Chinese market with a reduced number of basic frames
  Hino will reduce its existing 16 types of basic frames for light trucks to 2 types (standard and wide) in a few years according to its policy. Two basic frames will be first developed for the Chinese market, then they will be introduced in Japan and other ASEAN countries. (Nikkan Jidosha Shinbun 03.7.9)
■Production of buses with the engines manufactured in Japan in 2003
  The full-scale joint production of public buses and tour buses was projected to start in 2003 in Shenyang Shenfei Hino Automobile Manufacturing Co., Ltd. The company was established in 2000 with a 24% share held by Hino and 5% by Toyota Tsusho. However, this project has been postponed until the spring of 2004 or later.
  Hino's technologies are to be introduced into models currently manufactured by Shenyang Shenfei Hino Automobile Manufacturing Co., Ltd. for their model changeovers by procuring driving-system parts including engine parts from Japan in 2003.
  The current annual production scale of 1,000 to 2,000 units is scheduled to increase to 3,500 before 2008 through an additional introducion of four Hino models including heavy and medium premium tour buses beginning in 2004. In March 2003, a new plant was completed in the Shenyang Zhangshi Economic & Technical Development Zone. This plant has a site area of 33,000㎡ and an annual capacity of 3,500 heavy and medium buses and 5,000 bus chassis.

■Overview of the China Chunlan Group discussion on cooperation in joint production of heavy trucks with foreign automakers
  China Chunlan Group, which traditionally developed and produced mainly air-conditioners and refrigerators and other home electrical appliances, was established in 1985 in its facility located in Taizhou city, Jiangsu province. Chunlan Group entered the motorcycle business in 1994 when its annual production of air-conditioners reached 1.5 million units, then sold 90,000 motorcycles in 1999 and 100,000 motorcycles in 2000 through its core base, Jiangsu Chunlan Motorcycle Co., Ltd.
  In November 1997, Chunlan Group also bought out Nanjing Dongfeng Motor Co., which had been suffering from a slump in business, at a price of 720 million yuan, and consolidated a specially equipped vehicle maker, Nanjing Dongfeng Special Vehicle Factory, to set up Nanjing Chunlan Automobile Mfg. Co., Ltd. The new company started mass-production in March 2001 at an annual capacity of 20,000 units. Its medium truck production volume was ranked No. 3 in October 2001, following China FAW and Dongfeng Motor Corp. The projected production will increase to 100,000 units for the next five years from the 10,000 units of 2003 with the target share of 30% in the medium and heavy truck markets. It has been revealed there is a possibility that business leaders in Chunlan Group will steer the company to enter the passenger car business.
■Looking for a partner and considering Hino to be a most promising partner in the heavy truck area
  Chunlan Group is negotiating with several foreign automakers for a business alliance, mainly with Hino and Fiat. It has been reported that Chunlan Group started negotiations with Hino for cooperation in the heavy truck area in 2002. Chunlan Group has already bought 200,000㎡ of land next to Nanjing Chunlan Automobile Mfg. Co., Ltd. in order to set up a joint venture dealing with heavy trucks. The news report in China stated in May 2003 that Chunlan Group and Hino made an agreement to establish an equally shared joint venture to produce luxury heavy trucks by 50% shareholding each.
■Main targeted market of luxury-spec heavy trucks with a maximum payload of 15t
  Chunlan Group targets larger medium-duty trucks and smaller heavy-duty trucks with luxury-specifications, which cover 5, 6, 8, 10, 12, 15 and 20t trucks (trucks with a maximum payload of 6t to14t are medium trucks and trucks with over 14t payload are heavy trucks under the Chinese classification). In July 2002, a new 15t luxury truck, equipped with a quality interior equal to a passenger car using Nissan cab technologies, was launched at a price of 130,000 to 150,000 yuan.

■Chunlan Group's motor vehicle production and sales volumes (Units)
  2000 2001 2002 03.1-4
Nanjing Chunlan
Automobile Mfg.
Heavy truck Production 0 0 0 2,451
Sales 0 0 0 2,162
medium truck Production 270 2,861 7,700 69
Sales 278 2,830 7,853 67
Jiangsu Chunlan
Motorcycle
Motorcycle Production 85,425 65,987 n.a.
Sales 83,362 65,975
Source: China Auto Parts & Components Industry Operations Data


■Hino started a complementary system as well as local procurement in the ASEAN region on a large scale while expanding its business alliance with Toyota in the light truck area

  In the ASEAN region, Hino's core overseas market, Hino reorganized the business structures in its operation bases in Thailand and Indonesia, separating each local affiliate into independent manufacturing and sales organizations. This allowed Hino to start promoting the complementary system in the ASEAN region and improving its local parts procurement ratio on a large scale. A light truck, the Dyna, is a jointly developed model between Toyota and Hino as a sister model of the Hino Dutro. The production of the Dyna, which was conventionally performed by Toyota in Thailand, was consolidated into the exclusive production of the Hino Dutro during a model changeover (shifting to the existing model in Japan).

■Hino's export volume by destination (Units)
  1995JFY 1996JFY 1997JFY 1998JFY 1999JFY 2000JFY 2001JFY 2002JFY
Thailand
Indonesia
Malaysia
14,471
2,959
2,033
14,257
4,365
2,612
3,727
3,243
1,799
173
0
24
2,105
1,056
225
1,657
3,420
289
1,435
2,898
4,284
2,874
Philippines
Pakistan
Australia
900
1,312
1,288
721
2,029
917
419
211
1,625
36
353
1,957
41
820
2,470
72
735
2,695
1,166
2,202
2,121
3,061
Taiwan
Hong Kong
2,282
512
2,262
623
3,397
1,198
2,304
288
1,813
677
1,145
847
   
USA
South Africa
Others
750
1,202
3,999
886
755
4,246
1,395
780
6,884
1,714
475
6,428
1,700
308
3,544
1,823
520
5,260
1,418 1,718
Total 31,713 33,673 24,678 13,752 14,759 18,463 18,739 25,463
Source: Brief of Hino's Financial Statements, Facts Book 2001
Note: Five countries having figures in the breakdown for FY2001 and 2002 indicate Hino's top five export destinations in FY2002.

■Upgrading the ASEAN framework: Hino restructures its manufacturing companies in Thailand and Indonesia, substantially increasing the local parts procurement ratio
■Projecting to set up a suppliers park in Thailand and Indonesia to substantially increase the local parts procurement ratio
  Hino is considering the establishment of a suppliers park in Thailand and Indonesia, where Hino manufactures KD parts for medium and heavy trucks. Hino's small production scales, 4,000 units in Thailand and 3,000 units in Indonesia, prevent its affiliated Japanese medium and small truck parts makers from entering these markets. This causes Hino to procure most parts from Japan, resulting in its local content rate stagnating at 35%. Hino has secured land near its local production base to invite these Japanese medium and small truck parts makers which cannot easily enter the Thailand and Indonesian markets. This intends to improve its local content rate. It is expected that a maximum of 20 medium and small parts makers among Hino's affiliated group will participate in this project. This will allow Hino's local content rate to increase from 35% to 65-75%, enhancing its cost competitiveness. (Nikkan Jidosha Shinbun 03.4.15)
■Sharing cab production in Thailand and Malaysia to supply to each other
  Cab production requires the most complicated production processes along with the largest number of parts in the entire truck production. In order to bring cab productions for medium and small trucks under each cab-intensive production in one place, the production bases in Thailand and Malaysia must complement each other in truck cab supplies. Heavy and medium trucks are manufactured in Hino's own plant in Thailand. Also in Malaysia, heavy and medium trucks and buses are manufactured by Toyota's related company, ASSB, under a commission from Hino. Along with starting production of light trucks, the Dutro, in both production bases, cabs for medium trucks and those for light trucks will be manufactured in Thailand and Malaysia respectively to be supplied to each other. (Nikkan Jidosha Shinbun 03.2.4)
■Separating manufacturing and sales businesses in Thailand to restructure and strengthen both operations
  HMT (Hino Motors (Thailand) Limited) with Hino taking a 71.69% stake and its annual production capacity of 7,560 units (1 shift) traditionally performed manufacturing and sales functions. Its manufacturing division was separated to set up a new manufacturing company, HMMT (Hino Motors Manufacturing (Thailand) Ltd. HMMT produces the Hino vehicles while reinforcing the unit business mainly for Toyota vehicles. The current HMT remains as a sales company, changing its name to HMST (Hino Motors Sales (Thailand) Ltd.).
  HMMT would be set up at the end of June 2003, which was capitalized by Hino 80% and Mitsui 20%. The new company name, HMST which was capitalized by Hino 53.3%, Mitsui 42.3% and others 4.4%, would be available in July 2003. (Hino Press Release 03.4.23)
■Separating manufacturing and sales businesses in Indonesia and building a new plant
  HIM (P.T. Hino Indonesia Manufacturing with Hino a 60.15% share and its annual production capacity of 3,000 units) traditionally performed manufacturing and sales functions. Its sales division was separated to set up a new sales company. This is for intended sales promotion in Indonesia.
  HIM focuses on the manufacturing business with Hino Motor taking the initiative. A new plant was built in KBI (Kota Bukit Indah) to produce parts and engines through an annual production capacity of 3,000 units. This will allow Hino to upgrade its production system for the South East Asian market in order to improve productivity and quality. The total investment made by Hino for this restructuring program amounted to approximately 3 billion yen. Establishment of the new sales company was scheduled in April 2003.
  The revised investment stake in the manufacturing company, HIM, is broken down into Hino 90% and IMSI (PT Indomobil Sukses International Tbk) 10%. The investment stake in the new sales company is broken down into Hino 40%, IMSI 40% and Sumitomo Corporation 20%.(Hino Press Release 03.1.22)
■Increasing the local parts procurement ratio from 20% to 50%.
  Measures to reinforce the ASEAN business were included in Hino's mid-term "Plan 2002" announced in June 2002 as follows: (1) Increasing the market share through introducing new models. (2) Increasing the local parts procurement ratio from 20% in 2001 to over 50% in 2004. (3) Expanding value chains (promoting specially equipped vehicle and second-hand car businesses) (4) Promoting production business under a commission from Toyota. Carrying out these measures will increase Hino's sales from 40 billion yen in FY2001 to 45 billion yen in FY2003 and 57.3 billion yen in FY2004.
■Delegating Toyota's truck sales in Thailand to Hino around 2003
  Toyota delegates its light truck sales in Thailand to Hino around 2003 as a target period. Toyota will discontinue the local sales of the light truck under its brand name, the Dyna, which was available through Toyota's sales network, taking advantage of Hino launching local production of the new model, the Dutro, in 2003. Integrating separate light truck sales under 2 brands, Toyota and Hino, into single sales through Hino allows Hino's truck business to strengthen. Hino's local content rate in its new Dutro production will increase from the current 25% to over 40% then eventually to around 65% for the next two years to enhance its cost competitiveness. (Nihon Kogyo Shinbun 02.4.17)


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